1994 Us WSM - Ocr

1994 CONTENTS
Mazda General Information

Title
626/MX-6 Pre-Delivery Inspection and

Scheduled Maintenance
Workshop Engine
FS
KL
Manual Lubrication FS
System KL
Cooling FS
FOREWORD System KL
A thorough familiarization with this manual
is important for proper repair and maintenance. FS (MTX)
It should always be kept in a handy place for Fuel and Emission
KL
quick and easy reference. Control Systems
The contents of this manual, including draw FS (ATX)
ings and specifications, are the latest availa
ble at the time of printing. As modifications Engine Electrical System
affecting repair or maintenance occur, relevant Clutch
information supplementary to this volume will
be made available at Mazda dealers. This Manual Transaxle G25M-R
manual should be kept up-to-date.
Automatic GF4A-EL
Mazda Motor Corporation reserves the righ: Transaxle LA4A-EL
to alter the specifications and contents of this
manual without obligation or advance notice. Front and Rear Axles
All rights reserved. No part of this book may
be reproduced or used in any form or by any Steering System
means, electronic or mechanical— "eluding Braking System
photocopying and recording and the use of
any kind of information storage and retrieval Wheels and Tires
system—without permission in writing.
Suspension
Body
WARRANTY
The manufacturer’s warranty on Mazda ve *Body Electrical System
hicles and engines can be voided if improper
service or repairs are performed by persons * Heater and Air Conditioner Systems
other than those at an Authorized Mazda Technical Data
Dealer.
Special Tools
Mazda Motor Corporation
HIROSHIMA, JAPAN Wiring Diagram (Form No.5266-10-93G)
y y (Part No.9999-95-021G-94)
APPLICATION:
This manual is applicable to vehicles beginning * Refer to the 1994 626/MX-6 Body Electrical Troubl
with the Vehicle Identification Numbers (VIN) shooting Manual (Form No.1359-10-93G , Pa
shown on the following page. No.9999-95-084F-94) for servicing of the body electric
components.
© 1993 Mazda Motor Corporatior

Printed in the U.S.A. (6/93)
Form No. 1355-10-93G
Part No. 9999-95-019B-94
VEHICLE IDENTIFICATION NUMBERS (VIN)
626
1YV GE22C*R5 1 0 0 0 0 1 -
1YV GE22D*R5 100001 —
MX-6
1YV GE31C*R5 100001 —
1YV GE31D*R5 100001 —
1994 Mazda 626/MX-6
Workshop Manual
WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury and property damage
increase. The recommended servicing procedures for the vehicle
in this workshop manual were developed with Mazda-trained
technicians in mind. This manual may be useful to non-Mazda
trained technicians, but a technician with our service-related training
and experience w I be at less risk when performing servicing
operations. However, all users ofThis manual are expected to know
general safety procedures.
This manual contains "Warnings” and “ Cautions" applicable to

risks not normally encountered in a general technician’s experience.
They should be followed to reduce the risk of injury and the risk
that improper se^. ce or repair may damage the vehicle or render
it unsafe. It s a so "iportant to understand that the “ Warnings”
and Cautors are not exhaustive. It is impossible to warn of all
the hazardous consequences that might result from failure to follow
the procedures.
The procecês recommended and described in this manual are

effective methods of performing service and repair. Some require
tools specif ca resigned for a specific purpose. Nonrecommended
procedures arc :ools should include consideration for safety of the
technician a^c continued safe operation of the vehicle.
Parts shou;d be replaced with genuine Mazda replacement parts,

not parts of lesser quality. Use of a nonrecommended replacement
part should nclude consideration for safety of the technician and
continued safe operation of the vehicle.
© 1993 Mazda Motor Corporation

Printed in the U.S.A. (6/93)
Form No. 1355-10-93G
Part No. 9999-95-019B-94
A
PRE-DELIVERY INSPECTION
AND
SCHEDULED MAINTENANCE
PRE-DELIVERY INSPECTION..............A - 2 INSPECTION OF STEERING

PRE-DELIVERY INSPECTION OPERATIONS AND LINKAGES...... A -18
TABLE............................................... A - 2 BRAKE FLUID REPLACEMENT........A -18
SCHEDULED MAINTENANCE.............A - 3 INSPECTION OF FRONT
MAINTENANCE TABLE (USA).......... A - 3 SUSPENSION BALL JOINTS..........A -18
MAINTENANCE TABLE (CANADA)... A - 6 INSPECTION OF DRIVE SHAFT
INSPECTION AND ADJUSTMENT OF DUST BOOTS...................................A -19
DRIVE BELTS...................................A - 8 INSPECTION OF PCV VALVE........... A -19
ENGINE OIL REPLACEMENT........... A-11 INSPECTION OF BRAKE AND
ENGINE TIMING BELT CLUTCH FLUID...............................A -19
REPLACEMENT............................... A-11 INSPECTION OF POWER STEERING
ENGINE OIL FILTER FLUID LEVEL.................................. A -20
REPLACEMENT............................... A-12 INSPECTION OF TIRES..................... A -20
INSPECTION OF COOLING TIRE ROTATION................................. A -20
SYSTEM.............................................A—13 MANUAL TRANSAXLE OIL
ENGINE COOLANT REPLACEMENT...............................A -20
REPLACEMENT............................... A -14 INSPECTION OF AUTOMATIC
ADJUSTMENT OF IDLE SPEED........A -15 TRANSAXLE FLUID LEVEL............ A-21
FUEL FILTER REPLACEMENT.........A -16 INSPECTION OF EXHAUST SYSTEM
INSPECTION OF FUEL LINES.......... A -17 HEAT SHIELD.................................. A -22
INSPECTION OF EMISSION HOSES INSPECTION OF REFRIGERANT
AND TUBES..................................... A -17 AND A/C COMPRESSOR................ A -22
SPARK PLUG REPLACEMENT.........A -17 AIR CLEANER ELEMENT
INSPECTION OF BRAKE LINES, REPLACEMENT...............................A -23
HOSES AND CONNECTIONS.........A -17 TIGHTENING OF BOLTS AND NUTS
INSPECTION OF DISC BRAKE.........A -17 ON CHASSIS AND BODY...............A -23
INSPECTION OF DRUM BRAKE...... A -17 46U0AX-001
A PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
The following items may be done at any time prior to delivery to your customer.
EXTERIOR
INSPECT and ADJUST, if necessary, the following items to □ Power windows (if equipped)
specification: □ Heater, defroster and air conditioner at various mode
□ Glass, exterior bright metal and paint for damage selections (if equipped)
□ Wheel lug nuts, and locks (if equipped) CHECK the following items:
8 8 -1 1 8 N-m ( 9 - 1 2 kgf-m, 6 5 -8 7 ft-lbf) □ Presence of spare fuse
□ All weatherstrips for damage or detachment □ Upholstery and interior finish
□ Operation of hood release and lock CHECK and ADJUST, if necessary, the following items:
□ Operation of trunk lid, and fuel lid opener □ Pedal height and free play of brake and clutch pedal
□ Door operation and alignment Pedal height mm (in) Free play mm (in)
□ Headlight aim 186-211
INSTALL the following parts: Clutch 5 -1 4
(7.3 2-8 .31 )
pedal (0.2 0-0 .55 )
□ Wheel caps (with carpet)
191.5-196.5
UNDER HOOD—ENGINE OFF Brake 4 -1 2
(7.54-7.74)
pedal (0.16—0.47)
INSPECT and ADJUST, if necessary, the following items to (with carpet)
specification: □ Parking brake
□ Fuel, coolant and hydraulic lines, fittings, connections, 5—7 notches/98 N (10 kgf, 22 Ibf)
and components for leaks
□ Engine oil level UNDER HOOD—ENGINE RUNNING AT
□ Power steering fluid level OPERATING TEMPERATURE_________
□ Brake (clutch) fluid level CHECK the following items:
□ Windshield washer reservoir fluid level □ Automatic transaxle fluid level
□ Radiator coolant level
□ Tightness of battery terminals
ON HOIST
□ Manual transaxle oil level CHECK the following items:
□ Underside fuel, coolant, and hydraulic lines, fittings, con
INTERIOR nections, and components for leaks
CHECK operations of the following items: □ Tires for cuts or bruises
□ Seat controls (sliding and reclining) and head restraints □ Steering linkage, suspension, exhaust system, and all un
□ Folding rear seat derside hardware for looseness or damage
□ Door locks, including childproof door locks (if equipped)
□ Seat belts and warning system
ROAD TESf~
□ Ignition switch and steering lock CHECK the following items:
□ Air bag system using warning light □ Brake operation
□ Shift-lock system and transmission range sensor switch □ Clutch operation
(ATX only) □ Steering control
□ Starter interlock switch (clutch pedal, MTX only) □ Operation of gauge
□ All lights including warning, and indicator lights □ Squeaks, rattles or unusual noises
□ Sound warning system □ Emergency locking retractors
□ Horn, wipers, and washers □ Cruise control system (if equipped)
□ Audio system (if equipped)
AFTER ROAD TEST
□ Cigarette lighter and clock
□ Sunroof (if equipped) CHECK for necessary owner information materials, tools and
□ Power outside mirrors (if equipped) spare tire in vehicle
The following items must be done just before the delivery to your customer.
□ Load test battery and charge if necessary Volts □ Install fuses for accessories
□ Adjust tire pressure to specification Load test result □ Remove seat and cabin carpet protective covers
(Refer to section Q) □ Vacuum inside of vehicle
□ Clean outside of vehicle
46 U0AX-041
A—2
SCHEDULED MAINTENANCE A
MAINTENANCE TABLE (USA)
Schedule 1 (Normal driving conditions)
If the vehicle is mainly operated where none of the “ unique driving conditions” apply.
Schedule 2 (Unique driving conditions)

• Repeated short-distance driving.
• Driving in dusty conditions.
• Driving with extended use of brakes.
• Driving in areas where road salt or other corrosives are used.
• Driving on rough or muddy roads.
• Extended periods of idling or low-speed operation.
• Driving for long periods in cold temperatures or extremely humid climates.
46U0AX-002
o
A -3
A SCHEDULED MAINTENANCE
Schedule 1 (Normal Driving Conditions)
Maintenance Number of months or kilometers (miles), whichever comes first
Interval Months 6 12 18 24 30 36 42 48
kilometers 12 24 36 48 60 72 84 96
x 1000
Maintenance l t e m ^ \ Miles 7.5 15 22.5 30 37.5 45 52.5 60
Engine
Engine oil R R R R R R R R
Oil filter R R R R R R R R
Tension of all drive belts I I
Engine timing belt Replace every 96,000 km (60,000 miles)
*2 Inspect at 96,000 km (60,000 miles), and
Engine timing belt (California) again at 144,000 km (90,000 miles)
Replace every 168,000 km (105,000 miles)
Hose and tube for emission I
Air cleaner
Air cleaner element
Ignition system
Spark plugs
Fuel system
Idle speed *2 I*2 I*1
Fuel filter R*1
I*2 r i
Fuel lines and hose
Fuel hose (California) Inspect every 168,000 km (105,000 miles)
Cooling system
Cooling system 1 1
Engine coolant R R
Chassis and body

Brake lines, hoses and connections 1 1
Disc brakes 1 1
Drum brakes 1 1
Steering operation and linkage 1 1
Front suspension ball joints 1 1
Driveshaft dust boots 1 1
Bolts and nuts on chassis and body 1 1
Exhaust system heat shield 1 1
All locks and hinges L L L L L L L L
Air conditioner system (if equipped)

Refrigerant Inspect the refrigerant amount annually
A/C compressor Inspect the operation annually
Chart symbols:
I : Inspect, and repair, clean, or replace if necessary
R : Replace
L: Lubricate
Remarks:
• After 48 months or 96,000 km {60,000 miles}, continue to follow the described maintenance at the recom
mended intervals.
‘ ‘ This a maintenance is required for all states except California. However we recommend that it also be
performed on California vehicles.
*2This maintenance is recommendded by Mazda. However, it is not necessary for emission warranty cover
age or manufacturer recall liability.
46U0AX-003
Schedule 2 (Unique Driving Conditions)
Maintenance Number of months or kilometers miles), whichever comes first
Interval Months 4 8 12 16 20 24 28 32 36 40 44 48
kilometers 8 16 24 32 40 48 56 64 72 80 88 96
x 1000
Maintenance l t e m ^ \ Miles 5 10 15 20 25 30 35 40 45 50 55 60
Engine
Engine oil R R R R R R R R R R R R
Engine oil (For Puerto Rico) Replace every 4,800 km (3,000 miles (or 3 months)
Oil filter R R R R R R R R R R R R
Tension of all drive belts I I
Engine timing belt Replace every 96,000 km 60,000 miles)
*2 Inspect at 96,000 km (60,000 miles), and again at
Engine timing belt (California) 144,000 km (90,000 miles)
Replace every 168,000 km (105,000 miles)
Hose and tube for emission I*2
Air cleaner
I Air cleaner element I *2
R I*2 R
Ignition system
I Spark plugs R
R I
Cooling system
Cooling system I I
Engine cooling R R
Fuel system
Fuel filter R.i
Fuel lines and hoses I*2 I* 1
Idle speed r i
I*1
Fuel hoses (California) Inspect every 168,000 km 105,000 miles)
Chassis and body

Brake lines hoses and connections 1 1
Drum brakes 1 1
Disc brakes 1 1 1 1
Steering operation and linkage 1 1
Front suspension ball joints 1 1
Driveshaft dust boots 1 1
Bolts and nuts on chassis and body 1 1 1 1
Exhaust system heat shield 1 1
All lock and hings L L L L L L L L L L L L

Chart symbols:
I : Inspect, and repair, clean, or replace if necessary. (Inspect, and replace if necessary.... Air cleaner ele
ment only)
R: Replace
L: Lubricate
Remarks:
• After 48 months or 96,000 km {60,000 miles}, continue to follow the described maintenance at the recom
mended intervals.
This a maintenance is required for all states except California. However we recommend that it also be
performed on California vehicles. , .
*2This maintenance is recommendded by Mazda. However, it is not necessary for emission warranty cover
age or manufacturer recall liability.
a 46U0AX-004
A—5
MAINTENANCE TABLE (CANADA)
Maintenance Number of months or kilometers miles), whichever comes first
Interval Months 5 10 15 20 25 30 35 40 45 50 55 60
kilometers 8 16 24 32 40 48 56 64 72 80 88 96
x 1000
Maintenance I t e m " ^ ^ Miles 5 10 15 20 25 30 35 40 45 50 55 60
Engine
Engine oil R R R R R R R R R R R R
Oil filter R R R R R R R R R R R R
Tension of all drive belts 1 1 1 1 1 1 1 1 1 1 1 1
Engine timing belt * 1 R
Air cleaner
Air cleaner element
Ignition system
Spark plugs
Cooling system
Engine coolant level and strength 1 1 1 1 1 1 1 1 1 1 1 1
Cooling system for leaks 1 1 1 1
Engine coolant R R
Fuel system
Idle speed 1 1 1 1
Fuel lines and hoses 1 *2 1
Fuel filter R R
PCV valve *2 1
Emission hoses and tubes 1
Chassis and body

Automatic transaxle fluid level 1 I I I I I I I I I I I
Transaxle oil (MTX and ATX) R
Driveshaft dust boots I I
Brake lines and hoses I I
Brake and clutch fluid level 1 I I I I I I I I I I I
Brake fluid *3 R
Disc brakes (front and rear) I I I I
Rear drum brakes I I
Tire inflation pressure and tire wear 1 I I I I I I I I I I I
Rotate tires Rotate every 24,000 kilometers or every 15 months
Power steering fluid level I I I I I I I I I I I I
Steering operation and linkage
I I
(Includes four wheel alignment)
Suspension components front and rear I I
All chassis and body nuts and bolts I I I I
Exhaust system heat shield I I
All locks and hinges L L L L L L L L L L L
Washer fluid level I I I I I I I I I I I I
Function of all lights I I I I I I I I I I I I

A—6
Chart Symbols:
I : Inspect, and repair, clean, or replace if necessary, and replace if necessary... Air cleaner element only
R : Replace or change
L : Lubricate
Remarks:
After 60 months or 96,000 km {60,000 miles), continue to follow the described maintenance and intervals.
As for * marked items in this maintenance chart, please pay attention to the following points.
*1: Replacement of the timing belt is required every 96,000 km {60,000 miles). Failure to replace this
belt may result in damage to the engine.
*2: This maintenance operation is recommended by Mazda. However this maintenance is not necessary
for emission warranty coverage or manufacturer recall liability.
*3: This maintenance operation is recommended by Mazda.
46U0AX-005
INSPECTION AND ADJUSTMENT OF DRIVE BELTS
Inspection
(FS)
1. Check the drive belts for wear, cracks, and fraying. Replace
if necessary.
V-RIBBED BELT
2. Verify that the drive belts are correctly mounted on the
pulleys.
x o x
46U0AX-006
3. Check the drive belt deflection when the engine is cold, or
at least 30 minutes after engine has stopped. Apply moder
ate pressure 98 N {10 kgf, 22 Ibf} midway between speci
fied pulleys.
Deflection
mm (in)
/p /s oilN
/ [ PUMP Drive belt *New Used Limit
/ XPULLEY/ 10
6.5—7.0 7.0--9.0
Alternator (0.39)
y (0.26-0.27) (0.28--0.35)
7.5—9.0 8.0- -9.5 11
P/S, P/S + A/C
(0.30-0.35) (0.32- -0.37) (0.43)
f ---'N '' s '--- *A belt that has been on a running engine for less than five minutes.
/CRANK-\ //( A/C ^
SHAFT I'/ COMPRESSOR
\ pulley/ ^PULLEY/ 4. If the deflection is not within specification, adjust it.
46U0AX-008
Drive belt tension check
Belt tension can be checked in place of belt deflection.
1. Check the drive belt tension when the engine is cold, or
at least 30 minutes after the engine has stopped. Using the
SST, check the belt tension between any two pulleys.
Tension
N (kgf, Ibf)
’ New Used Limit
740-830 500-680 390
Alternator
(75-85,170-180) (50-70, 110-150) (40, 88)
590-780 500-680 390
P/S, P/S + A/C
(60-80, 140-170) (50-70,110-150) (40, 88)
*A belt that has been on a running engine for less than five minutes.
2. If the tension is not within specified, adjust it.
A—8
Adjustment
Alternator belt
1. Loosen the alternator mounting bolts A and B and adjust
the belt deflection by turning the adjusting bolt C.
2. Tighten the mounting bolts A and B and recheck the
defleciton.
t m m Tightening torque
A: 16—22 N m [1.6—2.3 kgf m, 12—16 ft Ibf)
B: 32—46 N m {3.2—4.7 kgf m, 24—33 ft Ibf)
46U0AX-010
P/S belt, P/S + A/C belt
<8r y p/s o il N 1. Loosen the bolt ® and (§) and adjust the belt deflection
A PUM P by turning the adjusting bolt (5).
2. Tighten the mounting bolts ® and (D and recheck the
y \P U L LE Y v
r"© deflection.
y f/
Tightening torque
® : 44—60 N m {4.4—6.2 kgf m, 32—44 ft Ibf)
/crank- \ A/C (§): 32—46 N m {3.2—4.7 kgf-m, 24—33 ft-lbf)
SHAFT I COMPRESSOR
VPULLEY I PULLEY
46U0AX-Q42
(KL)
if necessary.
2. Verify that the drive belts are correctly mounted on the
V-RIBBED BELT
pulleys.
A A A
A Im s m J
X O X
16E0AX-013
3. Check the drive belt deflection by applying moderate pres
sure 98 N {10 kgf, 22 Ibf) midway between the pulleys.
Note
• A belt is considered “ New” if it has been used on a run
ning engine for less than five minutes.
Set the deflection as specified below.
• Check the belt deflection when the engine is cold, or at
least 30 minutes after the engine has stopped.
46U0AX-043
A -9
Deflection
mm (in)
Drive belt New Used Limit
O 00
6.0—7.0 -8.0 9.0
I I
Alternator
o
(0.24-0.27) -0.31) (0.35)
Alternator + 5.5—6.5 6.5--7.5 8.0
A/C (0.22-0.25) (0.26--0.29) (0.31)
6.0—7.0 7.0--8.0 9.0
P/S
(0.24-0.27) (0.28--0.31) (0.35)
4. If the deflection is not within specifications, adjust it.
Note
• Belt tension can be checked in place of belt deflection.
• Belt tension can be measured between any two pulleys.
1. Using the SST, check the belt tension.
16E0AX-016
Tension
N {kgf, Ibf)
690-880 500-680 440
Alternator
{70-90, 160-190) (50-70, 110-150) (45, 99)
Alternator + 690-880 500-680 440
A1C (70-90, 160-190) (50-70, 110-150) (45, 99)
540-680 400-530 340
P/S
(55-70, 130-150) (40-55, 88-120) (35, 77)
2. If the tension is not within specification, adjust it.
Adjustment
Note
• A belt is considered “ New” if it has been used on a run
ning engine for less than five minutes.
Alternator + A/C belt

1. Loosen the idler pulley locknut.
2. Adjust the belt deflection by turning the adjusting bolt.
Deflection
New: 5.5—6.5mm {0.22—0.25 in)
Used: 6.5—7.5mm {0.26—0.29 in)
Limit: 8.0mm {0.32 in)
3. Tighten the pulley.
Tightening torque:
32—46 N m {3.2—4.7 kgf m, 24—33 ft-lbf)
46U0AX-045
A—10
Alternator, P/S
1. Loosen the idler pulley locknut.
2. Adjust the belt deflection by turning the adjusting bolt.
Deflection
New : 6—7mm {0.24—0.27 in)
Used: 7—8mm {0.28—0.31 in)
Limit: 9.0mm {0.35 in)
46U0AX-046
Tightening torque:
32—46 N m {3.2—4.7 kgf m, 24—33 ft Ibf}
ENGINE OIL REPLACEMENT

1. Remove the oil filler cap and the oil pan drain plug.
2. Drain the oil into a container.
3. Install a new gasket and the drain plug.
Tightening torque:
30—41 N-m {3.0—4.2 kgf-m, 22—30 ft-lbf}
4. Refill the engine with the specified type and amount of en
gine oil.
46U0AX-011
Oil capacity
L (US qt, Imp qt)
Engine type FS KL
Total (dry engine) 3.7 [3.9, 3.3) 4.9 (5.2, 4.3)
Engine oil replacement 3.3 {3.5, 2.9) 3.7 (3.9, 3.3)
Engine oil replacement (with oil filter) 3.5 (3.7, 3.1) 4.0 (4.2, 3.5)
5. Refit the oil filler cap.

6. Run the engine and check for leaks.
7. Check the oil level and add oil if necessary.
ENGINE TIMING BELT REPLACEMENT

Refer to sectios B1, B2.
46U0AX-013
A -11
ENGINE OIL FILTER REPLACEMENT
(FS)
1. Remove the oil filter with the SST.
2. Use a clean rag to wipe off the mounting surface on the
engine.
3. Apply a small amount of clean engine oil to the O-ring of
the new filter.
46U0AX-014
4. Install the oil filter and hand tighten it until the O-ring con
tacts the cylinder block.
5. Tighten the filter 1 and 1/6 turns with the SST.
Tightening torque:
13.8—17.6 N m {140—180 kgf cm, 122—156 in lb f}
6. Start the engine and check for leaks.

Oil filter capacity: 0.2 L {0.21 US qt, 0.18 Imp qt}

46U0AX-015
(KL)
oil cooler base.
the new filter.
36UOAX-O11
4. Install the oil filter and tighten it by hand until the O-ring con
tacts the oil cooler base.
Tightening torque:
13.8—17.6 N m {140—180 kgf cm, 122—156 in lbf)
36U0F2-012
Oil filter capacity: 0.3 L {0.3 US qt, 0.3 Imp qt}
46U0AX-016
A—12
INSPECTION OF COOLING SYSTEM
Warning
• Removing the radiator cap or radiator drain plug while the engine is running or when the en
gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause
serious injury.
Turn off the engine and wait until it is cool. Wrap a thick cloth around the cap and slowly turn
it counterclockwise to the first stop. Step back while the pressure escapes.
After all the pressure is gone, press down on the cap with the cloth and turn the cap to re
move it.
46U0AX-017
Coolant Level (Engine cold)

1. Verify that the coolant level is near the filler neck of the
radiator.
2. Remove the coolant level dipstick from the coolant reser
voir and verify that the coolant level is between the F and
L marks. Add coolant if necessary.
Coolant Quality
1. Verify that there is no buildup of rust or scale around the
radiator cap, and filler neck.
2. Verify that coolant is free of oil. Replace the coolant if
necessary.
Coolant Leakage
49 9 2 0 0 146 1. Connect a radiator tester (commercially available) and the
SST to the radiator filler neck.
2. Apply 123 kPa {1.25 kgf/cm2, 17.8 psi) (FS)or103 kPa
{1.05 kgf/cm2, 15.0 psi} (KL) pressure to the system.
3. Verify that the pressure is held. If not, check for coolant
leakage.
36U0AX-014
A—13
Coolant Protection
Caution
• Do not use alcohol or methanol in the cooling sys
tem. The engine has aluminum parts that can be
damaged by alcohol or methanol antifreeze. Use
only ethylene-glycol-based coolant.
Caution
• Use only soft (demineralized) water in the coolant
mixture. Water that contains minerals will cut down
on the coolant’s effectiveness.
1. Measure the coolant temperature and specific gravity with

a thermometer and a hydrometer.
2. Determine the coolant protection by referring to the graph
shown.
3. If the coolant protection is not proper, add water or coolant
as necessary.
Antifreeze solution mixture percentage

Volume percentage Cravity at
Coolant protection
Water Coolant 20°C (68°F)
Above -16 °C (3°F) 65 35 1.054
Above -2 6 °C {—15°FJ 55 45 1.066
Above - 4 0 °C |-4 0 °F ) 45 55 1.078
ENGINE COOLANT REPLACEMENT
Warning
• Removing the radiator cap or radiator drain plug
while the engine is running or when the engine and
radiator are hot is dangerous. Scalding coolant and
steam may shoot out and cause serious injury.
Turn off the engine and wait until it is cool. Wrap
a thick cloth around the cap and slowly turn it coun
terclockwise to the first stop. Step back while the
pressure escapes.
After all the pressure is gone, press down on the
cap with the cloth and turn the cap to remove it.
Caution
• Do not use alcohol or methanol in the cooling sys
tem. The engine has aluminum parts that can be
damaged by alcohol or methanol antifreeze. Use
Caution
A—14
1. Remove the radiator cap and loosen the drain plug.
2. Disconnect the oil cooler hoses. (KL)
3. Drain the coolant into a suitable container.
4. Flush the cooling system with water until all traces of color
are gone; then, let the system drain completely.
5. Install the drain plug.
6. Fill with the proper amount and mixture of ethylene glycol
based coolant by referring to the table above.
Coolant capacity
FS: 7.0 L {7.4 US qt, 6.2 Imp qt}
KL: 7.5 L {7.9 US qt, 6.6 Imp qt}
7. Run the engine with the radiator cap removed until the up
per radiator hose is hot.
8. With the engine idling, add coolant to the radiator until it
reaches the bottom of the filler neck.
9. Install the radiator cap.
ADJUSTMENT OF IDLE SPEED

1. Warm up the engine to normal operating temperature.
2. Shift the selector lever to P range (ATX) or Neutral (MTX).
3. Turn off all electric loads.
• Headlight
• Blower
• Rear window defroster
• Power steering
4. Wait until the coolant fan is stopped.
5. Connect a tachometer to the data link connector terminal
IG - as shown.
6. Verify that the idle speed is within the specification.
Idle speed (Neutral): 600—700 (650 ± 50) rpm
7. If not within the specification, connect the SST to the data

link connector.
8. Set switch A to position 1.
9. Set test switch to SELF TEST.
10. If the SST is not used, connect a jumper wire between the
TEN terminal and the GND terminal of the data link con
nector.
46U0AX-022
11. Adjust the idle speed by turning the air adjusting screw.
AIR ADJUSTING
SCREW '
Idle speed (TEN terminal grounded):
600—700 (650 ± 50) rpm
12. Disconnect the SST.
46U0AX-023
A—15
FUEL FILTER REPLACEMENT
FUEL PUMP
(GREEN)
Warning
• Fuel vapor is hazardous. It can very easily ignite,
causing serious injury. Keep sparks and flames
away from fuel.
Warning
• Fuel line spills and leaks are dangerous. Fuel can
ignite and cause serious injuries or death and dam
age. Fuel can also irritate skin and eyes. To prevent
46U0AX-024 this, always complete the following “ Fuel Line Safe
ty Procedures.”
Fuel Line Safety Procedures

Fuel in the fuel system is under high pressure when the en
gine is not running.
A. Release the fuel pressure before disconnecting a fuel line.
1. Start the engine.
2. Remove the fuel pump relay.
3. After the engine stalls, turn the ignition switch to OFF.
4. Install the fuel pump relay.
B. Avoid leakage.
1. When disconnecting a fuel line hose, wrap a rag around
it to protect against fuel leakage.
2. Plug the hose after removel.
High-pressure side
The fuel filter must be replaced at the intervals outlined in the
maintenance schedule.
1. Disconnect and plug the fuel hoses from the fuel filter.
2. Remove the fuel filter and bracket.
3. Install in the reverse order of removal.
Tightening torque:
7.9—10.7 N m [80—110 kgf cm, 70—95.4 in Ibf)
4. Verify that the fuel hoses are pushed fully onto the fuel filter
nipples.
5. Secure the fuel hoses with clips.
6. Start the engine and verify that the fuel line joints do not leak.
A—16
INSPECTION OF FUEL LINES
1. Check the fuel line fittings, connections and components
for leaks.
2. There should be no wetness or stained areas that might in
dicate leaks.
3. Replace any defective hoses or clips.
INSPECTION OF EMISSION HOSES AND TUBES

1. Check the emission hoses and tubes fitings, connections
and components for leaks.
2. There should be no wetness or stained areas that might in
dicate leaks.
3. Replace any defective hoses, tubes or clips.
36U0AX-O29
SPARK PLUG REPLACEMENT
Caution
• Pulling on the wire part of the spark plug lead may
break the wire. To remove the lead, pull only on the
boot.
1. Remove and install the high-tension leads carefully.
2. Remove and install the spark plug with a plug socket.

3. Apply anti-seize compound or molybdenum-based lubricant
to the spark plug threads.
4. Tighten the spark plug to the specified torque.
Tightening torque:
15—22 N-m {1.5—2.3 kgf m, 11—16 ft-lbf)
46U0AX-047
INSPECTION OF BRAKE LINES, HOSES AND
CONNECTIONS
Check the points below; replace parts if necessary.
1. Cracking, damage or corrosion of the brake hose.
2. Damage to the brake hose threads.
3. Scars, cracks or swelling of the flexible hose.
4. All lines for fluid leakage.
16E0AX-108 INSPECTION OF DISC BRAKE

Check the following disc brake components.
1. Check the caliper operation and inspect for leaks.
2. Check the pads for wear.
3. Check the condition and thickness of the disc plate.
Limit
Brake pad thickness
Front: 2.0mm {0.08 in)
Rear: 1.0mm {0.04 in)
Disc plate thickness
Front: 22.0mm {0.87 in)
46U0AX-048
Rear: 8.0mm {0.31 in)
A -1 7
INSPECTION OF DRUM BRAKE
1. Check the wheel cylinder operation and inspect for leaks.
2. Check the linings for wear or damage.
3. Check the condition of the inner surface and the inner di
ameter of the drum.
Limit:
Brake lining.................................. 1.0mm (0.04 in)
Inner diameter of drum ....... 230.1mm (9.059 in j
INSPECTION OF STEERING OPERATIONS AND

LINKAGES
1. Check the steering wheel free play.
Free play: 0—30mm (0—1.18 in}
2. Check the steering for proper operation and for looseness

of the steering housing.
3. Check the steering gear housing and hoses for fluid leak
age or seepage.
36U0AX-020
BRAKE FLUID REPLACEMENT
1. Remove the brake fluid from the reservoir by using a suc
tion pump.
2. Fill the reservoir with new brake fluid.
Fluid specification
FMVSS 116: DOT-3
3. Attach a vinyl tube to the bleeder screw and place the oth
er end of the vinyl tube in a container.
4. Remove all the old brake fluid from the brake lines by loosen
46U0AX-028 ing each bleeder screw (one by one) and pumping the brake
pedal.
5. Bleed air as described below.
Caution
• Brake fluid will damage painted surfaces. If brake
fluid gets on a painted surface, wipe it off im
mediately.
(1) Jack up the vehicle and support it with safety stands.

(2) Remove the bleeder cap and attach a vinyl hose to the
bleeder plug.
(3) Place the other end of the vinyl tube in a container.
(4) Slowly pump the brake pedal several times.
(5) While the brake pedal is pressed, loosen the bleeder screw
to let fluid and air escape.
(6) Repeat steps 4 and 5 until there are no air bubbles in the
fluid.
(7) Check for correct brake operation.
(8) Check to be sure that there is no fluid leakage. Be sure
to clean away any spilled fluid with rags.
(9) After bleeding the air, add brake fluid to the reservoir up
to the specified level.
A -1 8
INSPECTION OF FRONT SUSPENSION BALL JOINTS
Inspect the front suspension ball joints.
INSPECTION OF DRIVE SHAFT DUST BOOTS

Check the dust boot on the drive shaft for cracks, damage,
grease leakage, and a loose boot band.
INSPECTION OF PCV VALVE

1. Verify that the engine coolant temperature is below 20°C
{68°FJ.
2. Start the engine and let it idle.
3. Disconnect the PCV valve with the ventilation hose from the
cylinder head cover.
4. Block the PCV valve opening.
5. Verify that vacuum is felt.
46U0AX-031
6. Remove the PCV valve.

7. Blow through the valve from port A and verify that air comes
out of port B.
8. Blow through the valve from port B and verify that no air
comes out of port A.
9. Replace the PCV valve if not as specified.
jin
J®
46U0AX-032
A -1 9
A SCHEDULED MAINTENANCE SERVICES
INSPECTION OF BRAKE AND CLUTCH FLUID
Check fluid level in reservoir.The level should be between
the Max. and Min. lines on the reservoir.
If the fluid level is extremely low, check the brake system
for leaks.
16E0AX-110
INSPECTION OF POWER STEERING FLUID LEVEL
Check the fluid level on the reservoir.
The level should be between the “ HIGH” and “ LOW” lev
el. Add fluid if necessary.
Fluid specification: ATF Dexron®n or M-m
36U0AX-032
INSPECTION OF TIRES
Inspection and Adjustments
Check the following and adjust or replace as necessary.
1. Air pressure
Check the air pressure of all tires, including the spare tire,
with an air pressure gauge. (Refer to section Q.) Measure
the pressure when the tires are cold.
46U0AX-049
2. Tire wear
Remaining tread
Ordinary tires: 1.6mm {0.063 in) min.
Snow tires: 50% of tread
(Tire should be replaced if wear indicators are exposed.)
3. Check damage, cracks or foreign matter (metal pieces, nails,

stone, etc) in the tire and cracks or damage to the wheel.
WEAR INDICATOR
vvcam INDICATOR
4. Air leakage from the valve.
16E0AX-127
TIRE ROTATION
To prolong tire life and assure uniform tire wear, rotate the
tires as specified below. After rotating the tires, adjust each
tire to the specified air pressure. (Refer to page Q-2.)
USA: Every 6,000 km {3,750 miles)

Canada: Every 24,000 km {15,000 miles) or
15 months (whichever comes first)
46U0AX-033
A -2 0
SCHEDULED MAINTENANCE SERVICES A
MANUAL TRANSAXLE OIL REPLACEMENT
1. Visually check the manual transaxle for oil leakage. If leak
age is found, check for the cause, and repair.
2. Remove the drain plug with washer.
3. Drain the oil into a suitable container.
4. Install a new washer and the drain plug.
Tightening torque:
40—58 N m {4.0—6.0 kgf m, 29—43 ft-lbf]
5. Remove the oil level plug with washer add the specified
amount and type of oil through the oil level plug hole until
the level reaches the bottom of the oil level plug hole.
Specified oil
Grade: API Service GL-4 or GL-5
Viscosity: All-season SAE 75W-90
Above 10°C {50°F} SAE 80W-90
Capacity: 2.7 liters (2.9 US qt, 2.4 Imp qt)
6. Install a new washer and the oil level plug.
Tightening torque:
40—58 N m {4.0—6.0 kgf-m, 29—43 ft-lbf}
INSPECTION OF AUTOMATIC TRANSAXLE FLUID

LEVEL
1. Place the vehicle on a flat, level surface.
2. Apply the parking brake and position wheel chocks securely
to prevent the vehicle from rolling.
3. Warm up the engine until the ATF reaches one of the fol
lowing temperatures.
60—70°C (140—1 5 8 °F )...............................GF4A-EL

66—77°C (150—1 7 0 °F )...............................LA4A-EL
4. While depressing the brake pedal, shift the selector lever

to each range (P—L), pausing momentarily in each range.
5. Shift back to P.
16E0KX-052
6. Ensure that the ATF level is between MAX. and MIN., if
necessary.
RANGE
ATF type: Dexron®n or M -m ...................... GF4A-EL
COOL
46U0AX-036
A—21
ATF type: MERCON®H or M -m .................. LA4A-EL
DO NOT DRIVE MARK
MIN. MIX.
I I
r !> DON’T ADD IN THIS AREA
'-T_l
FLUD LEVEL AT NORMAL
OPERATING TEMPERATURE
6 6 °C — 77°C (1 5 0 °F — 170°F)
46U0AX-050
INSPECTION OF EXHAUST SYSTEM HEAT SHIELD
1. Visually check the exhaust system insulator for damage.
2. Replace it if necessary.
36U0AX-025
INSPECTION OF REFRIGERANT AND A/C COMPRESSOR
Sl(3 H T GL/ASS Checking Refrigerant Amount
1. Close the front windows.
2. Start the engine and run it at 1,500 rpm.
3. Follow the procedures in the table to determine the refriger
w ant amount condition.
46U0AX-037
Step Procedure Sight glass Action

Q) i
°CD
©
1 1. Turn ACS to ON and blower Too much or proper amount of

switch to fourth position. refrigerant
2. Press REC switch and VENT Go to step 2
switch to ON. Insufficient refrigerant
/ffv K Bubbles present
3. Set TEMP lever to MAX
Check refrigerant pressure
COLD.
4. Verify that A/C compressor
is operating and observe Cloudy Insufficient refrigerant
refrigerant condition in sight Check refrigerant pressure
glass.
2 Turn off A/C compressor by us *— ^ Iear immediately after Too much refrigerant
ing ACS and observe refriger \ .— Is. / S f A/C compressor turned Check refrigerant pressure
ant condition in sight glass. \ ° ° / r off; bubbles appear
and then disappear
y— v Bubbles appear and Proper amount of refrigerant
©
i— N / °o aJ then disappear Check refrigerant pressure
No refrigerant
Clear Check refrigerant pressure
46U0AX-038
A -2 2
Checking Refrigerant Pressure
1. Close the front windows.
REFRIGERANT 2. Install the manifold gauge set.
PRESSURE 3. Start the engine and run it at 1,500 rpm.
kPa (kgf/cm2)
4. Turn the ACS to ON and set the blower switch to the fourth
20 (1,961)
jf ,
position.
5. Press the REC switch and VENT switch to ON.
18 (1,765) HIGH-PRESSURE
SIDE V • s '
6. Set the TEMP lever to MAX COLD.
16 (1,569) 7. Verify that the pressure readings of the manifold gauge are
X s ' in the shaded zones.
14 (1,373) 8. If the pressures are not as specified, refer to the table and
. jis r
repair the system. (Refer to the 1994 626/MX-6 Body Elec
12 (1,177)
trical Troubleshooting Manual, section G.)
10 (98 1 ) ■
9. If the pressures are normal, inspect the control system.
2.5 (24 5 )
LOW-PRESSURE SIDE
2.0 (19 6 )
1.5 (147)
1.0 (9 8 )
( °F ) 68 77 86 95 104
°C 20 25 30 35 40
AMBIENT TEMPERATURE
46U0AX-039
AIR CLEANER ELEMENT REPLACEMENT
1. Check the air cleaner element for excessive dirt and for oil
and damage.
Caution
• Cleaning the element with compressed air will re
duce the element’s ability to filter air. Don’t use
compressed air to clean the element.
2. Replace the element if necessary.
TIGHTENING OF BOLTS AND NUTS ON CHASSIS AND

BODY
1. Tighten all seat mounting bolts.
2. Retighten any loose nuts and bolts on the chassis and body
to the specified torque.
36U0AX-024
B1
Before beginning any service procedure, refer to the 1994 626/MX-6 Body
Electrical Troubleshooting Manual; see section S for air bag system service
warnings and section J for audio antitheft system alarm conditions.
ENGINE
(FS)
INDEX................................................. B 1- 2 INSPECTION / REPAIR....................B 1 - 57

OUTLINE........................................... B 1- 3 PREPARATION...............................B 1 - 57
SPECIFICATIONS........................... B 1 - 3 CYLINDER HEAD..........................B 1- 57
TROUBLESHOOTING GUIDE.......... B 1- 3 VALVE MECHANISM.....................B 1- 58
ENGINE TUNE-UP.............................B 1 - 5 CAMSHAFT....................................B 1- 61
PREPARATION............................... B 1- 5 HLA................................................. B 1- 63
ENGINE O IL...................................B 1- 5 CYLINDER BLOCK.........................B 1- 64
ENGINE COOLANT........................B 1- 5 PISTON, PISTON RING, AND
DRIVE BELT...................................B 1- 6 PISTON PIN................................. B 1- 66
HLA TROUBLESHOOTING CONNECTING ROD...................... B 1- 67
GUIDE.......................................... B 1- 7 CONNECTING ROD BOLT........... B 1- 68
COMPRESSION................................ B 1 - 8 MAIN BEARING CAP BOLT.......... B 1 - 68
INSPECTION...................................B1— 8 CRANKSHAFT................................B 1- 68
ON-VEHICLE MAINTENANCE.........B 1- 9 BEARING....................................... B 1- 69
PREPARATION............................... B 1- 9 TIMING BELT................................. B 1- 69
TIMING BELT................................. B 1- 10 TENSIONER....................................B 1- 69
CYLINDER HEAD GASKET........... B 1 - 16 IDLER............................................. B1— 70
HLA................................................. B 1 - 22 TENSIONER SPRING..................... B 1- 70
FRONT OIL SEAL.......................... B 1 - 24 PULLEY..........................................B 1- 70
REAR OIL SEAL............................ B 1- 26 ASSEMBLY....................................... B 1 - 71
REMOVAL.......................................... B 1- 29 PREPARATION...............................B 1- 71
PROCEDURE................................. B 1- 29 CYLINDER BLOCK
ENGINE STAND MOUNTING.......... B 1- 37 (INTERNAL PARTS).....................B 1- 73
PREPARATION............................... B 1- 37 CYLINDER BLOCK
PROCEDURE................................. B 1- 38 (EXTERNAL PARTS)....................B 1 - 79
DISASSEMBLY................................. B 1- 40 CYLINDER HEAD..........................B 1 - 84
PREPARATION............................... B 1- 40 TIMING BELT................................. B 1- 89
AUXILIARY PARTS.........................B 1- 42 AUXILIARY PARTS.........................B 1- 94
TIMING BELT................................. B 1- 43 ENGINE STAND DISMOUNTING .... B 1- 98
CYLINDER HEAD.......................... B 1- 46 PROCEDURE................................. B 1 - 98
CYLINDER BLOCK INSTALLATION................................B1-101
(EXTERNAL PARTS)....................B 1- 49 PROCEDURE................................. B1-101
CYLINDER BLOCK 46U0B1-103
(INTERNAL PARTS)..................... B 1- 52
B1 INDEX
INDEX
COMPRESSION INSPECTION, PAGE B 1 -1 0
STANDARD: 1,177 kPa {12.0 kgf/cm2, 171 psi}-300 rpm
(3 ) HLA INSPECTION, PAGE B 1 -23 MINIMUM: 824 kPa (8.4 kgf/cm2, 119 psi)-300 rpm
INTAKE MANIFOLD
TIGHTENING TORQUE
1 9 - 2 5 N-m (1.9—2.6 kgf-m, 1 4 - 1 6 ft-lbf}
COOLANT,
SECTION E1
ENGINE OIL,
EXHAUST MANIFOLD
TIGHTENING TORQUE
NUT: 20—28 N-m (2.0—2.9 kgf-m, 15—20 ft-lbf)
BOLT: 16—22 N-m [1.6—2.3 kgf-m, 12— 16 ft-lbf)
DEFLECTION AT 98 N (10 kgf, 22 Ibf) mm (in)
DRIVE BELT NEW USED LIMIT
ALTERNATOR 6.5— 7.0 (0.26— 0.27) 7.0— 9.0 ( 0.28— 0.35) 10 (0.39)
P/S, P/S + A/C 7.5—9.0 (0.30—0.35) 8.0— 9.5 (0.32—0.37) 11 (0.43)
46U0B1-104
1. Timing belt 6. Engine

Removal / Installation............... page B1-10 Removal................................ page B1- 29
2. Cylinder head gasket Engine stand mounting......... page B1- 37
Replacement............................page B1-16 Disassembly.......................... page B1- 40
3. HLA Inspection / Repair................. page B1- 57
Removal / Installation............... page B1-22 Assembly............................... page B1- 71
4. Front oil seal Engine stand dismounting....page B1- 98
Replacement....... .................... page B1-24 Installation.............................. page B1-101
5. Rear oil seal
Replacement............................page B1-26
B 1 -2
OUTLINE, TROUBLESHOOTING GUIDE B1
OUTLINE
SPECIFICATIONS
------ ------------------------------------- Item
FS
Engine ------------------- -
Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinders
Combustion chamber Pentroof
Valve system DOHC, belt-driven
Displacement ml [cm 3, cu in) 1,991 (1,991 121.5)
Bore and stroke mm (in } 83.0x92.0 (3.27x3.62)
Compression ratio 9.0
Compression pressure kPa (kgf/cm2, psi)-rpm 1,177 (12.0, 171)-300
Open BTDC 8°
IN
Close ABDC 50°
Valve timing
Open BBDC 54°
EX
Close ATDC 8°
IN 0: Maintenance-free
Valve clearance mm (in)
EX 0: Maintenance-free
46U0B1-001
TROUBLESHOOTING GUIDE
Problem Possible Cause Action Page
Difficult starting Malfunction of engine-related components
Burnt valve Replace B1-58
Worn piston, piston rings, or cylinder Replace or repair B1-64, 66
Damaged cylinder head gasket Replace B1-16
Malfunction of fuel system Refer to sections F1, F3
Malfunction of ignition system Refer to section G
Poor Idling Malfunction of engine-related components
Malfunction of HLA* Replace B1-22
Poor valve-to-valve seat contact Replace or repair B1-60
Excessive oil Oil working up
consumption Worn piston ring groove or sticking piston ring Replace B1-66
Worn piston or cylinder Replace or repair B1-64, 66
Oil working down
Worn valve seal Replace B1-48, 84
Worn valve stem or guide Replace B1-58
Oil leakage Refer to section D1
* Tappet noise may occur if the engine has set idle for an extended period. The noise should stop after the engine has reached
normal operating temperature. (HLA troubleshooting: Refer to page B1-7.)
B 1-3
B1 TROUBLESHOOTING GUIDE
Insufficient power Insufficient compression

Compression leakage from valve seat Repair B1-60
Seized valve stem Replace B1-58
Weak or broken valve spring Replace B1-61
Cracked or distorted cylinder head Replace B1-57
Sticking, damaged, or worn piston ring Replace B1-66
Cracked or worn piston Replace B1-66
Others
Slipping clutch Refer to section H
Dragging brakes Refer to section P
Incorrect tire size Refer to section Q
Abnormal Malfunction of engine-related components
combustion Malfunction of HLA* Replace B1-22
Sticking or burnt valve Replace B1-58
Carbon accumulation in combustion chamber Eliminate carbon
Engine noise Crankshaft- or bearing-related parts
Excessive main bearing oil clearance Replace or repair B1-74
Main bearing seized or heat-damaged Replace B1-69
Excessive crankshaft end play Replace of repair B1-75
Excessive connecting rod bearing oil clearance Replace or repair B1-78
Connecting rod bearing seized or heat-damaged Replace B1-69
Piston-related parts
Worn cylinder Replace or repair B1-64
Worn piston or piston pin Replace B1-66
Seized piston Replace B1-66
Damaged piston ring Replace B1-66
Bent connecting rod Replace B1-67
Valves or timing-related parts
Broken valve spring Replace B1-61
Excessive valve guide clearance Replace B1-59
Malfunction of cooling system Refer to section E1
Others
Malfunction of water pump bearing Refer to section E1
Improper drive belt tension Adjust B1- 6
Malfunction of alternator bearing Refer to section G
Exhaust gas leakage Refer to sections F1, F3
Malfunction of timing belt tensioner Replace B1-10
46U0B1-105
* Tappet noise may occur if the engine has set idle for an extended period. The noise should stop after the engine has reached
normal operating temperature. (HLA troubleshooting: Refer to page B1-7.)
B 1 -4
ENGINE TUNE-UP B1
ENGINE TUNE-UP
PREPARATION
SST
49 9200 020 For

inspection of
Tension gauge, drive belt tension
V-ribbed belt
46U0B1-106
ENGINE OIL
Inspection
1. Be sure the vehicle is on level ground.
2. Warm up the engine to normal operating temperature and
stop it.
3. Wait for five minutes.
4. Remove the dipstick and check the oil level and condition.
5. Add or replace oil if necessary.
Note
• The distance between the L and F marks on the dipstick
represents 1.0 L {1.1 US qt, 0.9 Imp qt).
ENGINE COOLANT
Inspection
Coolant level (Engine cold)
Warning
• Removing the radiator cap or the coolant drain plug
while the engine is running, or when the engine and
steam can shoot out and cause serious injury. It can
also damage the engine and cooling system.
Turn off the engine and wait until it is cool. Even
then, be very careful when removing the cap. Wrap
a thick cloth around it and slowly turn it counter
clockwise to the first stop. Step back while the pres
sure escapes.
When you’re sure all the pressure is gone, press
down on the cap - still using a cloth - turn it, and
remove it.
radiator.
2. Remove the dipstick from the coolant reservoir and verify
that the coolant level is between the F and L marks. Add
coolant if necessary.
Coolant quality
radiator cap and radiator filler neck.
2. Verify that the coolant is free of oil.
3. Replace the coolant if necessary.
16E0B1-009
B1—5
B1 ENGINE TUNE-UP
DRIVE BELT
Inspection
if necessary.
V-RIBBED BELT 2. Verify that the drive belts are correctly mounted on the
pulleys.
a I
16E0B1-010
.M OUNTING BOLT
at least 30 minutes after the engine has stopped. Apply
3 moderate pressure98 N {10 kgf, 22 Ibf} midway between
the specified pulleys.
WATER
PUMP
CRANK
SHAFT
PULLEY
MOUNTING BOLT
46L30B1-004
Deflection
/ 3/s oii_N mm (in)
/\ PUMP Drive belt *New Used Limit
/ VPULLEYy 10
6.5—7.0 7.0—9.0
Alternator
V (0.26-0.27) (0.28-0.35) (0.39)
7.5—9.0 8.0—9.5 11
P/S, P/S + A/C
/X '/'t (0.30-0.35) (0.32-0.37) (0.43)
s\ '''s '— * A belt that has been on a running engine for less than five minutes.
/CRANK-\ ,'/ { A/C
SHAFT Y' COMPRESSOR 4. If the deflection is not within specifications, adjust it.
^PULLEY/ ^PULLEY/
46U0B1-005
N (kgf, ibf)
*New Used Limit
740-830 500-680 390
Alternator
(75-85, 170-180) (50-70, 110-150) (40, 88)
590-780 500-680 390
P/S, P/S+A/C
(60-80, 140-170) [50-70, 110-150) (40, 88)
* A belt that has been on a running engine for less than five minutes.
2. If the tension is not within specifications, adjust it.
B 1 -6
ENGINE TUNE-UP B1
Adjustment
Alternator belt
1. Loosen alternator mounting bolts A and B and adjust the
belt deflection/tension by turning adjusting bolt C.
2. Tighten mounting bolts A and B and recheck the deflec
tion/tension.
Tightening torque
A: 16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf}
B: 32—46 N-m {3.2—4.7 kgf m, 24—33 ft-lbf}
P/S belt, P/S + A/C belt

1. Loosen bolts A and B and adjust the belt deflection/tension
by turning adjusting bolt C.
2. Tighten mounting bolts A and B and recheck the deflec
tion/tension.
Tightening torque
A: 44—60 N m {4.4—6.2 kgf m, 32—44 ft-lbf}
B: 32—46 N-m {3 .2 -4 .7 kgf m, 24—33 ft Ib f}
HLA TROUBLESHOOTING GUIDE

Problem Possible Cause Action
1. Noise when engine is started immediately Oil leakage in oil passage Run engine at 2,000—3,000 rpm.
after oil is changed. If noise stops after 2 seconds—10 minutes*,
2. Noise when engine is started after setting HLA is normal.
approx. one day. If not, replace HLA.
*Time required for engine oil to circulate
3. Noise when engine is started after crank Oil leakage in HLA
within engine includes tolerance for engine
ing for 3 seconds or more.
oil condition and ambient temperature.
4. Noise when engine is started after new
HLA is installed.
5. Noise continues more than 10 minutes. Insufficient oil pressure Check oil pressure.
If lower than specification, check for cause.
Oil pressure: 400—490 kPa
(4.0—5.0 kgf/cm2, 57—71 psi)-3,000 rpm
Damaged HLA (Refer to page B1-22)
Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.

If more than 0mm (0 in), replace HLA.
6. Noise during idle after high-speed Incorrect oil amount Check oil level.
running. Drain or add oil as necessary.
Deteriorated oil condition Check oil quality.
If deteriorated, replace with specified type
and amount of oil.
36U0B1-007
B 1 -7
B1 COMPRESSION
COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1. Ignition system (Refer to section G.)
2. Compression (Refer to below.)
3. Fuel system (Refer to sections F1, F3.)
46U0B1-108
INSPECTION
1. Verify that the battery is fully charged. Recharge it if neces
sary. (Refer to section G.)
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool for about 10 minutes.
4. Remove the spark plugs.
5. Disconnect the primary wire connector from the ignition coil
as shown.
16E0B1-020
6. Connect a compression gauge to No.1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder as above.
Compression:
1,177 kPa (12.0 kgf/cm2, 171 psi}-300 rpm
Minimum:
824 kPa {8.4 kgf/cm2, 119 psi)-300 rpm
10. If the compression in one or more cylinders is low, pour a

small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder wall may be worn.
(2) If the compression stays low, the valve may be stuck
or seated improperly.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be damaged or the cylinder
head distorted.
11. Connect the ignition coil connector.
46U0B1-110
12. Install the spark plugs.
Tightening torque:
15—22 N m {1.5—2.3 kgf-m, 11—16 ft-lbf}
16E0B1-023
B 1 -8
ON-VEHICLE MAINTENANCE B1
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 S120 710 For 49E011 1A1 For

prevention of prevention of
Holder, coupling crankshaft Set, holder crankshaft
flange rotation rotation
49E011 101 For 49 E011 102 For

Holder crankshaft Bolts crankshaft
(Part of rotation (Part of rotation
49 E0111A1) 49 E011 1A1)
49G011 103 For 49 G017 5A0 For

prevention of support of
Bolts crankshaft Support, engine engine
rotation
49 G017 501 For 49 G017 502 For

support of support of
Bar engine Support engine
(Part of (Part of
49 G017 5A0) 49 G017 5A0)
49 G017 503 For 49E011 1A0 For

support of prevention of
Hook engine Brake set, crankshaft
(Part of ring gear rotation
49G017 5A0)
49E011 103 For 49E011 104 For

Shaft crankshaft Collar crankshaft
(Part of rotation (Part of a rotation
49E011 1A0) 49E011 1A0)
49E011 105 For 49 0118 850C For

prevention of removal of tie rod
Stopper crankshaft Puller, ball joint end
(Part of rotation
4 9 E 0 1 1 1 AO)
36U0B1-100
B 1 -9
B1 ON-VEHICLE MAINTENANCE
TIMING BELT
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove the right front wheel.
3. Remove in the order shown in the figure, referring to Removal Note.
4. Install in the reverse order of removal, referring to Installation Note.
5.9—7.8 N-m (60—80 kgf-cm, (9) 15—22 (1.5—2.3, 1 1 -1 6 )
7.9—10.7 N-m 53—69 ln-lbf)
180—110 kgf-cm, 5.9—7.8 N-m
70—95 ln-lbf I 160—80 kgf-cm,
53—69 ln-lbf |
©'
74—102 ( 7.5—10.5,
55—75}
86—116 (8.7—11.9
63—86
7.9—10.7 N-m
(80—110 kgf-cm,
70—95 in lbf I
7.9—10.7 N-m
(80—110 kgf-cm,
(4) 6.9—9.8 N-m (70—100 kgf-cm, 61—86 ln-lbf |
7 0 -9 5 ln-lbf) 3 2 -4 6 (3.2—4.7, 24—33
N-m (kgf-m, ft-lbf)
46U0B1-111
1. Undercover 11. Cylinder head cover

2. P/S and/or A/C drive belt Removal Note.................. page B1-11
Inspection.................................page B1- 5 Installation Note............... page B1-14
Adjustment...............................page B1 - 6 12. Dipstick and pipe
3. Alternator drive belt 13. Timing belt cover, upper
Inspection.................................page B1- 5 14. Timing belt cover, lower
Adjustment...............................page B1- 6 15. Engine mount No.3 rubber
4. Pulley shield Removal Note.................. page B1-11
5. P/S oil pump and hose Installation Note............... page B1-14
Removal Note.......................... page B1-11 16. Timing belt
6. Water pump pulley Removal Note.................. page B1-12
7. Crankshaft pulley Installation Note............... page B1-12
Removal Note.......................... page B1-11 Inspection........................ page B1-70
Installation Note....................... page B1-15 17. Tensioner and tensioner spring
8. Guide plate Inspection........................ pages B1-70, 71
9. High-tension lead 18. Idler
10. Spark plug Inspection........................ page B1-71
B 1 -1 0
-f
Removal Note
P/S oil pump and hose
1. Remove the P/S oil pump with the hoses still connected.
2. Position the pump away from the engine and affix it with
wire.
36U0B1-014
Crankshaft pulley
1. Hold the crankshaft pulley by using the SST.
2. Loosen the crankshaft pulley lock bolt.
3. Remove the crankshaft pulley lock bolt and the crankshaft
pulley.
36U0B1-015
Cylinder head cover
1. Loosen the cylinder head cover bolts in two or three steps
1© © (D (D in the order shown in the figure.
2. Remove the cylinder head cover bolts.
3. Remove the cylinder head cover.
®=
(D (D
Engine mount No.3 rubber

1. Suspend the engine by using the SST.
16A0B1-096
2. Remove the ground harness.
3. Remove the engine mount No.3 rubber.
SiA
?
B1—11
Timing belt
1. Install the crankshaft pulley lock bolt.
2. Turn the crankshaft to align the matching marks of the pul
leys as shown.
3. Turn the tensioner clockwise by using an Allen wrench.

4. Disconnect the tensioner spring from the hook pin.
46U0B1-013
Caution
MARK
DIRECTION OF
• The following will damage the belt and shorten its
ROTATION life; Forcefully twisting it, turning it inside out, bend
ing it, or allowing oil or grease on it.
5. When the belt will be reused, mark its rotation for proper
reinstallation.
6. Remove the timing belt.
46U0B1-014
7. Check the timing belt for damage, wear, peeling, cracks
and hardening. Replace the timing belt if necessary.
DAMAGE,
WEAR
PEELING
CRACK
46U0B1-015
Installation Note
Timing belt
1. Turn the crankshaft clockwise and align the timing marks
as shown.
Note
• The timing marks (grooves) can also be used to align the
pulleys.
46U0B1-O16
2. Verify that the camshaft pulley I and E marks are aligned
with the cylinder head upper line.
16E0B1-038
3. Install the timing belt so that there is no looseness at the
idler side or between the two camshaft pulleys.
16E0B1-379
4. Turn the crankshaft clockwise two turns, and align the tim
ing marks.
5. Verify that all timing marks are correctly aligned. If not
aligned, remove the timing belt and repeat from step 1.
16E0B1-040
6. Turn the tensioner clockwise by using an Allen wrench and
connect the tensioner spring to the hook pin. Verify that ten
sion is applied to the timing belt.
16E0B1-041
B 1-13
7. Turn the crankshaft clockwise two turns, and verify that all
timing marks are aligned. If not aligned, repeat from step 1.
16E0B1-042
1. Install the engine mount No.3 rubber.
Tightening torque
Bolt: 86—116 N-m
{8 .7 -1 1 .9 kgf m, 63—86 ft Ibf}
Nut: 74—102 N-m
{7.5—10.5 kgf m, 55—75 ft-lbf)
36U0B1-1Q1
2. Install the ground harness.
Tightening torque:
HARNESS 64—89 N m {6.5—9.1 kgf m, 48—65 ft-lbf)
16A0B1-003
3. Remove the SST from the engine.
49 G 0 1 7 5 A 0
16A0B1-004
Cylinder head cover
1. Apply a bead of silicone sealant as shown in the figure.
2. Install a new cylinder head cover gasket.
16E0B1-364
B 1-1 4
3. Apply silicone sealant to the shaded areas of the cylinder
head as shown in the figure.
16E0B1-365
4. Set the cylinder head cover on the cylinder head.
5. Tighten the cylinder head cover bolts in two or three steps
in the order shown in the figure.
Tightening torque:
5.9—7.8 N m {60—80 kgf cm, 53—69 in Ibf}
16E0B1-046
Crankshaft pulley
49 G011 103
1. Install the crankshaft pulley lock bolt.
49 E 0 1 1 1A 1
2. Tighten the crankshaft pulley lock bolt by using the SST.
Tightening torque:
157—166 N-m {16.0—17.0 kgf m, 116—122 ft-lbf}
49 S 1 2 0 710
16A0B1-005
Steps After Installation

1. Install the right front wheel.
2. Connect the negative battery cable.
3. Perform the necessary engine adjustments. (Refer to sections F1, F3.)
46U0B1-112
B 1-15
CYLINDER HEAD GASKET
Replacement
Warning
• Release the fuel pressure. (Refer to Section F1.)
• Keep sparks and open flame away from the fuel area.

2. Drain the engine coolant.
3. Remove the hood.
N-m (kgf-m, ft-lbf j

46U0B1-118
B 1-1 6
1. Undercover 11. Distributor
2. Resonance chamber No.1 Installation Note............... ....... page B1-20
3. Fresh-air duct 12. Camshaft pulley
4. Mass airflow sensor connector Removal Note.................. ....... page B1-18
5. Intake air temperature sensor connector Installation Note............... ....... page B1-20
6. Air cleaner housing and resonance chamber 13. Camshaft
No.2 Removal Note.................. ....... page B1-18
7. Accelerator cable Installation Note....................... page B1-19
Installation Note..................... page B1-21 14. Intake manifold bracket
8. Hose 15. Cylinder head bolt
Removal Note........................ ............ below Removal Note................... ....... page B1-18
Installation Note..................... .. page B1-21 Installation Note................ ....... page B1-18
9. Harness connectors 16. Cylinder head
10. Timing belt 17. Cylinder head gasket
Removal / Installation............. .. page B1-10 46U0B1-114
Removal Note
Hose
Disconnect the hoses shown in the figure.
HEATER HOSE
/ I BRAKE VACUUM HOSE
16E0B1-050
B1-17
Fuel hose
Warning
• Cover the hose with a rag because fuel will spray
out when disconnected.
• Keep sparks and open flames away from the fuel
area.
Plug the disconnected hoses to prevent fuel leakage.
36U0B1-019
Camshaft pulley
1. Hold the camshaft by using a wrench on the cast hexagon
as shown, and loosen the camshaft pulley lock bolt.
2. Remove the camshaft pulley.
46U0B1-115
Camshaft
1. Loosen the camshaft cap bolts in two or three steps in the
X - © ________________ © A y order shown in the figure.
2. Remove the camshaft caps.
3. Remove the camshafts.
4. Remove the camshaft oil seals from the camshafts.
M 8 r -----
16E0B1-054
Cylinder head bolt
1. Loosen the cylinder head bolts in two or three steps in the
order shown in the figure.
2. Remove the cylinder head bolts.
^ o n o r o o o r
® ® © ©
16E0B1-055
Installation Note
Cylinder head bolt
1. Measure the length of each cylinder head bolt below its
head.
Length
Standard: 104.2—104.8mm {4.103—4.125 in)
Maximum: 105.5mm (4.154 in)
36U0B1-074
B 1-1 8
2. If the length is not within specifications replace the bolt.
3. Apply clean engine oil to the bolt threads and head seat.
4. Install and tighten the cylinder head bolts.
(1) Tighten the bolts to the specified torque in the order
shown.
Caution
• Bolts must be tightened fully to prevent leaks and
poor compression.
Tightening torque: 17.2—22.0 N-m

46U0B1-116 {1.75—2.25 kgf m, 12.7— 16.2 ft-lbf}
(2) Make paint marks on the bolt heads, as shown.

(3) With the paint marks as a reference point, tighten each
cylinder head bolt 85 °—95° in order.
(4) Tighten them another 85°—95° in the tightening order
46UOB1-O17
Camshaft
Caution
• Because there is little camshaft thrust clearance,
the camshaft must be held horizontally while it is
mehhbsb^
installed. Otherwise, excessive force will be applied
to the thrust area, causing burr on the thrust receiv
ing area of the cylinder head journal. To avoid this,
the following procedure must be observed.
•' No. 3
C Y L IN D E R S 1. Assemble camshaft onto the cylinder head, facing the cam
46UQB1-018 noses at No.1 and No.3 cylinders as shown.
2. Apply silicone sealant to the areas shown. Keep the cam
shaft sliding surface free of sealant to prevent engine
damage.
3. Apply engine oil to the camshaft and the cylinder head

journals.
4. Install the camshaft caps to the positions from which they
Q ® g ® g© g ® n5® were removed.
5. Tighten the camshaft cap bolts in two or three steps in the
order shown.

0® 0 ® £5® {115— 145 kgf-cm, 100—125 in lbf)
6. Verify that the camshaft settles horizontally when two bear

16E0B1-Q60 ing cap bolts at No.3 journal .are tightened.
Revised 2/96 (1994 6 26/M X-6) B1-19
7. Apply a small amount of clean engine oil to the lip of each
new camshaft oil seal.
8. Push the oil seal slightly in by hand.
9. Using a pipe and hammer, tap the oil seal in evenly until
it is flush with the edge the camshaft cap.
Oil seal outer diameter: 48.0mm (1.89 in)

Oil seal inner diameter: 34.0mm {1.34 in }
46UOB1-O19
Camshaft Pulley
DOW EL PIN 1. Install the camshaft pulleys, positioning the dowel pins as
shown.
16E0B1-Q62
2. Apply engine oil to the lock bolt threads and temporarily
tighten the lock bolts.
as shown, and tighten each lock bolt.
Tightening torque:
50—60 N-m {5.0—6.2 kgf m, 37—44 ft-lbf}
4 6 7 0 B - 1 17
Distributor
1. Apply clean engine oil to a new O-ring and position it on
the distributor.
2. Apply clean engine oil to the drive gear.
3. Align the matching marks as shown.
1 6 E 0B 1 - 06 4
4. Install the distributor and hand tighten the mounting bolts.
R e v is ed 2/96
Hose
Connect the hoses as shown in the figure.
16E0B1-067
Accelerator cable
1. Verify that the throttle valve is fully closed.
2. Measure the free play of the accelerator cable.
Free play: 1.5—4.0mm {0.06—0.16 in)
3. If not as specified, adjust the cable free play by turning stop

per B while pressing lock button A with the throttle valve
fully closed.
4. Reset the cable lock.
46UOB1-020

1. Install the hood.
3. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E1.)
4. Start the engine and check as follows:
(1) Engine oil and engine coolant leakage
(2) Ignition timing, idle speed (Refer to sections F1, F3.)
(3) Operation of emission control system
46U0B1-119
B1-21
HLA
46U0B1-120
1. Timing belt 4. Camshaft

Removal / Installation............... page B1-10 Removal Note.......................... page B1-18
2. Distributor Installation Note....................... page B1-19
Installation Note....................... page B1-20 5. HLA
3. Camshaft pulley Removal Note.......................... page B1-23
Removal Note.......................... page B1-18 Inspection................................ page B1-23
Installation Note....................... page B1-20 Installation Note....................... page B1-23
B 1-2 2
Removal Note
HLA
Caution
• The HLA must be reinstalled in the same positions
from which they were removed. If they are not, it
can cause premature and uneven wear.
Note
• Mark the HLA to show their original positions.
46U0B1-021 1. Remove the HLA from the cylinder head.

2. Store the HLA upside down in an oil-filled container.
Inspection
1. Inspect the HLA friction surfaces for wear and damage. Re
place the HLA if necessary.
2. Hold the bucket body and press the plunger by hand. If
the plunger moves, it is defective. Replace the HLA — do
not attempt to repair it.
46U0B1-022
Installation Note
HLA
1. Apply clean engine oil to the friction surfaces.
2. If the HLA are being reused, install them in the positions
from which they were removed.
3. Verify that the HLA move smoothly in their bores.
16E0B1-073
Step After Installation

(1) Engine oil leakage
(2) Ignition timing, idle speed (Refer to sections F1, F3.)
(3) Operation of emission control system (Refer to section F1.)
(4) HLA tappet noise (Refer to page B1-7.)
46U0B1-121
B 1-23
FRONT OIL SEAL
Replacement
46U0B1-122
1. Timing belt 3. Oil seal

Removal / Installation............... page B1-10 Removal Note.......................... page B1-25
2. Timing belt pulley Installation Note....................... page B1-25
Removal Note.....................................below
Installation.................................page B1-25
Removal Note
Timing belt pulley
Note
• If necessary, remove the pulley with a steering wheel
puller.
1. Remove the timing belt pulley.

2. Remove the pulley key.
46U0B1-023
B1—24
Oil seal
1. Cut the oil seal lip by using a razor knife.
2. Remove the oil seal by using a screwdriver protected with
a rag.
Installation Note
Oil seal
1. Apply a small amount of clean engine oil to the lip of the
new oil seal.
it is flush with the edge of the oil pump body.
Oil seal outer diameter: 54.5mm (2.15 in]

Oil seal inner diameter: 42.5mm (1.67 in)
Timing belt pulley

1. Install the timing belt pulley.
2. Install the pulley key.
Step After Installation

2. Start the engine and check the ignition timing. (Refer to sections F1, F3.)
46U0B1-123
B 1-25
REAR OIL SEAL
Replacement
ATX
N-m I kgf-m, ft-lbf)

46U0B1-124
1. Transaxle 3. Flywheel (MTX)

MTX Removal Note............. ..................... below
Removal / Installation............... ....section J Installation Note........... .......... page B1-27
ATX 4. Drive plate (ATX)
Removal / Installation............... ... section K2 Removal Note.............. .......... page B1-27
2. Clutch cover, clutch disc (MTX) Installation Note........... .......... page B1-28
Removal / Installation............... .... section H 5. Oil seal
Removal Note.............. .......... page B1-27
Installation Note........... .......... page B1-27
Removal Note
Flywheel (MTX)
1. Hold the flywheel by using the SST.
2. Remove the flywheel bolts.
3. Remove the flywheel.
16EQB1-082
B 1 -2 6
Drive plate (ATX)
1. Hold the drive plate by using the SST.
2. Remove the drive plate bolts.
3. Remove the backing plate, drive plate, and adapter.
16E0B1-083
Oil seal
1. Cut the oil seal lip by using a razor knife.
a rag.
OIL SEAL LIP
16E0B1-084
Installation Note
Oil seal
new oil seal.
it is flush with the edge of the rear cover.
Oil seal outer diameter: 109mm (4.29 in)

Flywheel (MTX)
1. Remove the sealant from the flywheel bolt holes in the crank
shaft and from the flywheel bolts.
Caution
• If all of the old thread sealant cannot be removed
from the bolt, it will not torque properly. Replace
the bolt.
Note
• If a new bolt is used, do not apply thread locking seal
ant. New Mazda bolts have sealant on them.
2. Set the flywheel onto the crankshaft.

3. Apply sealant to the flywheel bolts and install them.
5. Tighten the bolts in two or three steps in the order shown
in the figure.
Tightening torque:
97—102 N m (9.8—10.5 kgf m, 71—75 ft-lbf)
36U0B1-102
B1—27
Drive plate (ATX)
1. Remove the sealant from the drive plate bolt holes in the
crankshaft and from the drive plate bolts.
Caution
• If all of the old thread sealant cannot be removed
from the bolt, it will not torque properly. Replace
the bolt.
Note
2. Install the adapter, drive plate, and backing plate onto the
crankshaft.
3. Apply sealant to the drive plate bolts and install them.
in the figure.
Tightening torque:
97—102 N m (9.8—10.5 kgf m, 71—75 ft-lbf}

2. Start the engine and perform engine adjustments as necessary.
3. Check the oil level.
46U0B1-126
REMOVAL B1
REMOVAL
Warning
• Release the fuel pressure. (Refer to section F1.)
PROCEDURE
2. Drain the engine coolant and transaxle oil.
3. Remove the hood and front wheels.
Step 1
46U0B1-027
1. Undercover 12. Radiator hose

2. Resonance chamber No.1 13. ATF cooler hose (ATX)
3. Fresh-air duct 14. Coolant fan motor connector
4. Mass airflow sensor connector 15. Coolant reservoir pipe
5. Intake air temperature sensor connector 16. Radiator bracket
6. Air cleaner housing assembly 17. Radiator and coolant fan assembly
7. Air hose 18. P/S oil pump and adjuster
8. Resonance chamber No.2 Removal Note.......................... page B 1 -3 0
9. Battery and carrier 19. A/C compressor (if equipped)
10. Accelerator cable Removal Note.......................... page B 1 -3 0
11. Fuel filter
B 1-29
B1 REMOVAL
Removal Note
P/S oil pump
1. Remove the P/S oil pump with the hoses still connected.
2. Position the pump away from the engine and affix it with wire.
46U0B1-028
A/C compressor
1. Remove the A/C compressor with the hoses still connected.
2. Position the compressor away from the engine and affix it
with wire.
46U0B1-029
Step 2
Disconnect the harness connectors.
46U0B1-127
B 1 -3 0
REMOVAL B1
Step 3
16A0B1-050
1. Fuel hose 3. Brake vacuum hose

Removal Note.....................................below 4. Vacuum hose (Purge)
2. Heater hose
Removal Note
Fuel hose
Warning
• Fuel vapor is hazardous. If can very easily ignite,
causing serious injury and damage. Always keep
sparks and flames away from fuel.
Disconnect the fuel hoses.
46U0B1-128
B1 REMOVAL
Step 4
GASKET,
NUT,
46U0B1-129
1. Clutch release cylinder (MTX) 7. Exhaust pipe

Removal Note.................... below 8. Shift control rod (MTX)
2. Shift control cable (ATX) 9. Extension bar (MTX)
3. Transverse member 10. Stabilizer control link
4. Engine mount No.5 rubber 11. Tie rod end
5. Engine mount No.2 nuts Removal Note.......... page B1-33
6. Engine mount member 12. Drive shaft
Removal Note...................... page B1-33 Removal Note.......... page B1-33
Removal Note
Clutch release cylinder (MTX)
1. Remove the bolts and clips shown in the figure.
Caution
• Bending the pipe can cause kinks or cracks.
2. Remove the release cylinder with the hose still connected

and position it away from the transaxle.
46U0B1-030
B 1 -3 2
REMOVAL B1
Engine mount member
Caution
• Support the engine before removing the member.
1. Suspend the engine by using a chain block.

2. Remove the engine mount No.2 nuts.
3. Remove the engine mount member bolts and nuts and re
move the engine mount member.
Tie rod end

1. Remove the cotter pin and loosen the nut so that it is flush
with the end of the ball joint stud.
Caution
• The ball-joint dust boots and oil seals are damaged
easily if this procedure is not done correctly.
2. Separate the knuckle arm and ball joint by using the SST.
Drive shaft
1. Remove the bolts and nuts from the lower arm ball joints.
2. Pry the lower arm downward to separate it from the
knuckles.
3. Separate the drive shafts from the transaxle by prying with

a bar inserted between the shaft and the case. (Left side)
46UQB1-033
4. As shown in the figure, insert a pry bar between the drive
shaft and the joint shaft and tap on the bar to uncouple them.
(Right side)
B 1-33
B1 REMOVAL
5. Remove the joint shaft.
REMOVAL B1
Step 5
46U0B1-130
1. Engine mount No.1 stay bracket 5. Engine mount No.4 rubber

2. Engine mount No.3 rubber 6. Engine mount No.4 bracket
3. Engine mount No.1 bolts (MTX) 7. Engine and transaxle assembly
4. Engine mount No.1 (ATX) Removal Note.................................... below
Removal Note
Engine and transaxle assembly
Slowly lift the engine and transaxle assembly a unit.
Keep the engine from swinging or bumping into compo
nents in the engine compartment.
46U0B1-034
B 1-35
B1 REMOVAL
Step 6
D
ATX
46U0B1-131
1. Intake manifold bracket 4. Manual transaxle

2. Starter 5. Automatic transaxle
3. Engine mount No.2 rubber 6. Engine assembly
B 1 -3 6
ENGINE STAND MOUNTING B1
ENGINE STAND MOUNTING
PREPARATION
SST
49 0107 680A For 49 L010 1A0 For

1 disassembly / disassembly /
assembly of assembly of
engine engine stand engine
i t = 4
49 L010 101 For 49 L010 102 For

» disassembly / disassembly /
Plate n
N? * * y assembly of Arms I- ) assembly of
(Part of engine (Part of engine
49 L010 1A0) \fi_ . ft / 49 L010 1A0) u
49 L010 103 For 49 L010 104 For

disassembly / disassembly /
Hooks O assembly of Nuts (0 !} assembly of
(Part of ^ engine (Part of engine
49 L010 1A0) 49 L010 1A0)
49 L010 105 For 49 L010 106 For

engine engine
49 L010 1A0) S . ^ L o t o 1A0)
..................... i|ip[i
16E0B1-108
B1 ENGINE STAND MOUNTING
PROCEDURE
Step 1
Remove in the order shown in the figure.
16E0B1-109
1. P/S oil pump bracket 6. Thermostat cover

2. Exhaust manifold insulator 7. Thermostat
3. EGR pipe 8. Water bypass pipes
4. Exhaust manifold 9. Thermostat housing
5. A/C compressor bracket (if equipped)
Step 2
Engine stand Mounting procedure
1. Use the holes shown in the figure.
46U0B1-035
B 1 -3 8
2. Install the SST (arms) to the holes as shown in the figure,
and hand tighten the SST (bolts).
49 L 0 1 0 106
46U0B1-036
3. Assemble the SST (bolts and plate) in the specified po
sition.
I 49 L 0 1 0 103
4. Assemble the SST (nuts, hooks, and bolts).
49 L 0 1 0 105
5. Install the SST to the respective arms.
fQ i O
i
*
49 L 0 1 0 104 49 L01 0 101
46U0B1-038
6. Adjust the SST (bolts) so that less than 20mm {0.79 in }
of thread is exposed.
7. Make the SST (plate and arms) parallel by adjusting the
SST (bolts and nuts).
8. Tighten the SST (bolts and nuts) to affix the SST firmly.
9. Mount the engine on the SST (engine stand).

49 0 1 0 7 6 8 0A
46U0B1-040
B 1-39
B1 DISASSEMBLY
DISASSEMBLY
PREPARATION
SST
49 E011 1A0 For 49 E011 103 For

Brake set, rsjapy® crankshaft Shaft crankshaft
ring gear rotation (Part of 6 rotation
49 E011 1A0)
49 E011 104 For 49 E011 105 ^ For

(a )
crankshaft Stopper \ / crankshaft
C0llar C ^> ) rotation (Part of \ / rotation
(Part of
49 E011 1A0) 49 E011 1A0) W
49 B012 0A2 For 49 B012 012 For removal /

removal / installation of
installation of Body < valves
valves (Part of
49 B012 0A2)
49 B012 013 For 49 B012 014 For

removal / removal /
Foot X installation of Locknut installation of
(Part of valves valves
49 B012 0A2) 4SHB012 0A2)
49 0636 100A For 49 L011 0A0B For

....... .. removal / removal /
Arm, valve 11// installation of Tool set, installation of
spring lifter I valves piston pin setting piston pins
49 L011 001 For 49 L011 006 jJ . For

removal / removal /
Body, support installation of Installer, piston installation of
block r piston pins piston pins
(Part of II (Part of
49 L011 0A0A) J r. 49 L011 0A0A)
49 E011 002 <3 N . For 49 H011 001B For

removal / removal /
Screw installation of Head, support installation of
piston piston pins
pins
49 E011 001 For 49 G014 001 For

removal / removal /
Guide, piston installation of Wrench, installation of
pin piston pins oil filter
oil filter
B 1 -4 0
DISASSEMBLY B1
49 S120 170 For
removal of
Remover, valve — valve seals — —
seal
46U0B1-041
1. Code or arrange all identical parts (such as HLA, pistons, piston rings, connecting rods, and valve springs)
so that they can be reinstalled in the cylinder from which they were removed.
2. Clean the parts by using a steam cleaner. Blow dry with compressed air.
B1 DISASSEMBLY
AUXILIARY PARTS
1. Drain the engine oil.
2. Disassemble in the order shown in the figure.
46U0B1 -042
1. Engine hanger 8. Alternator

2. Distributor and high-tension lead 9. Alternator bracket
3. Spark plug 10. Engine coolant temperature sensor
4. Intake manifold assembly 11. Heat gauge sender unit
5. Drive belt 12. Water outlet
6. Alternator stay (MTX) 13. Oil filter
7. Alternator strap Removal........................................section D
B 1-4 2
DISASSEMBLY B1
TIMING BELT
Disassemble in the order shown in the figure, referring to Disassembly Note.
46U0B1-132
1. Cylinder head cover 8. Timing belt guide plate

Disassembly N ote................... page B1-44 9. Timing belt
2. Crankshaft pulley Disassembly Note.......... . page B1-44
Disassembly N ote................... page B1-44 Inspection....................... • page B1-69
3. Water pump pulley 10. Tensioner, tensioner spring
4. Oil level dipstick and pipe Inspection....................... . pages B1-69, 70
5. Timing belt cover, upper 11. Idler
6. Timing belt cover, lower Inspection....................... . page B1-70
7. Engine mount No.3 bracket 12. Timing belt pulley
Disassembly Note.......... • page B1-45
B1 DISASSEMBLY
Disassembly Note
Cylinder head cover
1. Loosen the cylinder head cover bolts in two or three steps
2. Remove the cylinder head cover bolts.
36U0B1-120
Crankshaft pulley
1. Hold the flywheel (MTX) or the drive plate (ATX) by using
the SST.
16A0B1-057
2. Remove the crankshaft pulley lock bolt.
3. Remove the crankshaft pully.
36U0B1-121
Timing belt
1. Install the crankshaft pulley bolt.
2. Turn the crankshaft to align the matching marks as shown
in the figure.
CRANKSHAFT PULLEY LOCK

46U0B1-043
4. Disconnect the tensioner spring from the hook pin.
46U0B1-044
B 1 -4 4
DISASSEMBLY B1
Note
• Mark the timing belt rotation for proper reinstallation.
Caution
life; Forcefully twisting it, turning it inside out, bend
46U0B1 -045
Timing belt pulley
2. Remove the timing belt pulley key.
Note
• If necessary, remove the pulley by using a steering wheel
puller.
46U0B1-046
B1—45
B1 DISASSEMBLY
CYLINDER HEAD
46U0B1-133
1. Camshaft pulley 6. Cylinder head gasket

Disassembly Note..... ..... page B1-47 7. Valve keeper
Inspection.................. ..... page B1-70 Disassembly Note............ ...... page B1-47
2. Camshaft 8. Valve spring seat, upper
Disassembly Note..... ..... page B1-47 9. Valve spring
Inspection.................. ..... page B1-61 Inspection......................... ...... page B1-61
3. HLA 10. Valve
Disassembly Note..... ..... page B1-47 Inspection......................... ...... page B1-58
Inspection.................. ..... pages B1-23, 63 11. Valve seal
4. Cylinder head bolt Disassembly Note............ ...... page B1-48
Disassembly Note..... ..... page B1-47 12. Valve spring seat, lower
Inspection.................. ..... page B1-58 13. Valve guide
5. Cylinder head Inspection.......................... ...... page B1-59
Inspection.................. ..... page B1-57 Replacement..................... ...... page B1-59
DISASSEMBLY B1
Disassembly Note
Camshaft pulley
as shown, and loosen the camshaft pulley bolt.
46U0B1-134
Camshaft
1. Loosen the camshaft cap bolts in two or three steps in the
3. Remove the camshafts.
4. Remove the camshaft oil seals from the camshafts.
16E0B1-130
HLA
Caution
Note
1. Remove the HLA from the cylinder head.

46U0B1 -047 2. Store the HLA upside down in an oil-filled container.
Cylinder head bolt

16E0B1-132
4 9 0 6 3 6 10 0 A
Valve keeper
1. Set the SST against the upper valve spring seat as shown
in the figure.
2. Compress the spring and remove the valve keepers.
49 B 012 0A 2
16E0B1-133
B 1-4 7
B1 DISASSEMBLY
Valve seal
Remove the valve seal by using the SST.
16E0B1-134
B 1 -4 8
DISASSEMBLY B1
CYLINDER BLOCK (EXTERNAL PARTS)
46U0B1-135
1. Water pump 8. End plate

2. Rubber seal 9. Oil pan
3. Oil pump Disassembly Note................... page B1-50
Disassembly / Assembly............. section D1 Inspect for damage
4. Front oil seal 10. Oil strainer
Disassembly N ote................... page B1-51 Disassembly Note................... page B1-51
5. Clutch cover and clutch disc (MTX) Inspect for damage
Disassembly N ote................... page B1-50 11. Oil pan upper block
6. Flywheel (MTX) Disassembly Note................... page B1-51
Disassembly N ote................... page B1-50 12. Rear cover
7. Backing plate, drive plate, and adapter (ATX) 13. Rear oil seal
B1 DISASSEMBLY
Disassembly Note
Clutch cover and Clutch disc (MTX)
2. Loosen the clutch cover bolts evenly and gradually.
3. Remove the clutch cover bolts.
4. Remove the clutch cover and clutch disc.
46U0B1-048
Flywheel (MTX)
1. Hold the fly wheel by using the SST.
2. Loosen the flywheel bolts evenly and gradually.
3. Remove the flywheel bolts.
Backing plate, drive plate, and adapter (ATX)

2. Loosen the drive plate bolts evenly and gradually.
3. Remove the drive plate bolts.
46U0B1-136
Oil pan
1. Remove the oil pan mounting bolts.
Caution
• Pry tools can easily scratch the oil pan stiffener and
oil pan contact surfaces. Prying off the oil pan can
also easily bend the oil pan flange. Refer to the fol
lowing instructions before removing the oil pan.
2. Remove the sealant from the bolt threads.

3. Screw an oil pan bolt into the weld nut to make a small gap
46U0B1-137 between the oil pan upper block and the oil pan.
4. Using a screwdriver, pry apart the oil pan and oil pan up
per block.
5. Remove the oil pan.
46U0B1-138
B 1-5 0
DISASSEMBLY B1
Oil strainer
1. Remove bolt A.
2. Remove bolts B.
3. Remove the oil strainer.
Oil pan upper block

1. Remove the two nuts at the rear of the cylinder block.
2. Loosen the oil pan upper block bolts in two or three steps
3. Remove the bolts.
4. Insert a screwdriver as shown in the figure and pry loose

the oil pan upper block.
&
46U0B1-049
Front oil seal
Remove the front oil seal by using a screwdriver protected
with a rag.
Rear oil seal

Remove the rear oil seal by using a screwdriver protected
with a rag.
16E0B1-145
B1-51
B1 DISASSEMBLY
CYLINDER BLOCK (INTERNAL PARTS)
46U0B1-139
1. Connecting rod bolt 7. Piston
Inspection......................... ...... page B1-68 Inspection....................... ....... page B1-66
2. Connecting rod cap 8. Main bearing cap bolt
Disassembly Note........... ...... page B1-53 Inspection....................... ....... page B1-68
3. Connecting rod 9. Main bearing cap
Disassembly N ote........... ...... page B1-53 Disassembly Note.......... ....... page B1-54
Inspection......................... ...... page B1-67 10. Crankshaft
4. Connecting rod bearing Disassembly Note.......... ....... page B1-55
Inspection......................... ...... page B1-69 Inspection....................... ....... page B1-68
5. Piston ring 11. Main bearing
Disassembly N ote........... ...... page B1-53 Inspection....................... ....... page B1-69
Inspection......................... ...... page B1-66 12. Thrust bearing
6. Piston pin 13. Cylinder block
Disassembly N ote........... ...... page B1-53 Inspection....................... ....... page B1-64
Inspection......................... ...... page B1-66 Oil je t.............................. ....... page B1-55
B1—52
DISASSEMBLY B1
MEASURING LOCATION Disassembly Note
Connecting rod cap
Before removing the connecting rod caps, measure the con
necting rod side clearance. (Refer to page B1-78.)
46U0B1-140
Connecting rod
1. Before removing the connecting rods, measure the connect
ing rod bearing oil clearance. (Refer to page B1-78.)
2. Remove the Plastigage from the crankpin journals.

3. Use the handle of a hammer to remove the piston and con
necting rod assembly through the top of the cylinder block.
Piston ring
Remove the piston rings by using a piston ring expander
(commercially available).
Piston pin
Caution
• The connecting rods must be reinstalled in the same
positions from which they were removed. If they are
not, it can cause premature and uneven wear.
1. Before disassembling the piston and connecting rod, check

the oscillation torque as shown.
If the large end does not drop by its own weight, replace
the piston and/or the piston pin.
B 1-53
B1 DISASSEMBLY
2. Use the following SSTs and a press.
• Support block body (49 L011 001)
• Support block head (49 H011 001B)
• Piston pin installer (49 L011 006)
• Piston pin guide (49 E011 001)
• Screw (49 E011 002)
46U0B1-051
3. Insert the SST into the piston pin as shown.
16E0B1-153
4. Verify that the SST fits squarely into the piston before
pressing.
46U0B1-052
5. Set the piston and connecting rod on the SST as shown.
6. Press out the piston pin.
While removing the piston pin, check the pressure. If it is
lower than 4,903 N {500 kgf, 1,100 Ibf), replace the pis
ton pin and/or connecting rod.
46U0B1-053
Main bearing cap
1. Before removing the main bearing caps, measure the crank
shaft end play. (Refer to page B1-75.)
46U0B1-144
B 1-5 4
DISASSEMBLY B1
2. Loosen the main bearing cap bolts in two or three steps
3. Remove the main bearing caps.
16E0B1-157
Crankshaft
Before removing the crankshaft, measure the main bear
ing oil clearances. (Refer to page B1-73.)
46U0B1-145
Oil Jet
Removal
1. Drill a hole into the center of the oil jet head with a 7mm
drill bit.
2. Remove the spring and ball through the hole.
3. Tap the hole with a M 8x 1.25 tap to 8mm (0.31 in} deep.
4. Screw a M 8x 1.25 bolt into the tapped hole.
5. Attach the sliding hammer to the bolt.
Caution
46U0B1-146 • Twisting or turning the sliding hammer while remov
ing the oil jet can damage the cylinder block.
6. Pull the sliding hammer straight upward and discard the

oil jet.
Installation
1. Temporarily install the crankshaft, connecting rod, and pis
ton to the cylinder block.
2. Coat the oil jet installation hole with a small amount of clean
engine oil.
3. Fit the oil jet into the hole and align the nozzle with the
piston’s notch.
4. Remove the crankshaft, connecting rod and piston.
5. Remove the cylinder block from the SST (engine stand).
6. Put the cylinder block on the press stand.
7. Verify that the oil jet nozzle is properly aligned.
Caution
• If the oil jet nozzle is not properly aligned after be
ing pressed in, it can damage the oil jet, cylinder
block, and the piston.
46U0B1-147
B 1-55
B1 DISASSEMBLY
8. Press-fit the oil jet into the cylinder block.
M INIMUM “■-------
PRESSURE
3.2 kN Depth: 11.0—10.5mm (0.44—0.41 in}
330 kgf, 726 Ibf)
Pressure: 3.2 kN (330 kgf, 726 Ibf} minimum
STANDARD
Caution
11.0— 10.5mm • Depth over specification can damage the oil jet
10.44— 0.41 in)
nozzle.
• Pressure below specification indicates loose fit. Re
place the cylinder block and oil jet.
46U0B1-148 9. Mount the cylinder block on the SST (engine stand).

10. Install the crankshaft, connecting rod, and piston to the cyl
inder block.
11. Turn the crankshaft clockwise and check that the crankshaft
and piston do not contact the oil jet.
INSPECTION / REPAIR B1
INSPECTION / REPAIR
PREPARATION
SST
1. Clean all parts, being sure to remove all foreign materials.

2. Inspection and repairs must be performed in the order specified.
46U0B1-054
CYLINDER HEAD
1. Inspect the cylinder head for damage, cracks, and leakage
of water and oil. Replace if necessary.
2. Using a straightedge, measure the cylinder head for dis
tortion in the six directions shown in the figure.
Distortion: 0.10mm (0.004 in] max.
3. Inspect for the following and repair or replace.

(1) Sunken valve seats
(2) Damaged intake and exhaust manifold contact surfaces
46U0B1-055 (3) Excessive camshaft oil clearances and end play
4. If the cylinder head distortion exceeds the specification,
grind the cylinder head surface.
5. If the cylinder head height is not within the specification,
replace it.
Height: 124.45—124.55mm (4.8996—4.9035 in)

Grinding: 0.15mm (0.0059 in} max.
46U0B1-Q56
B 1-5 7
B1 INSPECTION / REPAIR
6. Using a straightedge, measure the manifold contact sur
faces for distortion in the six directions shown in the figure.
Distortion: 0.10mm (0.004 in) max.
7. If distortion exceeds the specification, grind the surface or

replace the cylinder head.
46U0B1-Q57
Cylinder Head Bolt
Measure the length of each bolt. Replace if necessary.
Length : 104.2—104.8mm (4.103—4.125 in)

36U0B1-076
VALVE MECHANISM
Valve and Valve Guide
1. Inspect each valve for the following. Replace or resurface
the valves as necessary.
(1) Damaged or bent stem
(2) Rough or damaged face
(3) Damaged or unevenly worn stem tip
2. Measure the head margin thickness of each valve. Replace
the valves as necessary.
Margin thickness
IN : 1.10mm (0.0433 in]
EX: 1.20mm (0.0472 in)
3. Measure the length of each valve and replace the valves

as necessary.
Length
Standard IN : 89.68mm (3.5307 in)
EX: 89.78mm (3.5346 in)
Minimum IN : 89.28mm (3.5150 in)
EX: 89.38mm (3.5189 in)
16A0B1-067
4. Measure the diameter of each valve stem and replace the
valves as necessary.
Diameter
Standard
IN : 5.970—5.985mm (0.2351—0.2356 in)
EX: 5.965—5.980mm (0.2349—0.2354 in)
Minimum IN : 5.940mm (0.2339 in)
EX: 5.935mm (0.2337 in)
36U0B1-077
B 1-5 8
5. Measure the inner diameter of each valve guide at the points
shown.
Inner diameter
IN : 6.01—6.03mm (0.2367—0.2374 in)
EX: 6.01—6.03mm (0.2367—0.2374 in)
6. Calculate the valve stem to guide clearance by subtracting

the outer diameter of the valve stem from the inner diameter
of the corresponding valve guide.
Clearance
IN : 0.025—0.060mm (0.0010—0.0023 in)
EX: 0.030—0.065mm (0.0012-0.0025 in)
7. If the clearance exceeds specifications, replace the valve

and/or valve guide.
8. Measure each valve guides projection height A. Replace

the guides as necessary.
Height A
IN : 13.5—14.1mm (0.532—0.555 in)
EX: 13.5—14.1mm (0.532—0.555 in)
Replacement of valve guide
Note
The intake and exhaust valve guides are the same.
Removal
Remove the valve guide from the side opposite the com
bustion chamber by using the SST.
B 1-59
Installation
1. Assemble the SST so that depth L is as specified.
Depth L: 13.5—14.1mm (0.532—0.555 in)
2. Tighten the locknut.
36UQB1-080
3. Tap the valve guide in from the side opposite the combus
tion chamber until the SST contacts the cylinder head.
4. Verify that the valve guide height is within specifications.
(Refer to page B1-59.)
5. If not within specifications, repeat steps 1—4.
46U0B1-149
Valve Seat
1. Inspect the contact surface of each valve seat and valve
face for the following:
(1) Roughness
(2) Damage
2. If necessary, resurface the valve seat with a 45° valve seat
cutter and/or resurface the valve face.
16E0B1-176
3. Apply a thin coat of Prussian blue to the valve face.
4. Check the valve seating by pressing the valve against the
seat.
(1) If blue does not appear 360° around the valve face, re
place the valve.
(2) If blue does not appear 360° around the valve seat,
resurface the seat.
16E0B1-177
5. Measure the seat contact width.
Width: 0.9—1.3mm (0.036—0.051 in)
36U0B1-081
B 1-6 0
6. Verify that the valve seating position is at the center of the
valve face.
(1) If the seating position is too high, correct the valve seat
using 65° (IN) or 75° (EX) cutter, and a 45° cutter.
(2) If the seating position is too low, correct the valve seat
using a 35° cutter and a 45° cutter.
7. Seat the valve to the valve seat by using a lapping
compound.
8. Check the sinking of the valve seat.
Measure the protruding length (dimension L) of the valve
stem.
Dimension L: 39.0mm {1.535 in)
(1) If L is 39.0—39.5mm {1.536— 1.555 in ), no correc

tion needed.
(2) If L is 40.6mm {1.598 in } or more, replace cylin
der head.
36U0B1-082
Valve Spring
1. Inspect each valve spring for cracks or damage.
2. Measure the free length and out-of-square. Replace the
valve springs as necessary.
Free length
Standard: 44.0mm {1.732 in)
Minimum: 36.5mm {1.437 in }/177.1—200.2 N
{18.05—20.42 kgf, 39.71—44.92 Ibf}
36U0B1-083
Out-of-square: 1.54mm {0.061 in) max.
16E0B1-182
CAMSHAFT
1. Set the front and rear journals on V-blocks.
2. Measure the camshaft runout. Replace the camshaft if
necessary.
Runout: 0.03mm {0.0012 in) max.
16E0B1-183
B 1-61
3. Inspect the camshaft for wear and damage. Replace the
camshaft if necessary.
4. Measure each camshaft lobe height at the point as shown.
Height
mm {in}
Standard 42.973 {1-6918}
IN
Minimum 42.823 {1.6859}
Standard 43.338 {1.7062}
EX
Minimum 43.188 {1.7003 J
36U0B1-049
5. Measure the journal diameters in X and Y directions at the
two points (A and B) shown.
Diameter:
25.940—25.965mm {1.0213—1.0222 in }
Minimum: 25.910mm {1.0201 in}
Out-of-round: 0.03mm {0.001 in} max.
16A0B1-101
6. Measure the camshaft journal oil clearances with the HLA
removed.
(1) Remove all foreign material and oil from the journals and
bearing surfaces.
(2) Set the camshaft onto the cylinder head.
(3) Position Plastigage atop the journals in the axial
direction.
(4) Install the camshaft caps according to the cap numbers
as shown in the figure.
46U0B1-058
(5) Tighten the camshaft cap bolt in two or three steps.

f l® 0 ® 0© 0® 9®
B® 0 ® B® s ®— 0 ®
^ .....
16E0B1-188
B 1 -6 9 M QQA R O R /M Y .W
(6) Loosen the camshaft cap bolts in two or three steps in
the order shown in the figure.
(7) Remove the camshaft caps.
16E0B1-189
(8) Measure the oil clearances.
Oil rlPflrflnrP'
0.035—0.081mm (0.0014—0.0031 in}
Maximum: 0.15mm {0.006 in)
(9) If the oil clearance exceeds specifications, replace the

cylinder head.
36U0B1-051
7. Measure the camshaft end play. If it exceeds specifica
tions, replace the camshaft and/or the cylinder head.
End play: 0.08—0.20mm {0.0032—0.0078 in)

Maximum: 0.21mm {0.008 in}
36U0B1-052
HLA
1. Measure the diameter of each HLA bore.
Diameter: 30.000—30.025mm {1.1811—1.1820 in}
36U0B1-053
2. Measure the diameter of each HLA .
Diameter: 29.959—29.975mm {1.1795—1.1801 in)
3. Calculate the clearance between the HLA and the related

HLA bore.
Clearance*
0 .0 2 5 -0 .066mm {0.00099—0.00259 in}
Maximum:
0.180mm {0.0071 in}
36U0B1-084
B 1-6 3
5. Hold the housing body and press the plunger by hand. If
the plunger moves, it is defective. Replace the HLA — do
46U0B1-15C)
CYLINDER BLOCK
1. Inspect the cylinder block for the following. Repair or re
place the cylinder block as necessary.
(1) Leak damage
(2) Cracks
(3) Scoring of wall
2. Using a straightedge, measure the top deck of the cylin
der block for distortion in the six directions shown in the
figure.

46U0B1-151
3. If the distortion exceeds the specification, replace it.
Height: 271.0mm (10.67 in]
36U0B1-054
4. Measure the cylinder bore in X and Y directions at three
levels (A, B, and C) in each cylinder as shown.
Cylinder bore
Base the boring diameter on the diameter of an oversize
piston. All cylinders must be the same diameter.
mm (in)
Bore size Diameter
Standard 83.000-83.019 (3.2678-3.2684)
0.25 (0.010) oversize 83.250-83.269 (3.2776-3.2783)
0.50 (0.020) oversize 83.500-83.519 (3.2874-3.2881)
46U0B1-059
(1) If the cylinder bore exceeds the maximum, rebore it to
tH 1 r oversize.
T-------- A --------- !-
i,
(2) If the difference between measurements A and C ex
i I
1 1 -- -"s; ceeds the maximum taper, rebore the cylinder to
1 1 oversize.
W m
|y » :3 g
1— B — f ■ IS i! Taper: 0.010mm (0.0004 in) max.
: i
cH t
46U0B1-06C)
B 1 -6 4
(3) If the difference between measurements X and Y ex
ceeds the maximum out-of-round, rebore the cylinder
to oversize.
Out-of-round: 0.010mm (0.0004 in) max.
5. If the upper part of a cylinder wall shows uneven wear,

remove the ridge with a ridge reamer.
16E0B1-200
PISTON, PISTON RING, AND PISTON PIN
Piston
If the piston is replaced, the piston rings must also be replaced.
1. Inspect the outer circumferences of all pistons for seizing
and scoring. Replace as necessary.
2. Measure the outer diameter of each piston at a right angle
(90°) to the piston pin, 16.5mm {0.650 in } below the oil
ring groove lower edge.
Piston diameter
mm (in)
Piston size Diameter
Standard 82.954-82.974 (3.2659-3.2666)
0.25 (0.010) oversize 83.204-83.224 (3.2758-3.2765)
0.50 (0.020) oversize 83.454-83.474 (3.2856-3.2863)
3. Measure the piston-to-cylinder clearance.
Clearance: 0.039—0.052mm {0.0016—0.0020 in)

4. If the clearance exceeds the maximum, replace the piston

or rebore the cylinders to accept oversize pistons.
C LEARAN C E
36U0B1-087
Piston and Piston Rings
1. Measure the piston ring-to-ring land clearance around the
entire circumference of the piston by using a new piston ring.
Clearance
Top: 0.035—0.065mm (0.0014—0.0025 in)
Second: 0.030—0.065mm (0.0012—0.0025 in)
Maximum: 0.085mm (0.0033 in)
2. If the clearance exceeds the maximum, replace the piston.
3. Inspect the piston rings for damage and abnormal wear.

Replace the piston rings if necessary.
4. Insert the piston ring into the cylinder by hand and use the
piston to push it to the bottom of the ring travel.
46U0B1-152
B 1-6 6
5. Measure the end gap of each piston ring by using a feeler
gauge. Replace the piston rings as necessary.
End gap
Top: 0.15—0.30mm (0.006—0.011 in)
Second: 0.15—0.30mm (0.006—0.011 in)
Oil rail: 0.20—0.70mm (0.008—0.027 in)
Maximum
Top, Second: 0.50mm (0.020 in)
Oil rail: 0.90mm (0.035 in)
36UQB1-089
Piston and Piston Pin
1. Measure each piston pin bore diameter in X and Y direc
tions at four points.
Diameter: 18.988—19.000mm (0.7476—0.7480 in)
2. Measure each piston pin diameter in X and Y directions at

four points.
Diameter: 18.974—18.980mm (0.7470—0.7472 in)
3. Calculate the related piston pin to piston clearance.
Clearance: 0.008—0.026mm (0.0003—0.0010 in)
4. If the clearance exceeds specifications, replace the piston

and/or piston pin.
CONNECTING ROD
1. Measure the small end inner diameter of each connecting
rod.
Diameter: 18.943—18.961mm (0.7458—0.7465 in)
2. Calculate the interference between the connecting rod small

end bore and the related piston pin.
Interference: 0.013—0.037mm (0.0005—0.0015 in)
If the connecting rod is replaced, the connecting rod cap,

bolts, and nuts must also be replaced because they are a
matched set.
3. Measure each connecting rod for bending. Repair or re

place connecting rods as necessary.
Bending:
0.05mm (0.002 in) max./50mm (1.97 in)
Length (Center to Center):

135.15—135.25mm (5.3209—5.3248 in)
B 1-67
CONNECTING ROD BOLT
Measure the length of each connecting rod bolt. Replace
as necessary.
Length: 46.7—47.3mm (1.839—1.862 in)

16E0B1-210
MAIN BEARING CAP BOLT
Measure the length of each main bearing cap bolt. Re
place as necessary.
Length: 67.7—68.3mm (2.665—2.689 in}

Maximum: 69.0mm (2.717 in]
16E0B1-211
CRANKSHAFT
1. Check the journals and pins for damage, scoring, and oil
hole clogging.
2. Set the crankshaft on V-blocks.
3. Measure the crankshaft runout at the center journal.
Replace the crankshaft if necessary.
Runout: 0.03mm (0.0012 in) max.
16E0B1-212
4. Measure each journal diameter in X and Y directions at
two points.
Main journal
Diameter:
55.937—55.955mm (2.2022—2.2029 in)
Crankpin journal
Diameter:
47.940—47.955mm (1.8874—1.8880 in)
5. If the diameter is less than the minimum, grind the jour

nals to accept undersize bearings.
Undersize bearing:
0.25mm (0.010 in) (MAIN JOURNAL AND CRANK
PIN),
0.50mm (0.020 in) (CRANKPIN)
Caution
• Do not remove the fillet roll area when grinding.
16E0B1-214
B 1-68
Main journal diameter undersize
mm (in)
Bearing size Journal diameter
0.25 (0.010) undersize 55.687-55.705 (2.1924-2.1931)
Crankpin journal diameter undersize

mm (in)
0.25 (0.010) undersize 47.690-47.705 [ 1.8776-1.8781)
0.50 (0.020) undersize 47.440-47.455 (1.8677-1.8683)
BEARING
Main Bearing and Connecting Rod Bearing
Check the main bearings and the connecting rod bearings
for peeling, scoring, and other damage.
TIMING BELT
Caution
1. Replace the timing belt if there is any oil or grease on it.

2. Check the timing belt for damage, wear, peeling, cracks,
and hardening. Replace if necessary.
TENSIONER
Caution
• Using cleaning fluids or a steam cleaner to clean the
tensioner can dissolve the grease in its sealed
bearing.
1. Use a clean, soft rag to wipe the tensioner contact surface.

2. If the tensioner does not rotate smoothly, replace it.
3. If there are silicone oil leaks, scratches or abnormal noise
when turning the tensioner, replace it.
4. If the spring bracket and grommet are loose or damaged,
replace the tensioner.
B1—69
IDLER
Caution
idler can dissolve the grease in its sealed bearing.
1. Use a clean, soft rag to wipe the idler contact surface.

2. If the idler does not rotate smoothly, replace it.
3. If there are silicone oil leaks, scratches or abnormal noise
when turning the idler, replace it.
TENSIONER SPRING
Measure the free length of the tensioner spring. Replace
the tensioner spring if necessary.
Free length: 36.6mm (1.441 in}
PULLEY
Timing Belt Pulley, Camshaft Pulley
Inspect the pulley teeth for wear, deformation, and other
damage. Replace the pulley if necessary.
B 1-7 0
ASSEMBLY B1
ASSEMBLY
PREPARATION
SST
49 E011 1AO For 49 E011 103 For

Brake set, engine rotation Shaft engine rotation
ring gear (Part of
49 E011 1A0)
49 E011 104 For 49 E011 105 For

Collar engine rotation Stopper engine rotation
(Part of a (Part of
49 E011 1AO) 49 E011 1A0)
49 SE01 310A For 49 L012 0A0 For

installation of installation of
Centering tool, clutch disc Installer set, valve seal
clutch disc valve seal &
valve guide
49 L012 005 For 49 L012 001 For

Spacer valve seals Installer valve seal
(Part of (Part of a m
49 L012 0A0) 49 L012 0A0)
49 L012 002 For 49 L011 0A0B For

installation of removal /
Body valve seal Tool set, installation of
(Part of piston pin setting' piston pin
49 L012 0A0)
49 L011 001 For 49 L011 005 For

removal / removal /
Body, installation of Bolt, stopper installation of
support block piston pin (Part of piston pin
(Part of 49 L011 0A0A)
49 L011 0A0A)
49 L011 006 For 49 E011 001 For

removal / removal /
Installer, piston installation of Guide, piston pin installation of
pin piston pin (Part of piston pin
(Part of 49 L011 0A0A)
49 L011 0A0A)
49 E011 002 For 49 H011 001B For

removal / removal /
Screw installation of Head, installation of
piston pin Support block piston pin
B1-71
B1 ASSEMBLY
49 0636 100A For 49 B012 0A2 For

removal / removal /
Arm, valve spring installation of Pivot installation of
lifter valve valve
49 B012 012 For 49 B012 013 For

removal / removal /
Body installation of Foot installation of
(Part of valve (Part of valve
49 B012 0A2) 49 B012 0A2)
49 B012 014 For 49 G014 001 For

removal / removal /
Locknut installation of Wrench, installation of
(Part of valve oil filter oil filter
49 B012 0A2)
46U0B1 -066
1. Do not reuse gaskets or oil seals.

2. Clean all parts before reinstallation.
3. Apply clean engine oil to all sliding and rotating parts.
4. Replace plain bearings if they are peeling, burned, or otherwise damaged.
5. Tighten all bolts and nuts to the specified torque.
46U0B1-155
ASSEMBLY B1
Torque Specifications ___________
850-95°
N-m (kgf-m, ft-lbf)

16E0B1-225
Crankshaft
1. Before installing the crankshaft, inspect the main bearing
oil clearances as follows.
Oil clearance inspection

(1) Remove all foreign material and oil from the journals and
bearings.
46U0B1-067
B 1-73
B1 ASSEMBLY
(2) Install the grooved upper main bearings in the cylinder
block.
(3) Install the thrust bearings with the oil groove facing the
crankshaft.
(4) Set the crankshaft in the cylinder block.
direction.
(6) Do not rotate the crankshaft when measuring the oil
clearances.
46U0B1-068
(7) Install the lower main bearings and the main bearing
caps according to the cap number, facing the □ mark
forward.
(8) Tighten the main bearing cap bolts in two or three steps

{1.75—2.25 kgf-m, 12.7—16.2 ft Ibf}
46U0B1-069
(9) Put a paint mark on each bolt head.
(10) Using the mark as a reference, tighten the bolts by turn
ing each 85°—95° in the sequence shown.
PAINT MARK
17.2—22.0 N-m
85° (1.75—2.25 kgf-m,
12.7—16.2 ft-lbf)
46U0B1-070
(11) Remove the main bearing caps, and measure the Plasti
gage at each journal at the widest point for the smallest
clearance, and at the narrowest point for the largest
clearance.
(12) If the oil clearance exceeds specifications, grind the
crankshaft and install undersize main bearings.
mm (in)
N o .1 , 2, 4, 5 N o .3
Oil c le a ra n c e 0.024-0.050 (0.0009-0.002] 0.030-0.056 (0.001-0.002)
M a xim u m 0 .0 6 7 (0 .0 0 2 6 )
46U0B1-071
2. Apply a liberal amount of clean engine oil to the main bear
FRONT ings, thrust bearings and main journals.
3. Install the main bearing caps according to the cap num
ber, facing the □ mark toward the front.
16E0B1-232
B 1-7 4
ASSEMBLY B1
4. Tighten the main bearing cap bolts in two or three steps

{1.75—2.25 kgf-m, 12.7—16.2 ft Ibf} + 8 5 °—95°
5. Measure the crankshaft end play.
End play: 0.080—0.282mm {0.0031—0.0111 in)

Maximum: 0.30mm {0.0118 in]
6. If the end play exceeds the maximum, grind the crankshaft

and install oversize thrust bearings, or replace the crank
shaft and thrust bearings.
Thrust bearing width

Standard:
2.500—2.550mm {0.0984—0.1004 in)
0.25mm {0.010 in) oversize:
2.625—2.675mm {0.1033—0.1053 in]
0.50mm {0.020 in] oversize:
2.750—2.800mm {0.1083—0.1102 in]
0.75mm {0.030 in] oversize:
2.875—2.925mm {0.1132—0.1152 in]
Connecting Rod
49 E011 001 1. Assemble the SST and piston pin as shown.
49 L011 006 2. Apply clean engine oil to the piston pin.
PISTON PIN
49 E 0 1 1 002
16E0B1-236
3. Adjust the SST (stopper bolt) so that the depth L is as
49 H 0 1 1 0 0 1 B specified.
DIMENSION
Depth L: 59.1mm {2.33 in]

49 L011 001
-LOCKNUT
w 49 L 0 1 1 005
16E0B1-237
B 1-75
B1 ASSEMBLY
5. Set the piston on the SST with the F mark facing upward.
6. Assemble the piston and the connecting rod in the direc
tion from which they were disassembled.
7. Verify that the SST is set squarely into the piston.
46U0B1-072
8. Set the piston and connecting rod on the SST as shown
and press the piston pin through the piston and connect
ing rod until the SST contacts the stopper bolt.
9. While inserting the piston pin, check the pressing force. If
it is less than specified, replace the piston pin and/or the
connecting rod.
Pressing force: 4,903—14,710 N

{500—1,500 kgf, 1,100—3,300 Ibf)
10. Check the oscillation torque of the connecting rod. If the

large end does not drop by its own weight, replace the pis
ton and/or piston pin.
46U0B1-074
Piston Ring
1. Install the three-piece oil rings on the pistons.
(1) Apply clean engine oil to the oil ring spacer and rails.
(2) Install the oil ring spacer with the ends upward.
Note
• The upper and lower rails are the same. They can be in
stalled with either face upward.
(3) Install the upper and lower rails.
2. Verify that the spacer tang separates the rails, and that the
SPACER TANG rails turn smoothly in both directions.
UPPER RAIL
fV -
-y
/ y u f\,
OIL RING
SPACER ENDS
■£Z
LOWER RAIL
PISTON
46U0B1-158
B 1 -7 6
ASSEMBLY B1
3. Install the rings with the R marks upward.
4. Install the second ring with the scraper face downward.
5. Apply clean engine oil to the top and second piston rings.
6. Install the second ring to the piston; then install the top ring.
Use a piston ring expander (commercially available).
7. Position the end gaps of the rings as shown in the figure.
OIL RING
LOWER RAIL TOP RING
OIL RING
PISTON
SPACER
OIL RING SECOND

UPPER RAIL RING
46U0B1-076
Piston and connecting rod assembly
The piston and cylinder block have matching marks on them
to ensure correct installation. Note these marks when in
stalling the pistons.
Mark
Standard
Piston Cylinder block
a A
b B
c C
Oversize (piston)
25 0.25 O.S.
50 0.50 O.S.
1. Apply a liberal amount of clean engine oil to the cylinder

walls, pistons, and piston rings.
2. Check the piston rings for correct end gap alignment.
3. Using a piston ring compressor (commercially available),
insert each piston assembly into the cylinder block with the
F mark facing the front of the engine.
16E0B1-247
B 1-7 7
B1 ASSEMBLY
Connecting Rod Cap
1. Measure the connecting rod bearing oil clearances using
KNOCK PIN the same procedure as for the main bearing oil clearance.
ALIGNMENT Tightening torque: 22.1—26.9 N-m

MARK
{2.25—2.75 kgf-m, 16.3—19.8 ft-lbf} + 85°—95°
Oil clearance: 0.024—0.061mm {0.0009—0.0024 in)

Maximum: 0.067mm {0.0026 in)
46U0B1-078
2. If the oil clearance exceeds the maximum, grind the crank
shaft to accept undersize bearings. (Refer to page B1-68.)
46U0B1-159
3. Measure the connecting rod side clearances.
MEASURING LOCATION
Side clearance:
0.110—0.262mm {0.0043—0.0103 in)
4. If the clearance exceeds the maximum, replace the con

necting rod and cap.
16E0B1-250
5. Apply a liberal amount of clean engine oil to the crankpin
journals and connecting rod bearings.
6. Install the connecting rod caps with the knock pins and the
alignment marks aligned.
7. Tighten the connecting rod cap bolts.

{2.25—2.75 kgf-m, 16.3—19.8 ft Ibf) + 85°—95°
46U0B1-160
ASSEMBLY B1
Torque Specifications
19—25 (1.9—2.6, 14—18)
GASKET, NEW
O-RING,
NEW
jiQgggl
7.9—10.7 Nm
GASKET, NEW (80—110 kgf-cm
70—95.4 ln-lbf)
7 .9 -1 0 .7 N m
7.9—10.7 N m (80—110 kgf-cm,
(80—110 kgf-cm, 70—95.4 In Ibf)
70—95.4 in lbf)
16E0B1-252
Rear Cover
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
3. Using a press, tap the oil seal in evenly until it is flush with
the edge of the rear cover.
Oil seal outer diameter: 109mm (4.29 in)

Oil seal inner diameter: 89.0mm {3.50 in)
46U0B1-079
B 1-79
B1 ASSEMBLY
4. Apply a continuous bead of silicone sealant to the rear cover
16E0B1-254
5. Install the rear cover.

(80—110 kgf cm, 70—95.4 in lbf ]
46U0B1-161
Oil Pump
oil seal.
the edge of the oil pump body.
Oil seal outer diameter: 54.5mm {2.15 in]

46U0B1-080
4. Apply a continuous bead of silicone sealant to the oil pump
housing as shown in the figure.
16E0B1-257
5. Install the oil pump.
Tightening torque:
19—25 N-m {1.9—2.6 kgf-m, 14—18 ft-lbf)
ASSEMBLY B1
6. Remove any sealant that is pushed out at the oil pan side.
46U0B1-162
Water Pump
RUBBER
Install the water pump along with a new gasket and new
SEAL
rubber seals.
Verify that the rubber seals stay in place when installing the
pump.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf}
RUBBER
SEAL
46U0B1-163
Oil Pan Upper Block
1. Remove all foreign material from the contact surfaces.
2. Apply a continuous bead of silicone sealant to the oil pan
upper block as shown in the figure.
46U0B1-081
3. Install the oil pan upper block.
4. Tighten the two nuts.
Tightening torque: 7.9—10.7 N m

(80—110 kgf cm, 70—95.4 in lbf)
46U0B1-082
5. Tighten the oil pan upper block bolts in two or three steps
Tightening torque:
19—25 N m (1.9—2.6 kgf m, 14—18 ft-lbf}
46U0B1-083
B1—81
B1 ASSEMBLY
Oil Strainer
1. Install the oil strainer along with a new gasket.
2. Tighten the bolts marked A first.

[80—110 kgf cm, 70—95.4 in lbf}
46U0B1-164
Oil Pan
46U0B1-165
3. Install the oil pan within five minutes of applying the sealant.
4. Tighten the oil pan bolts.
Tightening torque:
19—25 N-m(1.9—2.6 kgf-m, 14—18 ft-lbf}
46U0B1-166
End Plate
Install the end plate.

[80—110 kgf cm, 70—95.4 in lbf}
Flywheel (MTX)
1. Remove the sealant from the flywheel bolt holes in the crank
shaft and from the flywheel bolts.
46U0B1-167
Caution
• If all of the old thread locking sealant cannot be re
moved from the bolt, it will not torque properly. Re
place the bolt.
Note

3. Apply sealant to the flywheel bolts and install them.
B1—82
ASSEMBLY B1
in the figure.
Tightening torque:
97—102 N m [9.8—10.5 kgf m, 71—75 ft-lbf)
Clutch Disc and Clutch Cover (MTX)

1. Install the clutch disc and the clutch cover by using the SST.
2. Tighten the clutch cover bolts in two or three steps in the
Tightening torque:
1 8 -2 6 N-m [1 .8 -2 .7 kgf m, 1 4 -1 9 ft-lbf)
16E0B1-270
Drive Plate (ATX)
1. Remove the sealant from the drive plate bolt holes in the
crankshaft and from the drive plate bolts.
Caution
• If all of the old thread locking sealant cannot be re
moved from the bolt, it will not torque properly. Re
place the bolt.
Note
• If a new bolt is used do not apply thread locking sealant.
New Mazda bolts have sealant on them.
2. Set the adapter, drive plate, and backing plate onto the
crankshaft.
3. Apply sealant to the drive plate bolts and install them.
in the figure.
Tightening torque:
97—102 Nm [9.8—10.5 kgf m, 71—75 ft-lbf)
B 1-83
B1 ASSEMBLY
CYLINDER HEAD
r BOLT THREADS
5 0 — 60
(
SEAL,
N m [kgf-m, ft-lbt|
16E0B1-273
Valve Seal
The intake and exhaust valve seals are different.
The exhaust valve seal has ridges on the top for identifi
cation.
46U0B1-085
B 1-84
ASSEMBLY B1
4 9 L 0 1 2 00 5
Depth L: 17.7— 18.3mm {0.697—0.720 in)
4 9 L 0 1 2 001
49 L012 002 4 9 L 0 1 2 00 5
16E0B1-275
2. Slide the valve seal onto the valve guide.
3. Set the SST against the valve seal.
49 L 0 1 2 0 0 5
16E0B1-276
Caution
• Using a hammer will damage the valve seal.
4. Using the SST, press the valve seal on by hand until the
SST touches the cylinder head.
49 L012 002
46U0B1 -086
Valve and Valve Spring
1. Install the lower spring seat.
2. Install the valve.
3. Install the valve spring with the closer pitch toward the cyl
inder head.
4. Install the upper spring seat.
46U0B1-087
5. Com press the valve spring by using the SST, and install
the valve keepers.
6. Remove the SST.
7. Tap the end of the vaive stem lightly two or three times with
a plastic hammer to verify that the keepers are fully seated.
46U0B1 -088
B1 ASSEMBLY
Cylinder Head Gasket
1. Remove all foreign material from the top of the cylinder
block.
2. Place the new cylinder head gasket in position.
16E0B1-280
Cylinder Head
1. Install the cylinder head.
2. Tighten the cylinder head bolts.
(1) Apply clean engine oil to the bolt threads and seat faces.
(2) Tighten the cylinder head bolts in two or three steps in
the order shown.

[1.75—2.25 kgf-m, 12.7—16.2 ft-lbf}

(4) Use this mark as a reference, tighten the bolts 85°—95°
in the order shown.
(5) Further tighten each bolt another 8 5 °—95°.
46U0B1-169
HLA
1. Apply clean engine oil to the friction surfaces of the HLA.
2. If the HLA are being reused, install them in the position from
which they were removed.
36U0B1-062
Camshaft
Caution
the camshaft must be held horizontally while it is
installed. Otherwise, excessive force will be applied
to the thrust area, causing burr on the thrust receiv
ing area of the cylinder head journal. To avoid this,
the following procedure must be observed.
No. 3 _
CYLINDER 1. Assemble camshaft onto the cylinder head, facing the cam
noses at No.1 and No.3 cylinders as shown.
MQQA
ASSEMBLY B1
2. Apply silicone sealant to the areas shown. Keep the cam
shaft sliding surface free of sealant to prevent engine
damage.
46U0B1-089
3. Apply engine oil to the camshaft and the cylinder head
journals.
4. Install the camshaft caps to the positions from which they
were removed.
16E0B1-286
5. Tighten the camshaft cap bolts in two or three steps in the
order shown.
Tightening torque:
11.3— 14.2 N m {115—145 kgf cm, 100—125 in Ib f}
6. Verify that the camshaft settles horizontally when two bear

ing cap bolts at No.3 journal are tightened.
7. Apply a small amount of clean engine oil to the lip of each

new camshaft oil seal.
8. Push the oil seals slightly in by hand.
it is flush with the edge of the camshaft cap.
Oil seal outer diameter: 48.0mm {1.89 in]

Camshaft Pulley
1. Install the camshaft pulleys, positioning the dowel pins as
shown.
16E0B1-289
Revised 2/96 (1994 626/M X-6) B 1 -8 7
bl ASSEMBLY
2. Apply clean engine oil to the camshaft bolt threads and

hand tighten the bolts.
3. Hold the camshafts by using a wrench on the cast hexa
gon as shown, and tighten the bolts.
Tightening toque:
50—60 N m {5.0—6.2 kgf-m, 37—44 ft-lbf}
ASSEMBLY B1
TIMING BELT
5.9—7.8 N-m (80—80 kgf-cm, 53—68 ln-lbf |
7.9—10.7 N-m (80—110 kgf-cm,

70—95.4 Inlbf)
GASKET, NEW
O-RING, NEW
7.9—10.7 N-m
(80—110 kgf-cm,
70—95.4 in lbf)
j g_-10,7 N*m ^ 157—166 (16.0—17.0, 118—122)

(80—110 kgf cm, 70—95.4 In Ibf) BOLT THREADS
ft-lbf)
16E0B1-291
Timing belt
1. Install the timing belt pulley and key.
16E0B1-292
B 1-89
B1 ASSEMBLY
2. Install the tensioner spring to the tensioner.
3. Install the tensioner and the idler.
Tightening torque
A: 38—51 N-m {3.8—5.3 kgf-m, 28—38 ft-lbf)
B: 38—51 N-m {3.8—5.3 kgfm, 28—38 ft-lbf)
16E0B1-293
4. Using a torque wrench, rotate the tensioner right and left
to measure the resistance. Replace the tensioner if the tor
que (resistance) is not as specified.
Resistance:
0.49—2.25 N-m {5.0—23.0 kgf-cm, 4.4—19.9 inlbf)
AT 10—30°C {50—86°F)
36U0B1-091
5. Temporarily install the crankshaft pulley bolt.
6. Turn the crankshaft clockwise and align the timing marks.
36U0B1-063
7. Verify that the camshaft pulley marks are aligned with the
cylinder head parting line.
16E0B1-296
8. Install the timing belt so that there is no looseness at the
idler side or between the two camshaft pulleys.
IDLER
16E0B1-297
B 1-9 0
ASSEMBLY B1
9. Turn the crankshaft two turns clockwise, and align the tim
ing belt pulley marks.
10. Verify that all timing marks are correctly aligned.
If not aligned, remove the timing belt and repeat from ten
sioner installation.
16E0B1-298
12. Connect the tensioner to the hook pin.
16E0B1-299
13. Turn the crankshaft two turns clockwise and again verify
that the timing marks are correctly aligned.
16E0B1-30Q
the SST.
16E0B1-301
15. Remove the crankshaft pulley bolt.
16E0B1-302
B1-91
B1 ASSEMBLY
Engine Mount No.3 bracket
Install the engine mount No.3 bracket.
Tightening torque:
44—60 N m {4.4—6.2 kgf m, 32—44 ft-lbf}
46U0B1-171
Timing Belt Cover
1. Install the lower, then upper covers.
2. Install the oil level dipstick and pipe.

{80—110 kgf-cm, 70—95.4 in lbf}
46U0B1-172
Water Pump Pulley
Install the water pump pulley, facing the “ F” marks outward.

{80—110 kgf-cm, 70—95.4 in lbf)
46U0B1-091
the SST.
16E0B1-307
B 1-92
ASSEMBLY B1
3. Install the crankshaft pulley.
4. Tighten the crankshaft pulley bolt.
Tightening torque:
157—166 N-m {16.0—17.0 kgf-m, 116—122 ft-lbf)
16E0B1-308
Cylinder head cover
1. Apply silicone sealant as shown in the figure.
2. Install a new cylinder head cover gasket.
16E0B1-366
3. Apply silicone sealant to the shaded areas of the cylinder
head as shown in the figure.
16E0B1-309
4. Install the cylinder head cover.
5. Install the cylinder head cover bolts and tighten them in
two or three steps in the order shown in the figure.
Tightening torque:
5.9—7.8 Nm {60—80 kgfcm, 53—69 inlbf)
16E0B1-31Q
B 1-93
B1 ASSEMBLY
AUXILIARY PARTS
1 9 - 2 5 (1.9—2.6, 14— 18) 19—25 (1 .9—2.6, 14— 18)
1 9 - 2 5 (1.9—2.6, 1 4 - 1 8 )
38—51 (3.8—5 .3 ,2 8 —38
38—51 (3.8—5 .3 ,2 8 —38
.C T T W I 1 9 - 2 5 (1.9—2.6,
14— 18)
15—22 (1 .5—2.3, 11— 16 WASHER

NEW
- 2 3 (1 .6—2.4, 1 2 - 1 7 )
GASKET, NEW
19—25 (1.9—2.6, 14—18
O-RING, NEW
I f
N-m (kgf-m, ft-lbf)

16E0B1-311
B 1-94
ASSEMBLY B1
Oil Filter
1. Remove all foreign material from the oil filter mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil filter.
3. Install the oil filter and tighten it by hand until the rubber
seal contacts the mounting surface.
4. Tighten the filter 1-1/6 turns by using the SST.
Tightening torque:
13.8—17.6 N m (140—180 kgf cm, 122—156 in Ibf}
Water Outlet
1. Hand tighten bolt ® .
2. Install the water outlet.
Tightening torque:
19—25 N m {1.9—2.6 kgf-m, 14—18 ft Ibf}
46U0B1-092
Heat Gauge Sender Unit and Engine Coolant Tempera
ture Sensor
1. Apply silicone sealant to the top two-thirds of the threads.
2. Install the heat gauge sender unit.
Tightening torque:
6.4—9.3 Nm (65—95 kgf cm, 57—82 in lbf}
3. Install the engine coolant temperature sensors.
Tightening torque:
16—23 N m (1.6—2.4 kgf m, 12—17 ft-lbf}
36U0B1-093
Alternator
1. Install the alternator bracket.
Tightening torque:
38—51 N m (3.8—5.3 kgf-m, 28—38 ft-lbf}
B 1-95
B1 ASSEMBLY
2. Install the alternator and strap.
Tightening torque
A: 38—51 Nm {3.8—5.3 kgfm, 28—38 ft-lbf}
B: 38—51 Nm [3.8—5.3 kgfm, 28—38 ft-lbf}
C: 19—25 N-m [1.9—2.6 kgfm, 14—18 ft-lbf}
16E0B1-320
3. Install the alternator stay. (MTX)
Tightening torque:
19—25 N-m [1.9—2.6 kgfm, 14—18 ft-lbf)
16A0B1-012
Intake Manifold Assembly
1. Remove all foreign material from the intake manifold con
tact surface.
2. Install a new gasket and the intake manifold assembly.
Tightening torque:
19—25 N-m [1.9—2.6 kgfm, 14—18 ft-lbf)
16E0B1-314
Spark Plug
Install the spark plugs.
Tightening torque:
15—22 N-m [1.5—2.3 kgfm, 11—16 ft-lbf)
16E0B1-316
Distributor and High-tension Lead
the distributor.
2. Apply clean engine oil to the drive gear.
3. Verify that the No.1 cylinder is at top dead center and
align the distributor matching marks.
36U0B1-066
B 1-96
ASSEMBLY B1
4. Install the distributor and hand tighten the installation bolts.
5. Connect the high-tension leads.
Engine Hanger
Install the front and rear engine hangers.
Tightening torque:
38—51 Nm [3.8—5.3 kgf m, 28—38 ft-lbf}
B 1-9 7
B1 ENGINE STAND DISMOUNTING
ENGINE STAND DISMOUNTING
PROCEDURE
1. Remove the engine from the SST (engine stand).
2. Remove the SST (engine hanger) from the engine.
3. Install the parts shown in the figure.
N-m jkgt-m, ft-lbf)

16E0B1-323
Thermostat Housing
Install a new gasket and the thermostat housing.
Tightening torque:
19—25 Nm (1.9—2.6 kgfm, 14—18 ft-lbf}
16E0B1-324
B1—98
ENGINE STAND DISMOUNTING B1
Water Bypass Pipe
1. Apply a small amount of clean engine coolant to new
O-rings.
2. Install the water bypass pipes.
Note
• Bolt A is at the water outlet. (Refer to page B1-95.)
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf}
46U0B1-175 3. Connect the water hose.
JIGGLE PIN Thermostat, Thermostat Cover

1. Remove all foreign material from the thermostat cover
mounting surface.
2. Verify that the jiggle pins are aligned with the tab of the ther
mostat gasket as shown.
46U0B1-176
3. Install the thermostat and gasket into the thermostat hous
ing, aligning the tab to the housing as shown in the figure.
16E0B1-327
4. Install the thermostat cover.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf}
16E0B1-328
A/C Compressor Bracket (if equipped)
Install the A/C compressor bracket.
Tightening torque:
38—51 Nm {3.8—5.3 kgf-m, 28—38 ft-lbf}
16E0B1-329
B 1-99
B1 ENGINE STAND DISMOUNTING
Exhaust Manifold
1. Remove all foreign material from the exhaust manifold con
tact surface.
2. Install the new gasket and the exhaust manifold.
Tightening torque
Nut: 20—28 N-m {2.0—2.9 kgf-m, 15—20 ft-lbf}
Bolt: 16—22 N-m {1.6—2.3 kgf-m, 12—16 ft-lbf}
16E0B1-330
EGR Pipe
Install the EGR pipe.
Tightening torque
A: 7.9—10.7 Nm
{80—110 kgf cm, 70—95.4 in lbf}
B: 32—47 N-m {3.2—4.8 kgf m, 24—34 ft Ibf)
46U0B1-177
Exhaust Manifold Insulator
Install the exhaust manifold insulator.

{80—110 kgf cm, 70—95.4 inlbf)
46U0B1-178
P/S oil pump bracket
Install the P/S oil pump bracket.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf)
16E0B1-368
B 1-100
INSTALLATION B1
INSTALLATION
PROCEDURE
Tighten all bolts and nuts to the specified torques.
Step 1
INSTALLATION,
REFER TO SECTION J
86— 116 ( 8.7— 11.9, 63—86)
INSTALLATION,
REFER TO SECTION K2 N-m (kgfm , ft-lbf)
16E0B1-333
Engine mount No.2 bracket
Install the mount bracket.
Tightening torque:
44—60 Nm [4.4—6.2 kgfm, 32—44 ft-lbf)
16A0B1-103
B1-101
B1 INSTALLATION
Install the engine mount No.2 rubber and hand tighten the
through bolt.
46U0B1-179
Starter
Install the starter to the transaxle housing.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf}
16E0B1-335
Intake manifold bracket
Install the intake manifold bracket.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf}
16E0B1-336
INSTALLATION B1
Step 2
Warning
• Be sure the vehicle is securely supported on safety stands.

1. Suspend the engine and transaxle assembly.
Slowly lower the engine and transaxle assembly as a unit.
2. Position the engine and transaxle assembly in the engine
compartment.
3. Align the engine mounts with the engine mount member
mounting holes.
46U0B1-180
B 1-103
B1 INSTALLATION
Engine mount
1. Hand tighten the nuts marked B. (Engine mount No.2)
2. Install the bolts and nuts as shown.
Tightening torque
A: 67—93 N m [6.8—9.5 kgf m, 50—68 ft-lbf)
46U0B1-093
3. Install the engine mount No.1 mounting bolts.
Tightening torque
MTX:
67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf)
ATX
® : 75—104 N m {7.6—10.7 kgf m, 59—82.2 ft-lbf)
(§): 86—116 N-m {8.7—11.9 kgf m, 63—86.0 ft Ibf)
© : 67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf)
46U0B1-094
Tightening torque
Nut: 74—102 N-m
{7.5—10.5 kgf m, 54.3—75.9 ft-lbf)
Bolt: 86—116 N-m
{8.7—11.9 kgf m, 63—86.0 ft-lbf)
46U0B1-095
5. Install the engine mount No.4 bracket.
6. Hand tighten bolts B.
7. Tighten bolts B.
8. Tighten bolts A.
Tightening torque
A: 59—80 N-m {6.0—8.2 kgf m, 44—59 ft-lbf)
B: 59—80 N m {6.0—8.2 kgf m, 44—59 ft-lbf)

46U0B1-096
Tightening torque
MTX
® : 67—93 N m {6.8—9.5 kgf m, 50—68 ft-lbf)
(§): 86—116 N m {8.7—11.9 kgf-m, 63—86 ft-lbf)
ATX
(§): 38—51 N-m {3.8—5.3 kgf-m, 28—38 ft-lbf)
10. Remove the chain from the engine hangers.

11. Tighten the engine mount No.2 nuts. (Refer to Step 1.)
Tightening torque:
75—104 N-m {7.6—10.7 kgf m, 55—77.3 ft-lbf)
46U0B1-097
B 1-104
INSTALLATION B1
12. Tighten the engine mount No.2 rubber through bolt.
Tightening torque:
86—116 Nm {8.7—11.9 kgf m, 63—86 ft-lbf)
13. Install the engine mount No.5 rubber as shown.
Tightening torque
A: 67—93 Nm (6.8—9.5 kgfm, 50—68 ft-lbf)
B: 44—60 Nm (4.4—6.2 kgfm, 32—44 ft-lbf)
46U0B1-098
14. Install the engine mount No.1 stay bracket and ground har
ness (MTX).
Tightening torque:
10.8—14.7 Nm (110—150 kgf cm, 96—130 in Ibf)
46U0B1-099
Step 3
16E0B1-343
B 1-105
B1 INSTALLATION
Joint shaft
1. Install the new clip.
2. Install the joint shaft.
3. Tighten the bolts in the order shown.
Tightening torque:
43—61 N m (4.3—6.3 kgf m, 32—45 ft-lbf}
4. Apply grease to the end of joint shaft.
16A0B1-Q88
Drive shaft
1. Apply grease to the end of the drive shafts.
Caution
• The oil seals are damaged easily if this procedure
is not done correctly.
2. Install the drive shaft.

3. Install the new clip with the end gap facing upward.
4. Push the drive shaft into the joint shaft.
5. After installation, pull the front hub outward to confirm that
the drive shaft is securely held by the clip.
6. Install the lower arm ball joint to the knuckle and tighten the
through bolt.
Tightening torque:
35—56 N m {3.5—5.8 kgf m, 26—41 ft-lbf}
Tie rod end

1. Install the tie rod end to the knuckle.
Tightening torque:
32—44 N m {3.2—4.5 kgf m, 24—32 ft-lbf}
2. Install a new cotter pin.
16E0B1-347
Stabilizer control link
Install the stabilizer control link.
Tightening torque:
37—53 Nm {3.7—5.5 kgf-m, 27—39 ft-lbf}
36U0B1-115
B 1-106
INSTALLATION B1
Extension bar (MTX)
Install the extension bar to the transaxle.
Tightening torque:
3 8 -5 1 N m {3.8—5.3 kgf m, 28—38 ft Ib f}
Shift control rod (MTX)

Install the shift control rod to the transaxle.
Tightening torque:
16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf}
Front exhaust pipe

1. Install a new gasket and connect the front exhaust pipe to
the exhaust pipe. Hand tighten the new nuts.
2. Connect the exhaust pipe to the vehicle body by the mount
rubbers.
3. Tighten the exhaust pipe mounting nuts.
Tightening torque:
38—51 N m {3.8—5.3 kgf m, 28—38 ft-lbf}
Exhaust pipe
1. Install a new gasket and the exhaust pipe. Hand tighten the
new nuts.
2. Hand tighten the bracket bolts.
3. Tighten the exhaust pipe mounting nuts.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf}
4. Tighten the bracket bolts.
Tightening torque:
38—51 N m {3.8—5.3 kgf m, 28—38 ft-lbf}
Transverse member
Install the transverse member.
Tightening torque:
94—131 Nm {9.5—13.4 kgf m, 69—96 ft-lbf}
36U0B1-116
Clutch release cylinder
Install the clutch release cylinder.
Tightening torque:
16—22 Nm {1.6—2.3 kgf m, 12—16 ft-lbf}
16E0B1-350
B1—107
B1 INSTALLATION
Step 4
Connect the hoses shown in the figure.
HEATER HOSE
BRAKE VACUUM HOSE
VACUUM HOSE
/(PURGE)
FUEL HOSE
Step 5
Connect the harness connectors.
46U0B1-185
B 1-108
INSTALLATION B1
Step 6
19—25 (1.9—2.6, 14—18' 7.9—10.7 N m (80—110 kgf cm, 70—95.4 in Ibf)
7.9—10.7 N-m (80—110 kgf cm, 70—95.4 ln-lbf)
19—25 (1.9—2.6, 14—18)
7.9—10.7 N-m (80—110 kgf-cm,

70—95.4 ln-lbf)
44—60 ( 4.4—6.2, 32—44
32—46 (3.2—4.7, 2 4 -3 3 )
6.9—9.8 N-m
(70—100 kgf-cm, 70—86 ln-lbf) 7.9—10.7 N-m
(80—110 kgf-cm,
70—95.4 ln-lbf)
16—22 (1 .6 -2 .3 , 12—16)
7.9—10.7 N-m (80—110 kgf-cm,

70—95.4 ln-lbf)
24—35 12.4—3.6, 1 8 -2 6 )
N-m |kgf-m, ft-lbf)

16E0B1-355
A/C compressor (if equipped)
Install the A/C compressor to the bracket.
Tightening torque:
24—35 N m {2.4—3.6 kgf-m, 18—26 ft-lbf}
P/S oil pump and adjuster

16E0B1-356
1. Install the P/S oil pump adjuster.
Tightening torque:
16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf}
2. Install the P/S oil pump.
Tightening torque
A: 44—60 N-m {4.4—6.2 kgfm, 32—44 ft-lbf]
B: 32—46 Nm {3.2—4.7 kgfm, 24—33 ft-lbf}
3. Connect the P/S oil pump pressure switch connector.

16A0B1-Q94
B 1-109
B1 INSTALLATION
4. Install the P/S pipe brackets to the cylinder head cover.
Tightening torque:
7.9—10.7 N m {80—110 kgf cm, 70—95.4 in lbf}
46U0B1-186
Drive belt
1. Install the drive belt.
2. Adjust the drive belt deflections. (Refer to page B1-6.)
16E0B1-358
Radiator and coolant fan assembly
1. Install the radiator and coolant fan assembly.
Verify that the radiator is centerd in the radiator upper
brackets.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf}
46U0B1-187
2. Connect the upper and lower radiator hoses.
3. Connect the coolant reservoir hose.
4. Connect the coolant fan motor connector.
5. Connect the ATF cooler hoses. (ATX)
Accelerator cable
Free play: 1.5—4.0mm (0.06—0.16 in}

per (D while pressing lock button ® with the throttle valve
fully closed.
46U0B1-101
INSTALLATION B1
Battery
1. Install the battery.
Tightening torque:
7.9—10.7 Nm (80—110 kgf-cm, 70—95.4 in lbf)
2. Connect the positive battery terminal.
46U0B1-188
Resonance chamber No.2
1. Slide the hose clamp onto the hose and push it onto reso
nance chamber No.2.
16E0B1-380
2. Rotate the hose and hook it securely onto the locating knob.
16E0B1-381
3. Tighten the hose clamp.
16E0B1-382
Air cleaner assembly
1. Install the air cleaner assembly.
Tightening torque:
19—25 N m (1.9—2.6 kgf m, 14—18 ft Ibf)
2. Connect the mass airflow sensor connector.

3. Connect the intake air thermosensor connector.
46U0B1-189
B1-111
B1 INSTALLATION
Fresh air duct
Install the fresh air duct.
Tightening torque:
7.9—10.7 N m {80—110 kgf cm, 70—95.4 in lbf)
46U0B1-190
Resonance chamber No.1
Install resonance chamber No.1.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in lbf}
Undercover
Install the undercover.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in lbf)
46U0B1-191

1. Fill with the specified amount and type of engine oil. (Refer to section D1.)
3. Fill with the specified amount and type of transaxle oil. (Refer to sections J, K2.)
4. Install the hood and front wheels.
5. Start the engine and:
(1) Check the engine oil, transaxle oil, and engine coolant leakage
(2) Check the ignition timing, idle speed (Refer to sections F1, F3.)
(3) Check the operation of emission control system
6. Turn off the engine and check drive belt deflection. (Refer to page B1-6.)
7. Perform a road test.
8. Recheck the engine oil and coolant levels.
46U0B1-102
B1—112
B2
warning and section J for audio antitheft system alarm conditions._________
ENGINE
(KL)
INDEX......................................... .... B 2- 2 INSPECTION / REPAIR.................... B?-■ 72

OUTLINE...................................... .... B2— 3 PREPARATION............................... B2-- 72
SPECIFICATIONS...................... .... B 2- 3 CYLINDER HEAD.......................... B2-■ 72
TROUBLESHOOTING GUIDE..... .... B 2- 3 VALVE MECHANISM................... B2-■ 73
ENGINE TUNE-UP ...................... .... B 2- 5 CAMSHAFT................................. B2-■ 76
PREPARATION........................ .... B 2 - 5 HLA............................................. B2-■ 79
ENGINE O IL .............................. .... B 2- 5 CYLINDER BLOCK......................... B2-■ 79
ENGINE COOLANT................... .... B 2- 5 PISTON, PISTON RING, AND
DRIVE BELT.............................. .... B 2- 5 PISTON PIN................................. B2- 80
HLA TROUBLESHOOTING CONNECTING ROD...................... B2- ■ 82
GUIDE..................................... .... B 2- 7 CRANKSHAFT............................. B2- 82
COMPRESSION........................... .... B 2- 8 BEARING .................................... B2- 83
INSPECTION........................... .... B 2- 8 OIL JE T .......................................... B2- 83
ON-VEHICLE MAINTENANCE.... .... B 2- 9 TIMING BELT................................. B2- 83
PREPARATION.......................... .... B 2- 9 TIMING BELT AUTO TENSIONER. B2- 84
TIMING BELT............................ .... B 2- 10 PULLEY.......................................... B2- 84
CYLINDER HEAD GASKET...... .... B 2- 20 TIMING BELT COVER.................... B2- 84
HLA............................................. .... B 2- 34 ASSEMBLY .................................... B2- 85
FRONT OIL SEAL ................... .... B 2- 37 PREPARATION............................... B2- 85
REAR OIL SEAL ...................... .... B2— 39 CYLINDER BLOCK
REMOVAL..................................... .... B 2- 42 (INTERNAL PARTS)..................... B2- 87
PROCEDURE............................ .... B 2- 42 CYLINDER BLOCK
ENGINE STAND MOUNTING..... .... B 2- 51 (EXTERNAL PARTS).................... B 2- 95
PREPARATION.......................... .... B2— 51 CYLINDER HEAD.......................... B 2- 99
PROCEDURE............................ .... B2— 52 TIMING BELT................................. B 2- 106
DISASSEMBLY .......................... .... B 2- 55 AUXILIARY PARTS....................... B 2- 111
PREPARATION.......................... .... B 2- 55 ENGINE STAND DISMOUNTING .... B 2- 115
AUXILIARY PARTS.................. .... B2— 57 PROCEDURE.............................. B 2- 115
TIMING BELT.......................... .... B2— 59 INSTALLATION................................ B 2- 116
CYLINDER HEAD..................... .... B2— 61 PROCEDURE................................. B 2- 116
CYLINDER BLOCK 46U0B2-001
(EXTERNAL PARTS)............... .... B 2- 65
CYLINDER BLOCK
(INTERNAL PARTS)................ ..... B2— 68
B2 INDEX
INDEX
HLA INSPECTION PAGE B 2 -7
INTAKE MANIFOLD
TIGHTENING TORQUE
19—25 N m (1.9—2.6 kgf-m
14—18 ft-lbf
ENGINE COOLANT,
SECTION E2
ENGINE OIL, SECTION D2
COMPRESSION INSPECTION,
PAGE B 2 -8
EXHAUST MANIFOLD
TIGHTENING TORQUE
DRIVE BELT 19—25 N-m [1.9—2.6 kgf-m, 14— 18 ft-lbf)
DEFLECTION AT 98 N (10 kgf, 22 Ibf) mm (in) COMPRESSION kPa (kgf/cm2, psi)-rpm
DRIVE BELT NEW USED LIMIT STANDARD 1,402 (14.3, 203)-250
ALTERNATOR 6.0—7.0 (0.24-0.27) 7.0—8.0 (0.28-0.31) 9.0 (0.35) MINIMUM 981 (10.0, 142)-250
ALTERNATOR + A/C 5.5—6.5 (0.22-0.25) 6.5—7.5 (0.26-0.29) 8.0 (0.32)
P/S 6.0—7.0 [0.24-0.27] 7.0—8.0 (0.28-0.31) 9.0 (0.35)
46U0B2-002
1. Timing belt 5. Rear oil seal

Removal / Inspection / Replacement......................... page B2- 39
Installation...............................page B2-10 6. Engine
2. Cylinder head gasket Removal................................ page B2- 42
Replacement............................page B2-20 Engine stand mounting......... page B2- 51
3. HLA Disassembly.......................... page B2- 55
Removal / Installation............... page B2-34 Inspection / Repair................. page B2- 72
4. Front oil seal Assembly............................... page B2- 85
Replacement............................page B2-37 Engine stand dismounting....page B2-115
Installation.............................. page B2-116
B2—2
OUTLINE, TROUBLESHOOTING GUIDE B2
OUTLINE
SPECIFICATIONS
Engine KL
Item
Type Gasoline, 4-cycle
Cylinder arrangement and number 60°-V configuration, 6 cylinders
Combustion chamber Pentroof
B2
Valve system DOHC, belt-driven, 24 valves
Displacement ml (cm3, cu in) 2,496 (2,496, 152.3)
Bore and stroke mm (in) 84.5x74.2 (3.33x2.92)
Compression ratio 9.2
Compression pressure kPa (kgf/cm2, psi)-rpm 1,402 (14.3, 203)-250
Open BTDC 8°
IN
Close ABDC 47°
Valve timing
Open BBDC 50°
EX
Close ATDC 5°
IN mm (in) 0: Maintenance-free
Valve clearance
EX mm (in) 0: Maintenance-free
46U0B2-003
Cylinder Arrangement
RH
"\
LH
Hard starting Malfunction of engine-related components

Burned valve Replace B2-73
Worn piston, piston ring, or cylinder Replace or repair B2-80, 81
Malfunction of fuel system Refer to section F2
Malfunction of electrical system Refer to section G
Poor idling Malfunction of engine-related components
Poor valve-to-valve seat contact Repair or replace B2-75
‘ Tappet noise may occur if the engine has not been started for an extended period of time. The noise should stop after the engine
reaches normal operating temperature. (HLA troubleshooting: Refer to page B2-7.)
B 2-3
B2 TROUBLESHOOTING GUIDE
Insufficient power Insufficient compression

Compression leakage from valve seat Repair B2-75
Sticking valve Replace B2-73
Cracked or distorted cylinder head Replace B2-72
Sticking, damaged, or worn piston ring Replace B2-81
Cracked or worn piston Replace B2-80
Malfunction of fuel system Refer to Section F2
Others
Dragging brake Refer to Section P
Incorrect tire size Refer to Section Q
Abnormal Malfunction of engine-related components
combustion Malfunction of HLA* Replace B2-34
Sticking or burned valve Replace B2-73
Carbon accumulation in combustion chamber Eliminate carbon
Malfunction of fuel system Refer to Section F2
Excessive oil Oil working up
consumption Worn piston ring groove or sticking piston ring Replace B2-81
Worn piston or cylinder Replace or repair B2-80, 81
Oil working down
Worn valve seal Replace B2-64
Worn valve stem or guide Replace B2-73, 74
Oil leakage Refer to Section D2
Engine noise Crankshaft or bearing-related parts
Excessive main bearing oil clearance Replace or repair B2-89
Main bearing heat-damaged Replace B2-83
Excessive crankshaft end play Replace or repair B2-92
Excessive connecting rod bearing oil clearance Replace or repair B2-93
Connecting rod bearing heat-damaged Replace B2-83
Piston-related parts
Worn cylinder Replace or repair B2-79
Worn piston or piston pin Replace B2-80, 81
Damaged piston ring Replace B2-81
Bent connecting rod Replace B2-82
Valve train-related parts
Broken valve spring Replace B2-76
Excessive valve guide clearance Replace B2-73
Malfunction of timing belt auto tensioner Replace B2-84
Malfunction of friction gear Replace B2-76
Malfunction of cooling system Refer to section E2
Others
Malfunction of water pump bearing Refer to section E2
Improper drive belt tension Adjust B2- 5
Malfunction of alternator bearing Refer to section G
Exhaust gas leakage Refer to section F2
46U0B2-125
* Tappet noise may occur if the engine has not been started for an extended period of time. The noise should stop after the engine
reaches normal operating temperature. (HLA troubleshooting: Refer to page B2-7.)
B 2 -4
ENGINE TUNE-UP B2
ENGINE TUNE-UP
PREPARATION
SST
49 9200 020 For

inspection of
Tension gauge, drive belt tension
belt *
46U0B2-126
ENGINE OIL
Inspection
stop it.
5. Add or replace oil if necessary.
Note
represents 1.0 L (1.1 US qt, 0.9 Imp qt}.
ENGINE COOLANT
Inspection
Coolant level (Engine cold)
Warning
• Removing the radiator cap or the coolant filler cap
steam can shoot out and cause serious injury. It can
also damage the engine and cooling system.
sure escapes.
down on the cap—still using a cloth—turn it, and
remove it.
1. Verify that the coolant level is at the filler neck.

2. Verify that the coolant level on the dipstick is between the
F and L marks.
3. Add coolant if necessary.
Note
Coolant quality
radiator cap, filler cap, and filler neck.
2. Verify that the coolant is free of oil.
3. Replace the coolant if necessary.
B2—5
B2 ENGINE TUNE-UP
DRIVE BELT
Inspection
if necessary.
V-RIBBED BELT 2. Verify that the drive belts are correctly mounted on the
pulleys.
46U0B2-127
at least 30 minutes after the engine has stopped. Apply
moderate pressure 98 N {10 kgf, 22 Ibf} midway between
the specified pulleys.
46U0B2-007
Deflection
mm (in)
Drive belt *New Used Limit
6.0—7.0 7.0—8.0 9.0
Alternator
(0.24-0.27) (0.2 8-0 .31 ) (0.35)
Alternator + 5.5—6.5 6.5—7.5 8.0
A1C (0.22-0.25) (0.26—0.29) (0.32)
6.0—7.0 7.0—8.0 9.0
P/S
(0.24-0.27) (0.28-0.31) (0.35)
4. If the deflection is not within specifications, adjust it.

Tension
N (kgf, Ibf)
Drive belt ’ New Used Limit
690-880 5 00 -6 80 440
Alternator
(7 0 -9 0 , 160-190) (5 0 -7 0 , 110-150) (45, 99)
Alternator + 690-880 5 00 -6 80 440
A/C (70—90, 160—190) (50—70, 110—150) (45, 99)
5 40 -6 80 4 00 -5 30 340
P/S
(5 5 -7 0 , 130-150) (40—55, 8 8 -1 2 0 ) (35, 77)
2. If the tension is not within specifications, adjust it.
46U0B2-010
B 2 -6
ENGINE TUNE-UP B2
Adjustment
^>51
Alternator+ A/C belt
1. Loosen the idler pulley locknut ® .
2. Adjust the belt deflection by turning the adjusting bolt (§).
Deflection
(to
spgr /
(D 1
(Alternator + A/C)
New: 5.5—6.5mm [0.22—0.25 in)
Used: 6.5—7.5mm (0.26—0.29 in)
(Alternator)
New: 6.0—7.0mm (0.24—0.27 in)
46U0B2-Q11
Used: 7.0—8.0mm (0.28—0.31 in)
Tightening torque:
32—46 N-m (3.2—4.7 kgf m, 24—33 ft-lbf}
P/S
tfrI/M®
46U0B2-128
1. Loosen the idler pulley locknut ® .
2. Adjust the belt deflection by turning the adjusting bolt (§).
Deflection
New: 6.0—7.0mm (0.24—0.27 in)
Used: 7.0—8.0mm (0.28—0.31 in)
3. Tighten the pulley locknut.
Tightening torque:
32—46 N-m (3.2—4.7 kgf-m, 24—33 ft-lbf}
HLA TROUBLESHOOTING GUIDE
Problem Possible Cause Action
1. Noise when engine is first started after oil Insufficient oil in system Run engine at 2,000—3,000 rpm.
is changed. Oil leakage from HLA If noise stops after 2 seconds—10 minutes,*
2. Noise when engine is started after setting HLA is normal.
apporox. one day. If not, replace HLA.
*Time required for engine oil to circulate
3. Noise when engine is started after crank Insufficient oil in HLA within engine includes tolerance for engine
ing for 3 seconds or more. Oil leakage from HLA oil condition and ambient temperature.
4. Noise when engine is started after new
HLA is installed.
5. Noise continues more than 10 minutes. Insufficient oil pressure Check oil pressure.
If lower than the specification, check for
cause.
(3.4—5.0 kgf/cm2, 49—71 psi)-3,000 rpm
Faulty HLA (Refer to page B2-36)
Press down HLA by hand.
If it moves, replace HLA.
If it does not move, HLA is normal.
Measure valve clearance.
If more than 0mm (0 in), replace HLA.
6. Noise during idle after high speed Incorrect oil amount Check oil level.
running. Drain or add oil as necessary.
Deteriorated oil Check oil quality.
If deteriorated, replace with specified type
and amount of oil.
36U0B2-005
B 2 -7
B2 COMPRESSION
COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor
idle, check the following:
1. Ignition system (Refer to section G.)
2. Compression (Refer to below)
3. Fuel system (Refer to section F2.)
INSPECTION
1. Verify that the battery is fully charged. Recharge it if
necessary.
2. Warm up the engine to the normal operating temperature.

3. Remove the spark plugs.
4. Disconnect the primary wire connector from the ignition coil.
16E0B2-024
5. Insert a compression gauge into the No.1 spark plug hole.
6. Fully depress the accelerator pedal and crank the engine.
7. Record the maximum gauge reading.
8. Check each cylinder as above.
Compression:
1,402 kPa {14.3 kgf/cm2, 203 psi}-250 rpm
Minimum:
981 kPa {10.0 kgf/cm2, 142 psi)-250 rpm
9. If the compression in one or more cylinders is low, pour a

small amount of clean engine oil into the cylinder and
recheck the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder wall may be worn.
(2) If the compression stays low, a valve may be stuck or
improperly seating.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be damaged or the cylinder
head distorted.
10. Connect the ignition coil connector.
11. Install the spark plugs.
Tightening torque:
15—22 Nm {1.5—2.3 kgf m, 11—16 ft-lbf}
16E0B2-026
B 2 -8
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 S120 710 For 49 E011 1A1 For

Holder, coupling
flange
crankshaft
rotation
Set, holder
s i crankshaft
rotation
49 E011 101 For 49 E011 102 For

Holder crankshaft Bolts crankshaft
49 E011 1A1) 49 E011 1A1)
49 G017 5A0 For 49 G017 501 For

Support, engine engine Bar engine
(Part of
49 G017 5A0)
49 G017 502 For 49 G017 503 For

Support engine Hook engine
(Part of (Part of
49 G017 5A0) 49 G017 5A0)
49 E011 1A0 For 49 E011 103 For

Brake set, crankshaft Shaft crankshaft
ring gear rotation (Part of rotation
49 E011 1A0)
49 E011 104 For 49 E011 105 For

Collar crankshaft Stopper crankshaft
49 E011 1A0) 49 E011 1A0)
46U0B2-131
Warning
• Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Pro
tect your skin by washing with soap and water immediately after this work.
TIMING BELT
Removal / Inspection / Installation
2. Remove the sprash shield and right front wheel.
3. Remove the drive belts.
N m {kgfm, ft-lbf)
46U0B2-132
1. Water pump pulley 8. Engine harness bracket

2. Idler pulley bracket 9. Timing belt cover
3. P/S oil pump Removal Note.......................... page B2-13
Removal Note..............................page B2-11 Installation Note....................... page B2-16
Installation Note........................page B2-18 10. Timing belt
4. Crankshaft pulley Removal Note.......................... page B2-13
Removal Note.......................... page B2-12 Inspection................................ page B2-83
Installation Note....................... page B2-18 Installation Note....................... page B2-15
5. Timing belt pulley 11. Timing belt auto tensioner
Removal Note...........................page B2-12 Inspection................................ page B2-84
6. Dipstick and pipe Installation Note....................... page B2-14
Removal Note...........................page B2-12 12. Tensioner pulley
Installation Note........................page B2-17 13. No.2 idler pulley
7. Crankshaft position sensor harness bracket 14. No.1 idler pulley
B 2 -1 0
Removal Note
P/S oil pump
1. Remove the bolts shown in the figure and secure the P/S
oil reservoir away from the engine.
16E0B2-029
2. Loosen the pulley nut as shown.
3. Remove the pulley.
16E0B2-030
4. Remove the bolt shown in the figure.
16EQB2-031
5. Remove the bolts shown in the figure and remove the P/S
oil pump.
16E0B2-032
6. Position the P/S oil pump away from the engine and
secure it with wire.
16E0B2-033
B 2-11
Crankshaft pulley
Caution
• The crankshaft position sensor rotor is on the rear
of the pulley, and can be damaged easily.
46U0B2-015
1. Install the SST with bolts (M1 Ox 1.25) to the crankshaft
pulley.
Caution
• Install the bolts fully.
2. Remove the crankshaft pulley bolt and the pulley.
46U0B2-133
Timing belt pulley
Note
puller.
46U0B2-016
Dipstick and pipe
1. Disconnect the crankshaft position sensor connector.
2. Remove the clip from the dipstick pipe.
46U0B2-134
3. Remove the dipstick and pipe.
4. Plug the hole in the engine after removing the pipe.
46U0B2-017
B 2-12
Timing belt cover
1. Support the engine by using the SST (engine support).
2. Remove the engine mount No.3.
16A0B2-077
3. Remove the right and left timing belt covers.
16E0B2-041
Timing belt
1. Install the crankshaft pulley bolt into the crankshaft.
2. Turn the crankshaft so that the No.1 piston is at TDC of the
compression stroke.
3. Mark the timing belt rotation on the belt for proper reinstal
lation.
16A0B2-078
4. Loosen the auto tensioner bolts and remove the lower bolt.
Caution
• When removing the bolt, hold the tensioner so that
the bolt holes are aligned, otherwise the threads can
be damaged.
46U0B2-018
B2—13
5. Remove the No.1 idler pulley and remove the timing belt.
Caution
• When removing the pulley bolt, hold the pulley so
that the bolt holes are aligned, otherwise the threads
can be damaged.
No.1 IDLER PULLEY
46U0B2-019
Inspection
I*I Inspect the following and repair or replace as necessary.
(1) Timing belt (Refer to page B2-83.)
f &) (2) Timing belt auto tensioner (Refer to page B2-84.)
I Y (3) Timing belt pulley (Refer to page B2-84.)
(4) Camshaft pulleys (Refer to page B2-84.)
v
- • .’ • q )
46U0B2-135
Installation Note
Timing belt auto tensioner
WASHER
I ALIGN THE
HOLES
1. Set a flat washer under the tensioner body to prevent dam
age to the body plug.
2. Slowly press in the tensioner rod by using a press or a vise.
• Do not press the tensioner rod to more than 9,807

N {1,000 kgf, 2,200 Ibf). It will damage the ten
sioner.
46U0B2-136
3. Insert a pin into the second hole in the body as shown to
hold the tensioner rod.
Pin diameter: 1.6mm {0.063 in]
46U0B2-137
4. Set the tensioner in place and snugly tighten the tensioner
upper bolt.
Note
• This must be done to reduce the timing belt resistance
when the idler pulley is installed.
46U0B2-020
B 2-1 4
Timing belt
1. Turn the camshaft pulleys and align the timing marks of the
camshaft pulleys with those of the cylinder heads.
16E0B2-049
2. Using the crankshaft bolt, turn the crankshaft and align the
timing marks of the timing belt pulley and the oil pump.
3. Install the timing belt on the pulleys in the order shown

below.
Timing belt pulley
S Idler pulley No.2
(3) LH camshaft pulley
@ Tensioner pulley
© RH camshaft pulley
/ ■ '•'* ■
4. Verify that the belt has no looseness at the tension side.

5. Install the No.1 idler pulley while applying pressure on the
timing belt.
Tightening torque:
38—51 N-m {3.8—5.3 kgf m, 28—38 ft Ibf)
46U0B2-021
6. Push the auto tensioner in the direction of the arrow and
tighten the bolts.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf J
46U0B2-138
B 2-15
7. Remove the pin from the auto tensioner to apply tension
to the belt.
8. Turn the crankshaft twice in the direction of rotation, and

align the timing marks.
9. Verify that all timing marks are correctly aligned. If neces
sary, repeat the procedure beginning from installation of the
timing belt auto tensioner.
10. Check the timing belt deflection by applying moderate pres

sure 98 N {10 kgf, 22 Ibf) midway between the crank
shaft pulley and the auto tensioner. If not correct, replace
the auto tensioner.
Deflection: 6.0—8.0mm {0.24—0.31 in)
Timing belt cover

1. Install the right timing belt cover.
Tightening torque:
7.9—10.7 N m {80—110 kgf-cm, 70—95.4 in Ibf)
2. Install the left timing belt cover.
Tightening torque:
7.9—10.7 N-m {80—110 kgf cm, 70—95.4 in lbf}
46U0B2-143
B 2-1 6
3. Install the crankshaft position sensor connector bracket on
the left timing belt cover.
Tightening torque:
7.9—10.7 N m {8 0 -1 1 0 kgf cm, 70—95.4 in lbf)
46U0B2-144
4. Install the harness bracket on the right timing belt cover.
Tightening torque:
7.9—10.7 N m {80—110 kgf cm, 70—95.4 in Ibf)
46U0B2-145
5. Install the engine mount No.3.
Tightening torque
A: 74—102 Nm {7.5—10.5 kgf m, 55—75 ft-lbf)
B: 86—116 N-m {8.7—11.9 kgf m, 63—86.0 ft Ibf)
6. Remove the SST (engine support).
16E0B2-446
Dipstick and pipe
1. Apply clean engine oil to a new O-ring and install it on the
pipe.
2. Remove the plug from the engine and install the pipe.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in lbf)
3. Install the dipstick.
46U0B2-147
B 2-17
4. Install the crankshaft position sensor harness and clip to the
dipstick pipe.
5. Connect the connector.
36U0B2-081
Crankshaft pulley
2. Install the crankshaft pulley and hand tighten the bolt.
3. Mount the SST on the crankshaft pulley to hold the
crankshaft.
4. Tighten the crankshaft pulley bolt.
Tightening torque:
157—166 Nm {16.0—17.0 kgf m, 116—122 ft-lbf)
46U0B2-148
P/S oil pump
Tightening torque
A: 32—46 N m {3.2—4.7 kgf m, 24—33 ft Ibf)
B: 19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf)
16E0B2-065
2. Install the P/S oil pump pulley and hand tighten the pulley
nut.
3. Tighten the pulley nut by using a 12mm {0.47 in) socket
on one of the P/S oil pump mount bolts.
Tightening torque:
63—93 Nm {6.4—9.5 kgf m, 47—68 ft-lbf)
46U0B2-149
4. Install the P/S oil reservoir and the engine ground.
Tightening torque:
6.9—9.8 N-m {70—100 kgf-cm, 61—86 in-ibf)
36U0B2-155

1. Install the drive belts. (Refer to page B2-7.)
2. Install the sprash shield and right front wheel.
3. Fill the radiator and coolant reservoir with the specified amount and type of engine coolant.
4. Perform the necessary engine adjustments. (Refer to section F2.)
46U0B2-15Q
CYLINDER HEAD GASKET
Replacement
Warning
• Release the fuel pressure. (Refer to Section F2.)
• Keep sparks and open flames away from the fuel area.
• Do not support the engine by using a jack under the oil pan. It will damage the oil pan. Rein'
stall the engine mount No.3 to support the engine after removing the timing belt.

2. Piain the engine coolant. (Refer to section E2.)
3. Romove the timing belt. (Refer to page B2-10.)
4. Romove in the order shown in the figure, referring to Removal Note.
11.3—14.2 N m 5.0—8.8 N m
19—25 (1.9—2.6, 14—18) (2 ) 1115-145 kgf-cm, 100—125 In lbf) 150—90 kgfcm,
44—78 Inlbf)
GASKET,
REPLACE
Ir i r
BOLT THREADS
123—140
12.5—14.3,
91—103)
(1.9—2.6, 14—18)
—10.7 N m
-110 kgf-cm,
95.4 Inlbf)
.65, 17.0—19.1)
95° + 85°—95°
1 9 -2 5
(1.9—2.6, 14—18
GASKET,
REPLACE
7.9—10.7 N-m
(80—110 kgf-cm,
70—95.4 ln-lbf |
44—60 14.4—6.2, 32
7.9—10.7 Nm (80—110 kgfcm, 70—95.4 Inlbf)
N-m (kgf-m, ft-lbf)

46U0B2-151
B 2 -2 0
1. Fresh air duct 10. Radiator hose, upper
2. Air cleaner housing assembly 11. No.3 engine mount bracket
3. Accelerator cable Removal Note.......................... page B2-24
Installation Note.................... ... page B2-33 Installation Note....................... page B2-29
4. High-tention leads 12. Seal plate
5. Harness 13. Water outlet
Removal Note........................ ... page B2-22 14. Exhaust pipe
Installation Note.................... ... page B2-33 15. Engine hanger
6. Intake manifold assembly 16. Camshaft cap, blind cap, and oil seal
Removal Note........................ ... page B2-22 Removal Note.......................... page B2-24
7. Distributor 17. Camshaft
8. Cylinder head cover 18. Cylinder head bolt
Removal Note........................ ... page B2-24 Removal Note.......................... page B2-25
Installation Note.................... ... page B2-30 19. Alternator strap
9. Camshaft pulley 20. Cylinder head
Removal Note........................ ... page B2-24 Installation Note....................... page B2-26
Installation Note.................... ... page B2-29 21. Cylinder head gasket and O-ring
46U0B2-152
B2-21
Removal Note
Harness
Disconnect the harness connectors shown in the figure.
16E0B2-076
Intake manifold assembly
Warning
• Cover the hose with a rag because fuel will spray
out when disconnecting.
• Keep sparks and open flames away from the fuel
area.
1. Plug the disconnected hoses to avoid fuel leakage.
36U0B2-017
2. Temporarily install the engine mount No.3 bracket to sup
port the engine.
16A0B2-082
B 2-22
3. Remove the SST installed for timing belt removal.
4. Remove the stays, bracket, fuel pipe, and hoses as shown in the figure.
5. Loosen the mounting bolts and nuts in two or three steps.
MOUNTING BOLTS AND NUTS

INTAKE MANIFOLD STAY
FUEL PIPE AND HOSE
W ASHER,REPLACE
AIR CLEANER HOUSING BRACKET
16E0B2-448
B 2-23
Cylinder head cover
1. Remove the bolts shown in the figure.
2. Disconnect the ventilation pipe (left cylinder head).
16E0B2-082
Camshaft pulley
as shown, and loosen the camshaft pulley lockbolt.
46U0B2-153
1. Install the SST and support the engine.
16A0B2-083
2. Disconnect the engine mount No.3 bracket from the engine
mount rubber.
3. Remove the engine mount No.3 bracket from the engine.
16A0B2-084
Camshaft cap, blind cap, and oil seal
Caution
• When the camshaft lobe is pressing on the HLA,
removing the camshaft caps can damage the cylin
der head thrust journal support.
46U0B2-022
B 2 -2 4
1. Loosen the front camshaft cap bolts in five or six steps in
the order shown.
2. Remove the front camshaft cap.
Note
• Perform this same procedure for the right and left cylin
der head.
• Bolt © fits only the right cylinder head.
3. Loosen the camshaft cap bolts in five or six steps in the or
der shown.
Caution
• Remove the thrust cap only after removing all cam
shaft caps. Otherwise, the thrust cap can be
damaged.
Note
• Before removing the camshaft caps, note their locations.
They are identified as follows;
Right head: numbers
Left head: letters
46U0B2-025
Cylinder head bolt
1. Temporarily install the engine mount No.3 bracket to sup
port the engine.
2. Remove the SST.
B 2-25
order shown.
16E0B2-092
Installation Note
Cylinder head
1. Apply dean engine oil to new O-rings and install them to
the oil control plugs.
46U0B2-154
2. Thoroughly remove all dirt, oil, and other material from the
decks of the cylinder block.
3. Turn the crankshaft clockwise and apply engine oil to the
cylinder walls.
4. Place a new cylinder head gasket on the left bank with the
L mark.
5. Place a new cylinder head gasket on the right bank with
the R mark.
46U0B2-026
6. Install the cylinder head to the cylinder block.
7. Tighten the cylinder head bolts as described below.
(1) Before installation, measure the length of each bolt. Re
place a bolt if it exceeds the maximum length.
Length: 133.7—134.3mm (5.264—5.287 in)

Maximum: 135.0mm (5.315 in}
133.7— 134.3mm
{5.264— 5.287 in }
*
46U0B2-155
(2) Apply clean engine oil to the threads and the seat face
of each bolt, and install them and the washers.
(3) Tighten the bolts in two or three steps in the order shown.

(2.35—2.65 kgf m, 17.0—19.1 ft-lbf}
16E0B2-096
B 2-26
(5) Using the marks as a reference, tighten the bolts by
turning each 85°— 95° in the sequence shown.
(6) Further tighten each bolt by turning another
85°— 95°.
8. Support the engine by using the SST.
9. Disconnect the engine mount No.3 bracket.

10. Remove the engine mount No.3 bracket from the en
gine.
Camshaft, camshaft cap, blind cap, and oil seal

1. Apply clean engine oil to the camshaft journals, cam
shaft lobes, and camshaft gears.
2. Install the camshafts so that the intake camshaft gear
mark and exhaust camshaft gear marie align.
Adjust the friction gear position with a screwdriver so that
the HLAs are not lifted by the cam lobes. {Intake Side
cam lobes of the No.1 cylinder <RH) and No.2 cylinder
(LH) face straight up.)
r tp p iie u VMM.
B2 ON-VEHICLE MAINTENANCE 1YVGE22D*R5100001—

1YVGE31D*R5100001—
Caution
• Install the thrust caps (RH is 5 mark, LH is B m ark)
first. Otherwise, camshaft can be broken or dam
aged. .......
3. Install the thrust caps onto the cylinder head. Hand tight
en the cap bolts gradually in five or six steps in the order
shown, until the thrust caps fully seated on the cylinder
head.
4. Apply silicone sealant to the shaded areas as shown.
Caution
the camshaft m ust be held horizontally while it is
installed. Otherwise, excessive force will be ap
plied to the thrust area, causing burr on the thrust
receiving area of the cylinder head Journal. To
avoid this, the following procedure must be ob
served.
5. Install the camshaft caps according to their identification

marks, and hand tighten the bolts.
Note
• RH: numbers
• LH: letters
6. Tighten the bolts in the order shown. Verify that t ie cam

shaft remains horizontal as the camshaft cap bolts
(marked (T) in the figure) tightened.
Tightening torque:
11.3— 14.2 N m {115— 145 kgf-cm, 100— 125 in lbf)
7. Retighten the bolts in the order shown.
Tightening torque:
11.3— 14.2 N m {115— 145 kgf-cm, 100— 125 in lbf}
8. Apply a light coat of clean engine oil to the new oil seal
and the cylinder head.
9. Tap the camshaft oil seal into the cylinder head by using
a pipe.
Protrusion: 0— 0.5 mm {0— 0.02 in}
Note
• Oil seal outer diameter: 44.0 mm {1.73 in}
• Oil seal inner diameter: 30.0 mm {1.18 in}
46U0B2-162
Revised 5/96
10. Apply sealant to a new blind cap.
11. Tap in the blind cap by using a plastic hammer.
46U0B2-163
1. Install the engine mount No.3 bracket to the engine.
Tightening torque:
44—60 Nm {4.4—6.2 kgf m, 32—44 ft Ibf)
2. Temporarily install the engine mount No.3 bracket to the

engine mount rubber.
Camshaft pulley
The right and left pulleys are different and must be installed
on the same head that they were removed from.
1. Install the camshaft pulley so that the “ R” mark can be seen
and the groove aligns with the camshaft knock pin.
46U0B2-028
B 2-29
2. Install the camshaft pulley so that the “ L” mark can be seen
36U0B2-084
3. Apply engine oil to the lock bolt threads and hand tighten
the lock bolt.
4. Hold the camshaft by using a suitable wrench on the cast
hexagon as shown, and tighten the bolt.
Tightening torque:
123—140 N m (12.5—14.3 kgf m, 91—103 ft-lbf)
46U0B2-164
Cylinder head cover
1. Remove all old silicone sealant from the cylinder head and
cover.
2. Coat a new gasket with silicone sealant, and install onto the
16A0B2-017
» 3. Remove all dirt and other material from the cylinder head,
& and apply sealant to the shaded areas as shown.
<
f l l r B
f i t ■sassii |
16A0B2-018
4. Install the cylinder head cover and tighten the bolts in two
or three steps in the order shown.
Note
• Left cylinder head cover bolts are round.
Tightening torque:
5.0—8.8 N m (50—90 kgf cm, 44—78 in lb f)
46U0B2-029
B 2-3 0
5. Recheck the torque of the bolts indicated, and tighten them
if necessary.
RH: © , ©
LH: © , ®
6. Install the ventilation pipe to the left cylinder head cover.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95 in lbf}
36U0B2-085
Distributor
the distributor.
2. Apply clean engine oil to the drive blade.
16AOB2-060
3. Install the distributor with the blade fit into the camshaft
groove.
4. Hand tighten the distributor mounting bolts.
46U0B2-Q30
B2-31
Intake manifold assembly
1. Install a new gasket and the intake manifold. Hand tighten
the bolts and nuts.
2. Connect the stays, bracket, fuel pipe, and hoses as shown in the figure.
3. Tighten the intake manifold bolts and nuts in two or three steps.
19—25 11.9—2.6, 14—18
19—25 {1.9—2.6, 14—18)
7.9—10.7 Nm (80—110 kgf-cm, 70—95 Inlbf)
WASHER, NEW
N-m{kgf.m, ft-lbf)
46U0B2-167
B 2-32
Harness
Connect the harness connectors as shown in the figure.
16E0B2-124
Accelerator cable
Free play: 1.5—4.5mm (0.06—0.17 in)
3. If not as specified, turn stopper © while pressing lock but

ton (A) to release the lock.
4. Push the spring in direction (5) and adjust the cable free
play.
UNLOCK
5. Lock stopper ® after locking stopper (§).
46U0B2-168

1. Install the timing belt. (Refer to page B2-10.)
2. Fill the radiator and coolant reservoir with the specified amount and type of engine coolant.
(Refer to section E2.)
(1) Engine oil and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to section F2.)
(3) Operation of emission control system.
4. Recheck the engine coolant and oil levels.
46U0B2-169
B 2-33
HLA
Warning
• Release the fuel pressure. (Refer to section F2.)
• Keep sparks and open flames away from the fuel area.

2. Remove the timing belt. (Refer to page B2-10.)
3. Remove in the order shown in the figure, referring to Removal Note
11.3—14.2 N-m 5.0—8.8 N-m

(115—145 kgf-cm, (50—90 kgf-cm,
100—125 ln-lbf) 44—78 Inlbf)
11.3—14.2 N m
(115—145 kgf-cm,
100—125 ln-lbf)
GASKET,
REPLACE
7.9—10.7 N m
(80—110 kgf-cm,
70—95.4 in Ibf)
BOLT THREADS
123—140
(12.5-14.3, 9 1 -1 0 3 )
N-m( kgf-m, ft-lbf)

46U0B2-170
1. Accelerator cable 7. Camshaft pulley
Installation Note....................... page B2-33 Removal Note.......................... page B2-24
2. High-tension leads Installation Note....................... page B2-29
3. Harness 8. Camshaft cap, blind cap, and oil seal
Removal / Installation Note................. below Removal Note.......................... page B2-24
4. Intake manifold assembly Installation Note....................... page B2-28
Removal Note...........................page B2-22 9. Camshaft
Installation Note........................page B2-32 Installation Note....................... page B2-27
5. Cylinder head cover 10. HLA
Installation Note....................... page B2-30 Inspection................................ page B2-36
6. Distributor 46U0B2-171
Installation Note....................... page B2-31
Removal / Installation note

Harness
Disconnect the harness connectors as shown in the figure.
Inspection
HLA
Note
• Refer to page B2-7 for HLA troubleshooting.
the plunger moves, it is defective. Replace the HLA—do

1. Install the timing belt. (Refer to page B2-10.)
2. Fill the radiator and coolant reservoir with the specified amount and type or engine coolant.
(Refer to Section E2.)
3. Start the engine and check the following.
(1) Engine oil and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to section F2.)
(3) Operation of emission control system.
4. Recheck the engine coolant and oil levels.
46U0B2-172
FRONT OIL SEAL
Replacement
46U0B2-173
1. Tinning belt 3. Oil seal

Removal / Installation page B2-10 Removal Note.......................... page B2-38
2. Timing belt pulley Installation Note....................... page B2-38
Removal Note.......... page B2-38
Installation Note....... page B2-38
B 2-37
Removal Note
Timing belt pulley
Note
puller.

2. Remove the crankshaft key.
46UOB2-032
Oil seal
1. Cut the oil seal lip with a razor knife.
a rag.
16E0B2-134
Installation Note
Oil seal
new oil seal.
3. Tap the oil seal in evenly with a pipe and a hammer.
Protrusion: 0—0.7mm {0—0.03 in)

Oil seal outer diameter: 48.0mm {1.89 in)
46U0B2-174
Timing belt pulley
1. Install the timing belt pulley.
2. Install the crankshaft key with the tapered side toward the
oil pump body.
16E0B2-136
2. Start the engine and check the following.
• Ignition timing. (Refer to section F2.)
46U0B2-175
Removal Note
Flywheel (MTX)
1. Mount the SST to hold the flywheel.
2. Remove the flywheel mounting bolts in two or three steps
16E0B2-139
Drive plate, backing plate, adapter (ATX)
1. Mount the SST to hold the drive plate.
2. Remove the drive plate mounting bolts.
16E0B2-140
Oil seal
1. Cut the oil seal lip with a razor knife.
a rag.
16E0B2-141
Installation Note
Oil seal
new oil seal.

Oil seal outer diameter: 93.0mm {3.66 in}
Flywheel (MTX)
2. Hand tighten the mounting bolts.
in the figure.
49 E011 1A0 Tightening torque:

61—67 N m {6.2—6.9 kgf m, 45—49 ft-lbf}
46U0B2-178
B 2-4 0
Drive plate (ATX)
1. Install the adapter, drive plate, and backing plate onto the
crankshaft.
(1) Adapter
(2) Drive plate
(3) Backing plate
2. Hand tighten the mounting bolts.

in the figure.
Tightening torque:
61—67 N m {6.2—6.9 kgf m, 45—49 ft-lbf}
49 E 0 1 1 1 AO
16E0B2-146
Steps after installation

2. Start the engine and perform engine adjustments as necessary.
3. Check the oil level.
16E0B2-147
B2-41
B2 REMOVAL
REMOVAL
Warning
• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death
and damage. Fuel cab also irritate skin and eyes. To prevent this, always complete the “ Fuel
Line Safety Procedures” on section F2.
PROCEDURE
2. Drain the engine coolant and transaxle oil. (Refer to section E2 and section J, K1.)
3. Remove the hood and front wheels.
Step 1
46U0B2-034
1. Splash shield 10. Drive belts

2. Fresh-air duct Removal Note.......................... page B2- 5
3. Air cleaner housing assembly 11. P/S oil pump
4. Battery and carrier Removal Note.......................... page B2-43
5. Accelerator cable 12. A/C compressor (if equipped)
6. Radiator hoses Removal Note.......................... page B2-44
7. ATF cooler hose (ATX) 13. Cruise actuator
8. Coolant fan motor connector Removal / Installation.................... section T
9. Radiator and coolant fan assembly 14. Control cable (ATX)
REMOVAL B2
Removal Note
P/S oil pump
1. Remove the bolts shown in the figure and secure the P/S
oil reservoir away from the engine.
16E0B2-149
2. Loosen the pulley nut as shown.
3. Remove the pulley.
16E0B2-150
4. Remove the bolt shown in the figure.
16E0B2-151
5. Remove the bolts shown in the figure and remove the P/S
oil pump.
16E0B2-152
6. Position the P/S oil pump away from the engine and se
cure it with wire.
16E0B2-153
B 2-43
B2 REMOVAL
A/C compressor (if equipped)
1. Remove the A/C compressor with the hoses still connected.
2. Position the compressor away from the engine and secure
it with wire.
46U0B2-035
Step 2
Disconnect the harness connectors shown in the figure.
REMOVAL B2
Step 3
16E0B2-156
Removal note
Fuel hose
Warning
Disconnect the fuel hoses.
46U0B2-179
Heater hose
Press the heater hose retainer tabs and remove the heater
hoses.
46U0B2-036
B 2-45
B2 REMOVAL
Step 4
46U0B2-180
1. Clutch release cylinder (MTX) 7. Tie rod end

Removal Note................... below Removal Note.......................... page B2-47
2. Transverse member 8. Drive shaft
3. Exhaust pipe Removal Note.......................... page B2-47
4. Shift control rod (MTX) 9. Joint shaft
5. Extension bar (MTX) Removal Note.......................... page B2-47
6. Stabilizer control link
Removal Note
1. Remove the bolts and clips as shown.
Caution
• Bending the pipe can cause kinks or cracks.
2. Remove the release cylinder and position it away from the

transaxle with the hose still connected.
46U0B2-181
B 2-4 6
REMOVAL B2
Tie rod end
1. Remove the cotter pin and loosen the nut so that it is flush
with the end of the ball joint stud.
2. Separate the knuckle arm and ball-joint by using the SST.
46U0B2-182
Drive shaft
1. Remove the bolts and nuts at the left and right lower arm
ball joints.
Caution
• The ball-joint dust boots and oil seals are damaged
easily if this procedure is not done correctly.
2. Pry the lower arms downward to separate them from the

knuckles.
3. Separate the drive shafts from the transaxle by prying with

a bar inserted between the shaft and the case.
46U0B2-183
Joint shaft
1. Remove the joint shaft mounting bolts.
2. Remove the joint shaft.
16A0B2-024
B2 REMOVAL
Step 5
46U0B2-184
1. Engine mount No.3 rubber 4. Engine and transaxle assembly

2. Engine mount No.4 rubber and bracket Removal Note.......................... page B2-49
3. Engine mount member
Removal Note.....................................below
Removal Note
Engine mount member
Caution
• Removing the member without first suspending the
engine can cause the engine to tilt or fall and cause
injury. Suspend the engine properly before remov
ing the member.
1. Suspend the engine by using a chain block.
2. Remove the engine mount No.2 nuts.
3. Remove the engine mount No.5 rubber bolts and engine
mount member bolts and nuts and remove the No.5 en
46U0B2-038 gine mount rubber and engine mount member.
B 2-4 8
REMOVAL B2
Slowly lift the engine and transaxle assembly as a unit. Keep
the engine from swinging or bumping into components in
the engine compartment.
46U0B2-039
B2—49
B2 REMOVAL
Step 6
(MTX)
46U0B2-185
1. Starter 4. Torque converter mounting nuts (ATX)

2. Engine mount No.2 rubber 5. Transaxle
3. Engine mount No.2 bracket
B 2-5 0
ENGINE STAND MOUNTING
PREPARATION
SST
49 0107 680A For 4 9 L0101A0 For

disassembly / a disassembly /
Stand, assembly of Hanger set, assembly of
engine engine engine engine
49 L010101 For 49 L010 102 For

Plate assembly of Arms assembly of
49 L0101A0) 49 L0101A0)
49 L010103 For 49 L010104 For

Hooks o assembly of Nuts assembly of
49 L0101A0) 49 L0101A0)
49 L010105 For 49 L010106 For

Bolts assembly of Bolts assembly of
49 L0101A0) (H i 49 L0101A0)
flMllilllllllllllllllllllllllllllll
49 E0101A0 For 4 9 E010101 For

Hanger set, assembly of Body assembly of
engine engine (Part of engine
49E0101A0)
49 E010102 For 49 E0101A1 For

Bolt assembly of Hanger set, assembly of
(Part of engine engine engine
49 E0101A0)
49 E010103 For 49 E010102 For

Hanger assembly of Bolt assembly of
49 E010 1A1) 49 E0101A1)
49 E010104 For
disassembly /
Bolt assembly of
(Part of engine
49 E0101A1)
36U0B2-089
B2-51
PROCEDURE
When using SST (49 E010 1A0)
1. Remove the right exhaust manifold insulator.
2. Remove the EGR valve bolts.
16E0B2-170
3. Remove the right exhaust manifold and gasket together
with the EGR valve and pipe.
16E0B2-171
4. Install the SST at the positions shown in the figure.
16E0B2-172
5. Mount the engine on the SST.
16E0B2-173
When using SST
(49 E010 1A1 and 49 L010 1A0)
1. Remove the right exhaust manifold insulator.
2. Remove the right exhaust manifold and gasket.
3. Install the SST as shown in the figure.
16E0B2-174
B 2-52
4. Install the SST (arms) to the holes as shown in the figure,
49 L 0 1 0 102
and hand tighten the SST (bolts).
49 L 0 1 0 106
5. Assemble the SST (bolts, nuts and plate) as shown in the

figure.
16E0B2-176
6. Install the SST assembled in Step 5 to the SST installed
in Step 4.
7. Adjust the SST (bolts) so that less than 20mm {0.79 in)
of thread is exposed.
8. Make the SST (plate and arms) parallel by adjusting the
SST (bolts and nuts).
9. Tighten the SST (bolts and nuts) to affix the SST firmly.
10. Mount the engine on the SST.
46U0B2-041
Coolant Draining
1. After installing the engine to the engine stand, disconnect
the oil cooler hose (cylinder block side) to drain the coolant.
46U0B2-187
B2—53
2. Remove the blind cover and drain the engine coolant (cyl
inder block, right side).
3. After draining the coolant, install a new O-ring and install
the blind cover.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft lbf)
36U0B2-091
DISASSEMBLY B2
DISASSEMBLY
PREPARATION
SST
49 0636 100A For 49 L011 0A0B For

removal / removal /
Arm, valve installation of Tool set, installation of
spring lifter valves piston pin setting piston pins
49 L011 001 For 49 L011 006 For

removal I removal /
Body, support installation of Installer, piston installation of
block piston pins pin piston pins
(Part of (Part of
49 L011 0A0A) u 49 L011 0A0A)
49 E011 002 For 49 H011 001B For

removal / removal /
Screw installation of Head, support installation of
piston pins block piston pins
49 L011 007 For 49 G014 001 For

removal / removal /
Guide, piston installation of Wrench, installation of
pin piston pins oil filter oil filter
(Part of
49 L011 0A0A)
49 H018 001 For 49 S120 170 For

removal of removal of
Wrench, knock sensor Remover, valve valve seals
knock sensor seal
49E011 1A0 For 49E011 103 For

Brake set, crankshaft Shaft crankshaft
ring gear rotation (Part of rotation
49E011 1A0)
49E011 104 For 49E011 105 For

Collar crankshaft Stopper crankshaft
49E011 1A0) 49E011 1A0)
49 B012 0A2 For 49 B012 012 For

removal / removal /
Pivot installation of Body installation of
valves (Part of valves
49 B012 0A2)
B 2-55
B2 DISASSEMBLY
49 B012 013 For 49 B012 014 For

removal / removal /
F °°t installation of Locknut installation of
(Part of valves (Part of VA/Q5VT''^^=s^'''Tft) valves
49 B012 0A2) 49 B012 0A2)
46U0B2-042
1. Code or arrange all identical parts (such as HLA, pistons, piston rings, connecting rods, and valve springs)
so that they can be reinstalled in the cylinder from which they were removed.
2. Clean the parts by using a steam cleaner. Blow dry with compressed air.
Warning
tect your skin by wasing with soap and water immediately after this work.
46U0B2-043
DISASSEMBLY B2
AUXILIARY PARTS
1. Drain the engine oil.
R EPLACE
46U0B2-188
1. A/C compressor bracket (if equipped) 7. Intake manifold assembly

2. Alternator 8. Engine hangers
3. Bracket and tensioner 9. Spark plugs
4. Exhaust manifold insulator (LH) 10. Oil filter
5. Exhaust manifold (LH) Disassembly Note................... page B2-58
6. Distributor and high-tension lead
B 2 -5 7
B2 DISASSEMBLY
Disassembly Note
Oil filter
Remove the oil filter by using the SST.
16E0B2-184
B 2-58
DISASSEMBLY B2
TIMING BELT
46U0B2-189
1. Crankshaft pulley 8. Timing belt

2. Water pump pulley 9. Timing belt auto tensioner
3. Dipstick and pipe Disassembly Note................... page B2-60
4. Crankshaft position sensor 10. Tensioner pulley
5. Timing belt cover (LH) 11. No.2 idler pulley
6. Timing belt cover (RH) 12. No.1 idler pulley
7. Engine mount bracket 13. Timing belt pulley
Disassembly Note................... page B2-60
B 2-59
B2 DISASSEMBLY
Disassembly Note
Crankshaft pulley
1. Hold the flywheel (MTX) or driveplate (ATX) by using the
SST
Caution
• The crankshaft position sensor rotor is on the rear
of the pulley, and can be damaged easily.
2. Remove the pulley bolt.

3. Remove the crankshaft pulley.
46U0B2-044
Timing belt
1. Temporarily install the crankshaft pulley bolt.
2. Turn the crankshaft to align the timing marks of the pulleys.
16E0B2-187
3. Mark the timing belt rotation for proper reinstallation.
16E0B2-188
Caution
• When removing the bolt, hold the tensioner so that
the bolt holes are aligned, otherwise the threads can
be damaged.
4. Remove the auto tensioner bolts in the order shown in the

figure.
46U0B2-045
Timing belt pulley
2. Remove the crankshaft key.
Note
puller.
46U0B2-046
B 2-60
DISASSEMBLY B2
CYLINDER HEAD
46U0B2-190
1. Cylinder head cover 10. Cylinder head bolt

2. Camshaft pulley Disassembly N ote............ ..... page B2-63
Disassembly N ote................... page B2-62 11. Cylinder head
Inspection.................................page B2-84 Inspection......................... page B2-72
3. Seal plate 12. Cylinder head gasket
4. Water outlet 13. Valve keeper
5. Camshaft cap Disassembly Note............ page B2-63
Disassembly N ote................... page B2-62 14. Valve spring seat, upper
6. Blind cap 15. Valve spring
7. Camshaft Inspection.........................
Inspection.................................page B2-63 16. Valve spring seat, lower
8. Camshaft oil seal 17. Valve
9. HLA Inspection......................... page B2-73
Disassembly Note................... page B2-63 18. Valve seal
Inspection.................................page B2-74 Disassembly Note............
B2-61
B2 DISASSEMBLY
Disassembly Note
Camshaft pulley
of the camshaft.
2. Remove the camshaft pulley bolt.
46U0B2-191
Camshaft cap
Caution
• When the camshaft lobe is pressing on the HLA,
removing the camshaft caps can damage the cylin
der head thrust journal support.
46U0B2-047
1. Loosen the front camshaft cap bolts in five or six steps in

the order shown.
2. Remove the front camshaft caps.
Caution
• Remove the thrust cap only after removing all cam
shaft caps. Otherwise, the thrust cap can be
damaged.
46U0B2-192
3. Loosen the remaining camshaft cap bolts in five or six steps
in the order shown.
46U0B2-193
46U0B2-048
B2—62
DISASSEMBLY B2
Camshaft
Inspect the following when removing the camshaft.
(1) Camshaft end play (Refer to page B2-79.)
(2) Camshaft journal oil clearance
46U0B2-194
HLA
Caution
Note
ADD Note-See Notes

1. Remove the HLA from the cylinder head.
2. Store the HLA upside down in an oil-filled container.
46U0B2-049
Cylinder head bolt

16E0B2-199
Valve keeper
1. Set the SST against the upper valve spring seat as shown
in the figure.
2. Compress the spring and remove the valve keepers.
46U0B2-050
B 2-63
B2 DISASSEMBLY
Valve seal
Using the SST, remove and discard the valve seal.
46U0B2-051
DISASSEMBLY B2
46U0B2-052
1. Clutch cover, clutch disc (MTX) 6. Knock sensor

2. Flywheel (MTX) 7. Oil pan
Disassembly Note................... page B2-66 Disassembly Note................... page B2-67
3. Drive plate, backing plate, adapter (ATX) 8. Oil strainer
Disassembly N ote................... page B2-66 9. Baffle
4. Oil cooler 10. Water pump
5. Water pipe and thermostat housing 11. Oil pump
Disassembly Note................... page B2-66 12. Front oil seal
Disassembly Note................... page B2-67
B 2-65
B2 DISASSEMBLY
Disassembly Note
Clutch cover, clutch disc (MTX)
2. Loosen the clutch cover bolts in two or three steps.
3. Remove the clutch cover and disc.
16E0B2-203
Flywheel (MTX)
2. Remove the flywheel mounting bolts in two or three steps
4. Remove the SST.
16E0B2-204
Drive plate, backing plate, adapter (ATX)
2. Remove the drive plate mounting bolts.
16E0B2-205
Water pipe and thermostat housing
1. Disconnect the clip and separate the knock sensor har
ness from the water pipe.
16E0B2-206
2. Remove the water pipe and thermostat housing as an
assembly.
16E0B2-2Q7
B 2-66
DISASSEMBLY B2
Knock sensor
Remove the knock sensor by using the SST.
Oil pan
2. Remove the old sealant from the bolt threads.
3. Turn a bolt into the special bolt hole as shown to make a
small gap between the oil pan and the lower cylinder
block.
4. Separate the oil pan from the lower cylinder block by us
ing a scraper or a separator tool (commercially available).
Front oil seal

Remove the oil seal by using a screwdriver protected with
a rag.
B2 DISASSEMBLY
46U0B2-195
. Connecting rod cap 6. Piston

Disassembly Note............ ....... page B2-69 Inspection................................ page B2-81
. Connecting rod bearing 7. Lower cylinder block
Inspection................................. page B2-83 Disassembly Note................... page B2-70
. Piston ring 8. Main bearing and thrust bearing, lower
Disassembly N ote............ ...... page B2-69 9. Crankshaft
Inspection.......................... ...... page B2-81 Inspection................................ page B2-82
Piston pin 10. Rear oil seal
Disassembly Note............ ...... page B2-69 11. Main bearing and thrust bearing, upper
Inspection......................... ...... page B2-81 12. Oil jet
Connecting rod Inspection................................ page B2-83
Disassembly N ote............ ...... page B2-69 13. Cylinder block
Inspection.......................... ...... page B2-82 Inspection................................ page B2-79
B 2-68
DISASSEMBLY B2
Disassembly Note
Connecting rod cap
Before removing the connecting rod caps, measure the con
necting rod side clearance. (Refer to page B2-94.)
46U0B2-196
Connecting rod
1. Before removing the connecting rods, measure the connect
ing rod bearing oil clearance by using Plastigage.
46U0B2-197
2. Remove the Plastigage from the journals and bearings.
3. Use the handle of a hammer to push the piston and con
necting rod assembly through the top of the cylinder block.
46U0B2-053
Piston ring
Remove the piston rings by using a piston ring expander.
46U0B2-054
Piston pin
Caution
• The connecting rods must be reinstalled in the same
positions from which they were removed. If they are
not, it can cause premature and uneven wear.
1. Before disassembling the piston and connecting rod, check

the oscillation torque as shown. If the large end does not
drop by its own weight, replace the piston or the piston pin.
46U0B2-055
B 2-69
B2 DISASSEMBLY
2. Use the following SSTs and a press.
• Support block body (49 L011 001)
• Support block head (49 H011 001B)
• Piston pin installer (49 L011 006)
• Piston pin guide (49 E011 007)
• Screw (49 E011 002)
46U0B2-056
3. Assemble the SST into the piston pin as shown.
pressing.
46U0B2-057
5. Set the piston and connecting rod on the SST as shown.
6. Press out the piston pin.
PISTON PIN
While removing the piston pin, note the pressing pressure.
If it is less than 4,910 N {500 kgf, 1,100 Ibf}, replace the
PISTON piston pin or connecting rod.
CONNECTING
ROD
CONNECTING ROD
4 9 L0 1 1 0 0 7
4 9 L011 001
46U0B2-058
Lower cylinder block
1. Before removing the lower cylinder block, measure the
crankshaft end play. (Refer to page B2-92.)
46U0B2-198
B2—70
DISASSEMBLY B2
2. Loosen the cylinder block bolts and crankshaft cap bolts
in two or three steps in the order shown in the figure.
3. Insert a screwdriver or a suitable tool only at the points

shown in the figure.
4. Remove the lower cylinder block.
B2-71
INSPECTION / REPAIR
PREPARATION
SST
16E0B2-225
1. Clean all parts, being sure to remove all gasket fragments, dirt, oil, etc.
2. Perform the inspections and repairs in the order specified.
46UOB2-060
CYLINDER HEAD
1. Inspect the cylinder head for damage, cracks, and leakage
of water and oil. Replace if necessary.
2. Using a straightedge, measure the cylinder head for dis
tortion in the six directions shown in the figure.
16E0B2-227
3. If the distortion exceeds the specification, grind the cylin
der head.
If the cylinder head height is not within the specification,
replace it.
Grinding: 0.15mm (0.0059 in) max.

Height: 133.4—133.6mm (5.252—5.259 in}
46U0B2-061
4. Using a straightedge, measure the intake and exhaust man

ifold contact surfaces for distortion in the six directions shown
in the figure.
Distortion: 0.10mm (0.0039 in} max.
5. If distortion exceeds the specification, grind the surface or

replace the cylinder head.
VALVE MECHANISM
Valve and Valve Guide
1. Inspect each valve for the following. Replace or resurface
as necessary.
(1) Damaged or bent stem
(2) Rough or damaged face
(3) Damaged or unevenly worn stem tip
2. Measure the valve head margin thickness. Replace the valve
if necessary.
Margin thickness
IN: 0.9mm (0.0355 in} min.
EX: 1.0mm (0.0394 in} min.
3. Measure the valve length and replace the valve if necessary.
Length mm
IN 93.91 (3.697)
Standard
EX 94.99 (3.740)
IN 93.41 (3.678)
Minimum
EX 94.49 (3.720)
4. Measure the valve stem diameter and replace the valve if

necessary.
Diameter
46U0B2-062 Standard
IN: 5.970—5.985mm (0.2351—0.2356 in}
EX: 5.965—5.980mm (0.2349—0.2354 in}
Minimum IN: 5.920mm (0.2331 in}
EX: 5.915mm (0.2329 in}
5. Measure the valve guide inner diameter and replace the

guide if necessary.
Inner diameter
IN: 6.01—6.03mm (0.2367—0.2374 in}
EX: 6.01—6.03mm (0.2367—0.2374 in}
16E0B2-232
B 2-73
6. Calculate the valve stem-to-guide clearance.
Subtract the outer diameter of the valve stem from the in
ner diameter of the corresponding valve guide.
Clearance
IN: 0.025—0.060mm (0.0010—0.0023 in)
EX: 0.030—0.065mm (0.0012—0.0025 in]
7. If the clearance exceeds the maximum, replace the valve

and/or valve guide.
8. Measure the valve guide projection height

(dimension A).
Replace the guide if necessary.
Height A
IN: 14.7—15.3mm (0.579—0.602 in}
EX: 12.2—12.8mm (0.481—0.503 in}
Replacement of valve guide
Note
• The intake and exhaust valve guides are the same.
16E0B2-235
Remove the valve guide from the side opposite the com
bustion chamber by using the SST.
16E0B2-236
2. Assemble the SST so that the depth L is as specified.
Depth L
IN: 14.7—15.3mm (0.579—0.602 in}
EX: 12.2—12.8mm (0.481—0.503 in}
16E0B2-237
B 2-74
4. Tap the valve guide in from the side opposite the combus
tion chamber until the SST contacts the cylinder head.
5. Verify that the valve guide projection height is within the
specification. (Refer to page B2-74.)
6. If not within the specification, repeat steps 2-4.
46U0B2-199
Valve Seat
1. Inspect the contact surface of the valve seat and valve face
for the following.
(1) Roughness
(2) Damage
2. If necessary, resurface the valve seat by using a 45° valve
seat cutter and/or resurface the valve face.
16E0B2-239
3. Apply a thin coat of Prussian blue to the valve face.
4. Check the valve seating by pressing the valve against the
seat.
(1) If blue does not appear 360° around the valve face, re
place the valve.
(2) If blue does not appear 360° around the valve seat,
resurface the seat.
16E0B2-240
5. Measure the seat contact width.
Width: 0.8—1.4mm (0.031—0.055 in)
16E0B2-241
(1) If the valve seating position on the valve face is too high,
correct the valve seat with a 75° cutter.
(2) If the valve seating position of the valve face is too low,
correct the valve seat with a 45° cutter.
6. Seat the valve to the valve seat by using a lapping
compound.
16E0B2-242
B 2-75
7. Check the sinking of the valve seat.
Measure the protruding length (dimension L) of the valve
stem.
Dimension L: 41.5mm {1-634 in)
(1) If L is as below, it can be used as it is.
41.5—42.0mm {1.634— 1.653 in)
16E0B2-243
(2) If L is as below, insert a washer onto the spring seat
area so that L will be as specified.
42.1—43.0mm {1.658—1.692 in)
(3) If L is more than below, replace the cylinder head.
43.1mm {1.697 in)
46U0B2-200
Valve Spring
1. Inspect the valve springs for cracks and damage.
2. Check the free length of each spring.
Free length
Minimum length:
38.7mm {1.524 in) with a set load of
233.0—263.6 N
{23.75—26.88 kgf, 52.25—59.14 Ibf)
3. If not within specification, measure spring pressure when

the spring length is compressed to 35.5mm {1.398 in).
Replace if necessary.
4. Check the out-of-square of the springs. Replace as
necessary.
Out-of-square: 1.63mm {0.0642 in)
46U0B2-202 CAMSHAFT
1. Visually inspect helical gears and the friction gear. Replace
the camshaft assembly if a problem is found with the heli
cal gear. Replace the friction gear if a problem is found with
it.
2. Secure the camshaft cast hexagon in a vise protected with
aluminum plates.
3. Loosen the locknut and remove the friction gear.
4. Assemble the friction gear so that the matching marks align.
Tightening torque:
69—78 N m {7.0—8.0 kgf m, 51—57 ft-lbf)
B 2-76
INSPECTION/REPAIR B2
4. Set the No.1 and No.5 journals on V-blocks.
Measure the camshaft runout. Replace the camshaft if
necessary.
Runout: 0.02 mm {0.0007 in} max.
5. Check the camshaft for wear and damage. Replace it if

necessary.
6. Measure the cam lobe height at the two points as shown.
Replace the camshaft if necessary.
Height
mm {in}
Height 43.549 {1.7145}
IN
Minimum 43.349 {1.7067}
Height 43.549 {1.7145}
EX
Minimum 43.349 {1.7067}
7. Measure the journal diameters in X and Y directions at

the two points (A and B) as shown. Replace the cam
shaft if necessary.
Journal diameter
mm {in}
Journals Standard Minimum
No.1 (RH EX, LH IN) 25.940—25.960 25.890
and No.5 {1.0213— 1.0220} {1.0193}
No.1 (RH IN, LH EX) 29.975—29.995 29.925
{1.1802— 1.1809} {1.1782}
No.2— No.4 25.910—25.930 25.860
{1.0201— 1.0208} {1.0182}
8. Measure the camshaft oil clearances with the HLA

removed.
(1) Remove all oil, dirt, etc. from the journals and the
camshaft saddles.
(2) Install the camshafts so that the intake camshaft
gear mark and exhaust camshaft gear mark align.
Adjust the friction gear position with a screwdriver so
that the HLAs are not lifted by the cam lobes. (Intake
side cam lobes of the No.1 cylinder (RH) and No.2
cylinder (LH) face straight up.)
(3) Position Plastigage atop each journal in the journal
axial direction.
(4) Do not rotate the camshaft when measuring the oil
clearance.
R e v ic p H fi/Q fi
B2 INSPECTION /REPAIR
Caution
• Install the thrust caps (RH is 5 mark, LH is B mark)
aged.
(5) Install the thrust caps onto the cylinder head. Hand
tighten the cap bolts gradually in five or six steps in
the order shown, until the thrust caps fully seated on
the cylinder head.
THRUST
CAPS (3
Caution
installed. Otherwise, excessive force will be ap
receiving area of the cylinder head Journal. To
served.
(6) Install the camshaft caps according to their identifi

cation marks, and hand tighten the bolts.
Note
• RH: numbers
• LH: letters
(7) Tighten the bolts in the order shown. Verify that the
camshaft remains horizontal as the camshaft cap
bolts (marked (J) in the figure) tightened.
Tightening torque:
11.3— 14.2 N*m {115— 145 kgf-cm, 100— 125 in-lbf}
(8) Retighten the bolts in the order shown.
Tightening torque:
11.3— 14.2 N-m (115— 145 kgf-cm, 100— 125 in-lbf}
Caution
• Remove the thrust cap only after removing all
camshaft caps. Otherwise, the thrust cap can be
damaged.
(9) Loosen the camshaft cap bolts in five or six steps in

the reverse order of installation.
INSPECTION/REPAIR
(10) Measure the oil clearance.
Oil clearance
No.1, No.5: 0.040—0.081 mm {0.0016—0.0031 in}
No.2— No.4: 0.070—0.111 mm {0.0028—0.0043 in}
Maximum
No.1, No.5: 0.120 mm {0.0047 in}
No.2— No.4: 0.150 mm {0.0059 in}
(11) If the oil clearance exceeds the maximum, replace

the camshaft or the cylinder head.
9. Measure the camshaft end play. If it exceeds the maxi

mum, replace the camshaft or the cylinder head.
End play: 0.05— 0.10 mm {0.0020—0.0039 in}

Maximum: 0.14 mm {0.0056 in}
HLA
1. Inspect the friction surfaces of each HLA for wear and
damage. Replace the HLA if necessary—do not attempt
to repair it.
the plunger moves, it is defective. Replace the HLA—do
CYLINDER BLOCK
1. Check the cylinder block for the following and repair or
replace as necessary.
(1) Leakage damage
(2) Cracks
(3) Scoring of wall
2. Using a straightedge, measure the cylinder block decks
for distortion in six directions as shown in the figure.
Distortion: 0.15 mm {0.0059 in} max.
16E0B2-262 3. If distortion exceeds the maximum, replace the cylinder

block.
4. Measure the cylinder bores in X and Y directions at three
levels (A,B and C) as shown.
Cylinder bore
mm fin)
84.500—84.522
Standard
(3.3268—3.3276)
0.25 [0.010J 84.750-84.772
oversize (3.3367-3.3374)
0.50 {0.020) 85.000—85.022
oversize (3.3465-3.3473)
46U0B2-Q70
Cylinder bore
Base the boring diameter on the diameter of an oversize
piston. All cylinders must be the same diameter.
(1) If the cylinder bore exceeds the maximum, rebore the
cylinder to oversize.
(2) If the difference between measurements A and C ex
ceeds the maximum taper, rebore the cylinder to
oversize.
Taper: 0.022mm {0.0008 in} max.
46U0B2-071 (3) If the difference between measurements X and Y ex

ceeds the maximum out-of-round, rebore the cylinder
to oversize.
Out-of-round: 0.020mm {0.0007 inj max.
5. If the upper part of a cylinder wall shows uneven wear, re

move the ridge with a ridge reamer.
o PISTON, PISTON RING, AND PISTON PIN

Piston
46U0B2-205 1. Inspect the outer circumferences of all pistons for seizing
and scoring. Replace as necessary.
2. Measure the outer diameter of each piston at a right angle
(90°) to the piston pin, 16.5mm {0.650 in) below the oil
ring groove lower edge.
Piston diameter
mm (in)
84.453—84.485
Standard (3.3250—3.3261)
0.25 (0.010) 84.703-84.735
oversize (3.3348-3.3360)
0.50 (0.020) 84.953-84.985
oversize (3.3446-3.3458)
3. Measure the piston-to-cylinder clearance.
Clearance: 0.028— 0.056mm {0.0012— 0.0022 in)

4. If the clearance exceeds the maximum, replace the piston

or rebore the cylinders to fit oversize pistons.
If the piston is replaced, the piston rings must also be
replaced.
C LEARAN C E
46U0B2-073
B 2-80
Piston and Piston Rings
1. Measure the piston ring-to-ring land clearance around the
entire circumference by using a new piston ring.
Clearance
Top: 0.020—0.065mm (0.0008—0.0025 in)
Second: 0.030—0.065mm (0.0012—0.0025 in)
Oil: 0.025—0.052mm (0.0010—0.0020 in]
36U0B2-098
2. If the clearance exceeds the maximum, replace the piston.
3. Inspect the piston rings for damage, abnormal wear, and
breakage. Replace as necessary.
4. Insert the piston ring into the cylinder by hand and use the
piston to push it to the bottom of the ring travel.
PISTON
RING
36U0B2-099
5. Measure each piston ring end gap by using a feeler gauge.
End gap
Top: 0.15—0.30mm (0.0060—0.0118 in]
Second: 0.25—0.40mm (0.010—0.015 in)
Oil rail: 0.20—0.70mm (0.008—0.027 in)
Piston and Piston pin

1. Measure the piston pin bore diameter in X and Y directions
at four points.
Diameter:
19.988—20.000mm (0.7870—0.7874 in)
2. Measure the piston pin diameter in X and Y directions at

four points.
x
Diameter:
19.974—19.980mm (0.7864—0.7866 in)
3. Calculate the related piston pin-to-piston clearance.
Clearance: 0.008—0.026mm (0.0004—0.0010 in)
4. If the clearance exceeds the specification, replace the pis

ton and/or piston pin
36U0B2-051
B2—81
CONNECTING ROD
1. Measure the connecting rod small end bore.
Diameter: 19.943—19.961mm {0.7852—0.7858 in)
2. Calculate the interference between the small end bore and

piston pin.
Interference: 0.013—0.037mm (0.0006—0.0014 in)
If the connecting rod is replaced, the connecting rod cap

and bolts must also be replaced because they are a
matched set.
3. Check each connecting rod for bending. Repair or replace

as necessary.
Bend: 0.05mm (0.0019 in}/50mm (1.9685 in)
Length (Center to Center):

137.80—137.90mm (5.426—5.429 in)
CRANKSHAFT
1. Check the journals and pins for damage, scoring, and oil
hole clogging.
2. Set the crankshaft No.1 and No.4 journals on V-blocks.
3. Measure the crankshaft runout at the No.2 and No.3
journals.
Replace the crankshaft if necessary.
Runout: 0.015mm (0.0005 in) max.
16E0B2-275
4. Measure each journal diameter in X and Y directions at two
points.
Main journal
Diameter:
61.938—61.955mm (2.4385—2.4391 in)
Crankpin journal
Diameter:
52.940—52.955mm (2.0843—2.0848 in)
5. If the diameter is less than the minimum, grind the journals
to match undersize bearings.
Undersize bearing: 0.25mm {0.010 in)
Main journal diameter undersize

mm (in)
0.25 (0.010) undersize 61.688-61.705 (2.4287-2.4293)
Crankpin journal diameter undersize

mm (in)
0.25 (0.010) undersize 52.690-52.705 (2.0745-2.0749)
BEARING
Main Bearing and Connecting Rod Bearing
Check the main bearing and the connecting rod bearings
for peeling, scoring, and other damage.
OIL JET
Check the oil jets for clogging by applying compressed air.
TIMING BELT
1. Replace the timing belt if there is any oil or grease on it.
2. Check the timing belt for damage, wear, peeling, cracks,
and hardening. Replace it if necessary.
Caution
25mm (1.0 in) MIN
46U0B2-Q76
B 2-83
TIMING BELT AUTO TENSIONER
Caution
tensioner can dissolve the grease in its sealed
bearing.
1. Use a clean, soft rag to wipe the idler contact surface.

2. If the idler does not rotate smoothly, replace it.
3. If there are oil leaks, or if there are scratches or abnormal
noise when turning the idler, replace it.
4. Check the tensioner pulley for rough rotation and abnor
mal noise. Replace it if necessary.
5. Check the auto tensioner for oil leakage. Replace it if
fL M® necessary.
6. Check the tensioner rod projection ® . Replace the auto
tensioner if necessary.
1 f
Projection A (free length): 14—16mm {0.56—0.62 in]
,*
l>
46U0B2-078
PULLEY
Timing Belt Pulley and Camshaft Pulley
Inspect the teeth of each pulley for wear, deformation, and
other damage. Replace as necessary.
TIMING BELT COVER

Inspect the timing belt covers for damage and cracks.
Replace as necessary.
46U0B2-079
B 2 -8 4
ASSEMBLY B2
ASSEMBLY
PREPARATION
SST
49 L011 OAOB fv For

removal /
49 L011 001
®) For
removal /
j)
Tool set, \ k installation of Body, installation of
piston pin setting Cv piston pins support block piston pins
(Part of
49 L011 OAOA) (-^
49 L011 005 For 49 L011 006 For

removal / removal /
Bolt, stopper installation of Puller & installer installation of
piston pins (Part of piston pins
49 L011 0A0A) 49 L011 OAOA) \W
49 L011 007 For 49 E011 002 For

removal / removal /
Guide C installation of Screw xx. installation of
(Part of piston pins piston pins
49 L011 OAOA)
49 H011 001B For 49 H018 001 For

removal / installation of
Head, installation of Wrench, knock knock sensor
support block piston pins sensor
49E011 1AO For 49 E011 103 For

Brake set, engine rotation Shaft engine rotation
ring gear js?R®\ ^ v \ (Part of
49E0111A0) V **
49 E011 104 For 49 E011 105 For

Collar ( engine rotation Stopper engine rotation
(Part of V (Part of
49E0111A0) 49 E011 1A0)
f \
49L012 0A0 For 49SE01 310A For

Installer set, <3*3^ % valve seals Centering tool, clutch disc
valve seal & ^ clutch disc
valve guide ® K î
isr
49 L012 001
49 L012 0A0)
cup
For
installation of
valve seals
4Q i m ? nn?
B° dy
(Part of
49 L012 0A0)
0 liii
^ J
For
installation of
valve seals
B2—85
B2 ASSEMBLY
49 L012 005 For 49 0636 100A For

Spacer valve seals Arm, valve spring installation of
(Part of lifter valves
49 L012 0A0)
49 B012 0A2 For 49 B012 012 For

removal / removal /
Pivot installation of Body installation of
valves (Part of valves
49 B012 0A2)
49 B012 013 For 49 B012 014 For

removal / removal /
Foot installation of Locknut installation of
(Part of valves (Part of valves
49 B012 0A2) 49 B012 0A2)
49 G014 001 For

removal /
Wrench, installation of
oil filter oil filter
46U0B2-080
1. Do not reuse gaskets or oil seals.

2. Clean all parts before reinstallation.
3. Apply clean engine oil to all sliding and rotating parts.
4. Replace plain bearings if they are peeling, burned, or otherwise damaged.
5. Tighten all bolts and nuts to the specified torque.
46U0B2-081
ASSEMBLY B2
CYLINDER WALLS
APPLY THREAD LOCKING COMPOUND

2.9—4.9 N m
(30—50 kgf-cm, 27—43 Inlbf I
JOURNALS AND
CRANK PINS^
16E0B2-286
Connecting Rod
1. Assemble the SST (tool set, piston pin setting) to the pis
ton pin.
PISTON PIN
2. Apply clean engine oil to the piston pin.
- I ------ D
49 E011 002
49 L011 007 49 L01 1 006
16E0B2-287
B 2-87
B2 ASSEMBLY
3. Set the SST (stopper bolt) so that the depth L is as specified.
49 H011 0 0 1 B
DIMENSION L
Depth L: 61.5mm (2.421 in]
t
1 ------
== 4. Tighten the locknut.

49 L 0 11 001 1 -
I n
B
— i
36U0B2-055
5. Assemble the piston and the connecting rod.
6. Insert the SST (tool set, piston pin setting) assembled in step
1 into the piston pin hole.
7. Mount the piston and connecting rod onto the SST (sup
port block).
36U0B2-056
pressing.
9. Press the piston pin into the piston and connecting rod un
til the SST (piston pin guide) contacts the SST (stopper bolt).
10. While inserting the piston pin, note the pressing force. If it
is not within specification, replace the piston pin and/or the
connecting rod.
Pressing force:
3,923—12,748 N (400—1,300 kgf, 880—2,860 Ibf]
11. Check the connecting rod oscillation torque.

Piston Ring
Note
• The upper and lower rails are the same.
• Each rail can be installed with either face upward.
• When reusing an oil ring, make sure that it is reinstalled
in the same place and that it is facing in the same direc
tion as it was before.
1. Install the three-piece oil rings on the pistons.

(1) Apply clean engine oil to the oil ring spacer and rails.
(2) Install the oil ring spacer so that the opening faces
upward.
(3) Install the upper rail and lower rail.
2. Verify that both rails are expanded by the spacer tangs, as
shown in the figure, by verifying that they turn smoothly in
both directions.
36U0B2-102
B 2-8 8
ASSEMBLY B2
3. Using a piston ring expander, install the second ring with
the scraper face downward.
4. Using a piston ring expander, install the top ring.
5. Apply a liberal amount of clean engine oil to the piston rings.
46U0B2-084
6. Position the end gap of each ring as shown in the figure.
OIL RING
UPPER RAIL / TOP RING
OIL RING (
30° \ . PISTON
SPACER H ~ 30° T P'N
OIL RING / SECOND

LOWER RAIL \ ____ RING
46U0B2-085 Oil jet

1. Apply a thread locking compound to the oil jet threads.
2. Install the oil jets into the upper cylinder block.
Tightening torque:
2.9—4.9 N m {30—50 kgf cm, 27—43 in-lbf]
Crankshaft
1. Measure the main bearing oil clearances as described
below.
Oil clearance inspection
2. Install the upper main bearings (with oil groove) and the up
per thrust bearings.
(1) Remove any foreign material and oil from the journals
and bearings.
(2) Install the upper main bearings and upper thrust
bearings.
Note
• No.4 bearing is wider than other bearings.
46U0B2-086
8.05—8.15mm (3) Install the lower cylinder block along with the lower main
(0.317—0.321 in) bearings and lower thrust bearings.
® a t (4) Measure the length of each crankshaft cap bolt.
135.7—136.3mm( 5.343—5.366 in Replace any that exceed the maximum length.
7.45—7.55mm (0.293—0.297 in)
& Main cap bolt (A and B)
u s *
1135.7—136.3mm (5.343—5.366 in)| Length: 135.7—136.3mm (5.343—5.366 in)
Maximum: 138.5mm {5.452 in]
Sub cap bolt (C)
Length: 119.7—120.3mm {4.713—4.736 in]
119.7—120.3mm (4.713—4.736 in) Maximum: 121.0mm {4.763 in)
46U0B2-206
B 2-89
B2 ASSEMBLY
(5) Apply clean engine oil to the bolt threads and seat faces
of the crankshaft cap bolts.
(6) Tighten the bolts in two or three steps in the order shown
in the figure.
Tightening torque
Main bolt: 23.1—25.9 N m
{2.35—2.65 kgf m, 17.0—19.1 ft-lbf) .......... A, B
Sub bolt: 18.2—21.0 N-m
{1.85—2.15 kgf m, 13.4—15.5 ft-lbf}................ C
16E0B2-298 Note
• A bolts are marked “ 4” on the head.
• B bolts are marked " I” on the head.
16E0B2-299
(7) Put a paint mark on the lower cylinder block next to the
A, B, C bolts flange marks as shown.
(8) Using the marks as a reference, further tighten the A,
B, C bolts in the order shown.
Main cap bolt A (No.4 journals): 75°—85°

Main cap bolt B (No.1—No.3 journals): 65°—75°
Sub cap bolt: 55°—65°
PAINT
(9) Tighten the bolts till the mark on each bolt flange aligns
with the corresponding paint mark.
46U0B2-087
(10) Further tighten each bolt by performing Step (7), (8).
PAINT MARKS
46U0B2-088
(11) After tightening, measure the cylinder block No. 1—No.4
journal bore diameter.
(12) Subtract the crankshaft journal diameter from the bore
diameter.
(13) If the oil clearance exceeds the maximum, replace the
bearing or grind the crankshaft and install undersize
main bearings. (Refer to page B2-83.)
Oil clearance: 0.037—0.057mm {0.0015—0.0022 in]

Maximum: 0.064mm {0.0025 in]
46UQB2-089
B 2-9 0
ASSEMBLY B2
CRANK PIN
Main journal diameter
Standard:
61.938—61.955mm {2.4385—2.4391 in)
0.25mm {0.0098 in} undersize:
61.688—61.705mm {2.4287—2.4293 in)
16E0B2-303
(14) Remove the lower cylinder block in the reverse order
of Step (6).
46U0B2-090
3. Install the lower cylinder block as follows:
(1) Install the upper thrust bearings in the upper cylinder
block.
(2) Apply a liberal amount of clean engine oil to the main
bearings, thrust bearings, and main journals.
(3) Install the crankshaft in the upper cylinder block.
(4) Remove any foreign material, oil, and sealant from the
contact surfaces of the upper cylinder block and lower
cylinder block.
(5) Apply a continuous bead of silicone sealant to the con
tact surface as shown.
(6) Install the lower cylinder block, lower main bearings, and
lower thrust bearings within five minutes of applying the
sealant.
(7) Install the lower cylinder block along with the lower main
bearings and lower thrust bearings.
(8) Apply clean engine oil to the threads and seat faces of
the bearing cap bolts.
(9) Tighten the main cap bolts A, B and sub cap bolts C
as in Steps 1—(6)/1—(9).
46U0B2-092
(10) Tighten the lower cylinder block bolts in the order as
shown.
Tightening torque:
19—21 N m {1.9—2.2 kgf m, 14—15 ft-lbf}
46U0B2-093
B2-91
B2 ASSEMBLY
4. Inspect the crankshaft end play.
End play: 0.08—0.282mm {0.0032—0.0111 in}

Maximum: 0.32mm {0.0125 in}
5. If the end play exceeds the maximum, grind the crankshaft

and install oversize thrust bearings or replace the crankshaft
and thrust bearing.
Thrust bearing width

Standard:
2.000—2.050mm {0.0788—0.0807 in}
0.25mm {0.0098 in} oversize:
2.125—2.175mm {0.0837—0.0856 in}
0.50mm {0.020 in) oversize:
2.250—2.300mm {0.0886—0.0905 in}

rear oil seal.
7. Push the rear oil seal slightly in by hand.
Protrusion: 0—0.7mm {0—0.03 in}

Oil seal outer diameter: 93.0mm {3.66 in}
Oil seal inner diameter: 75.0mm {2.95 in}
Piston and Connecting Rod Assembly

1. Rotate the engine on the engine stand as shown in the
figure.
Note
• Assembly is easier if the pistons are installed with the
crankpin at the BDC position.
46U0B2-096
2. Remove any foreign material and oil from the connecting
rod journals and bearings.
3. Install the upper connecting rod bearings in the connect
ing rods.
4. Apply a liberal amount of clean engine oil to the cylinder
walls, pistons, piston rings and connecting rod cap bolts.
46U0B2-097
5. Check the piston rings for proper end gap positioning.

6. Insert the piston assemblies into the cylinder block with the
L mark (left bank) and the R mark (right bank) facing the
front of the engine. Use a piston installer tool to install.
46U0B2-207
B 2-92
ASSEMBLY B2
Connecting Rod Cap
1. Measure the connecting rod bearing oil clearances as
follows.
(1) Measure the oil clearance with the connecting rod in
BDC position.
(2) Do not rotate the crankshaft when measuring the oil
clearances.
46U0B2-098
direction.
(4) Remove any foreign material and oil from the lower con
necting rod bearing and connecting rod cap.
(5) Install the connecting rod bearing in the cap.
I (6) Measure the length of connecting rod cap bolt.
I I Replace it if the length exceeds the maximum.
46.7— 47.3m m {1.84-- 1 .8 6 in )

Length: 46.7—47.3mm (1.84—1.86 in)
46U0B2-099 (7) Apply engine oil to the threads and seat faces of the
connecting rod cap bolts.
(8) Install the connecting rod cap.

(9) Tighten the connecting rod cap bolts.

(2.25—2.75 kgf-m, 16.3—19.8 ft-lbf)

(11) Using this mark as a reference, tighten the bolts
83°—97°.
(12) Remove the connecting rod cap.
(13) Measure the Plastigage at each journal at the widest

point for the smallest clearance, and the narrowest point
for the largest clearance.
Oil clearance: 0.023—0.043mm (0.0010—0.0016 in)

46U0B2-101
(14) If the oil clearance exceeds the maximum, grind the
CRANK PIN
crankshaft and install undersize bearings.
46U0B2-102
B 2-93
B2 ASSEMBLY
2. Install the connecting rod caps as follows.
(1) Remove the Plastigage from the journals and bearings.
(2) Apply a liberal amount of clean engine oil to the con
necting rod bearings.
(3) Install the connecting rod bearings and caps.
(4) Apply engine oil to the threads and seat faces of the
cap bolts and tighten them as in step 1.
(5) Verify that the crankshaft rotates smoothly by hand.
16E0B2-318
3. Measure the connecting rod side clearances.
(1) Measure each connecting rod side clearance.
Side clearance:
0.178—0.330mm (0.0071—0.0129 in)
(2) If the clearance exceeds the maximum, replace the con

necting rod and cap assembly.
16E0B2-319
ASSEMBLY B2
16E0B2-320
Oil Pump
1. Apply clean engine oil to the oil pump body and a new oil
seal.
2. Install the oil seal into the oil pump body by hand.
3. Press the oil seal into the oil pump body by using a pipe.

Oil seal outer diameter: 48.0mm {1.89 in)
46U0B2-208
B 2-95
B2 ASSEMBLY
4. Remove any dirt or other material from the contact surfaces.
O-RING
5. Apply a continuous bead of silicone sealant to the contact
surface of the oil pump.
6. Apply engine oil to a new O-ring and install it into the pump
body.
Caution
• Keep the oil hole free of sealant to prevent engine
damage.
46U0B2-103
7. Apply clean engine oil to the oil seal lip.
8. Install the oil pump within five minutes of applying the seal
ant, making sure that the O-ring doesn’t come out.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf}
Bolt length
A: 40mm (1.57 in)
B: 25mm (0.98 in)
46U0B2-104 9. Cut away the portion of the gasket that projects toward the
oil pan.
Water Pump
1. Remove all dirt, grease, and other material from the water
pump mounting surface.
2. Install a new rubber seal and the water pump.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft Ibf)
36UQB2-107
Baffle
1. Remove any dirt or other material from the baffle.
2. Install the baffle.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf}
16E0B2-325
Oil Strainer
Install a new gasket and the oil strainer onto the oil pump
body.
Tightening torque:
7.9—10.7 N-m {80—110 kgf cm, 70—95 in Ibf)
Caution
• Tighten bolts A first.
36U0B2-162
B 2-9 6
ASSEMBLY B2
Oil Pan
1. Remove the sealant from the oil pan bolts and bolt holes
(CRACKS in the lower cylinder block.
Caution
• If the bolts are reused, remove the old sealant from
the bolt threads. Tightening a bolt that has old seal
ant on it can cause thread damage.
OLD SEALANT
46U0B2-1Q5
2. Remove any dirt and oil from the contact surfaces.
along the inside of the bolt holes, and overlap the ends.
46U0B2-209
4. Install the oil pan, within five minutes of applying the sealant.
Tightening torque
A: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf)
B: 7.9—10.7 Nm {80—110 kgf m, 70—95 in-lbf}
46U0B2-210
Knock Sensor
49 H018 001
Install the knock sensor by using the SST.
Tightening torque:
20—34 N-m {2.0—3.5 kgf m, 15—25 ft-lbf}
16E0B2-330
Water Pipe and Thermostat Housing
1. Install a new gasket and install the water pipe and thermostat
housing as an assembly.
Tightening torque:
19—25 Nm {1.9—2.6 kgf-m, 14—18 ft-lbf)
2. Secure the knock sensor harness to the water pipe with the
clip as shown.
16E0B2-332
B2—97
B2 ASSEMBLY
Oil cooler
1. Install a new gasket and the oil cooler.
Tightening torque:
19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf]
2. Connect the water hose.

46U0B2-211
Flywheel (MTX)
3. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
61—67 Nm {6.2—6.9 kgf-m, 45—49 ft-lbf]
16E0B2-334
Clutch Disc and Clutch Cover (MTX)
Install the clutch disc and clutch cover by using the SST.
(Refer to Section H.)
Tightening torque:
18—26 Nm {1.8—2.7 kgf-m, 14—19 ft-lbf]
16E0B2-335
Drive Plate (ATX)
Caution
• Verify that the adapter and the backing plate are
mounted in the directions shown. Incorrect mount
ing can damage the engine and transmission.
1. Install the following parts to the crankshaft.

(1) Adapter
(2) Drive plate
(3) Backing plate
2. Loosely tighten the lock bolts.

in the figure.
Tightening torque:
61—67 Nm {6.2—6.9 kgf m, 45—49 ft-lbf]
46U0B2-107
B 2-9 8
ASSEMBLY B2
CYLINDER HEAD
5.0—8.8 N-m 150—90 kgf-cm, 44—78 in-lbf |
5.0—8.8 N-m (50—90 kgf-cm, 44—78 in-lbf)
11.3— 14.2 N-m 1115— 145 kgf-cm, 100—125 In-lbf)
1 1 .3 -1 4 .2 N-m
(115—145 kgf-cm,
100— 125 in-lbf 23.1—25.9 (2.35—2.65,
17.0— 19.1) + 85°—95°
+ SS'-SS0
HEAD COVER
CONTACT
SURFACES
11.3— 14.2 N-m
115— 145 kgf-cm
100— 125 in-lbf)
CAMSHAFT CAP HEAD COVER

CONTACT SURFACES
123—140 CONTACT
SURFACES
( 1 2 .5 - 1 4 .3 ,9 1 — 103) -x>
BOLT THREADS
r
7.9—10.7 N m CAMSHAFT CAP
(80—110 kgf-cm, CONTACT SURFACES
70—95 in-lbf)
19—25 (1 .9—2.6, 14—18)
7.9— 10.7 N m (80—110 kgf-cm, 70—95 in-lbf)
19—25 (1
N-m (kgf-m, ft-lbf)
16E0B2-338
Valve Seal
The intake and exhaust valve seals are different. The exhaust
valve seal has ridges on the top for identification.
Depth L
IN: 16.3mm (0.642 in)
EX: 13.8mm (0.543 in]
46U0B2-212
B 2-99
B2 ASSEMBLY
2. Slide the valve seal onto the valve guide with the SST.
3. Set the SST against the valve seal.
Caution
• Using a hammer will damage the valve seal.
4. Using the SST, press the valve seal on by hand until the
SST touches the cylinder head.
46U0B2-108
Valve and Valve Spring

1. Install the lower spring seat.
2. Install the valve.
3. Install the valve spring with the closer pitch toward the cyl
inder head.
46U0B2-109
5. Compress the valve spring with the SST, and install the
valve keepers.
6. Remove the SST.
7. Tap the end of the valve stem lightly two or three times with
a plastic hammer to verify that the keepers are fully seated.
8. Using a flashlight, verify that all valve springs are fully seat
ed in the cylinder head.
49 B012 0A2
46U0B2-110
Cylinder Head
1. Apply clean engine oil to new O-rings and install them to
the oil control plugs.
46U0B2-213
2. Thoroughly remove all dirt, oil, and other material from the
decks of the cylinder block.
3. Turn the crankshaft clockwise and apply engine oil to the
cylinder walls.
4. Place a new cylinder head gasket on the left bank with the
L mark.
5. Place a new cylinder head gasket on the right bank with
the R mark.
46U0B2-214
B 2-100
ASSEMBLY B2
6. Install the cylinder heads to the cylinder block.
7. Tighten the cylinder head bolts as described below.
(1) Before installation, measure the length of each bolt.
Length: 133.7— 134.3mm {5.264—5.287 in)

46U0B2-215
(2) Apply clean engine oil to the threads and the seat face
of each bolt and install them and new washers.
(3) Tighten the bolts in two or three steps in the order shown
in the figure.

{2.35—2.65 kgf m, 17.0—19.1 ft-lbf)
36U0B2-108
(5) Using the marks as a reference, tighten the bolts by turn
ing each 85°—95° in the sequence shown.
(6) Further tighten each bolt by turning another 85°—95°.
46U0B2-216
8. Connect the water pipe to the water pipe elbow and secure
to the cylinder head.
Tightening torque:
7.9—10.7 N-m {80—110 kgf cm, 70—95 in-lbf}
O-RING
46U082-217
HLA
1. Apply clean engine oil to the friction surfaces.
2. If the HLA are being reused, install them in the positions
from which they were removed.
16E0B2-349
B2-101
B2 ASSEMBLY
Camshaft
1. Apply clean engine oil to the camshaft journals, cam-
shaft lobes, and camshaft gears.
2. Install the camshafts so that the intake camshaft gear
mark and exhaust camshaft gear mark align.
Adjust the friction gear position with a screwdriver so that
the HLAs are not lifted by the cam lobes. (Intake side
cam lobes of the No.1 cylinder (RH) and No.2 cylinder
(LH) face straight up.)
Caution
• Install the thrust caps (RH is 5 mark, LH is B mark)
aged.
3. Install the thrust caps onto the cylinder head. Hand tight
en the cap bolts gradually in five or six steps in the order
shown, until the thrust caps fully seated on the cylinder
head.
4. Apply silicone sealant to the shaded areas as shown.
Caution
* Because there is little camshaft thrust clearance,
instalied. Otherwise, excessive force will be ap
receiving area of the cylinder head journal. To
served.
LH TH R U S T RH TH R U ST
FRONT
* *
DawiraW R/QC
Appuea v i i m .
1 Y V G E 2 2 D *R 5 100001 —
1YV GE31 D * R 5 1 0 0 0 0 1 -
ASSEMBLY B2
5. Install the camshaft caps according to their identification
marks, and hand tighten the bolts.
Note
• RH: numbers
• LH: letters
6. Tighten the bolts in the order shown. Verify that the cam
shaft remains horizontal as the camshaft cap bolts
(marked © in the figure) tightened.
Tightening torque:
11.3— 14.2 N-m {115— 145 kgf-cm, 100— 125 in lb f}
7. Retighten the bolts in the order shown.
Tightening torque:
11.3— 14.2 N-m {115— 145 kgf-cm, 100— 125 in-lbf}
ASSEMBLY B2
9. Lightly apply clean engine oil to the new oil seal and the
cylinder head.
10. Tap the camshaft oil seal into the cylinder head by using
a pipe.
Protrusion: 0—0.5mm (0—0.02 in)
Note
• Oil seal outer diameter: 44.0mm (1.73 in)
• Oil seal inner diameter: 30.0mm (1.18 in)
11. Apply sealant to a new blind cap.

12. Tap in the blind cap by using a plastic hammer.
Water Outlet
Install the water outlet with new O-rings.
Tightening torque:
19—25 N m (1.9—2.6 kgf m, 14—18 ft-lbf)
36U0B2-110
Seal Plate
Install the seal plate.
Tightening torque:
7.9—10.7 N m (80—110 kgf cm, 70—95 in lbf)
B 2-103
B2 ASSEMBLY
Camshaft Pulley
The right and left pulleys are different and must be installed
on the same head that they were removed from.
1. Install the camshaft pulley so that the "R" mark can be seen
46U0B2-112
2. Install the camshaft pulley so that the “ L” mark can be seen
46U0B2-113
Camshaft Pulley Lockbolt
1. Apply clean engine oil to the lock bolt threads.
as shown, and tighten the bolt.
Tightening torque:
123—140 N m (12.5—14.3 kgf m, 91—103 ft-lbf}
46U0B2-222
Cylinder Head Cover
LH RH 1. Remove all dirt, old sealant and other material from the cyl
inder head and cover.
2. Apply sealant to the shaded area as shown in the figure.
f ♦
16A0B2-039
3. Coat a new gasket with silicone sealant.
4. Install the gasket onto the cylinder head cover.
16A0B2-040
B 2-104
ASSEMBLY B2
5. Install the cylinder head cover and tighten the bolts in two
or three steps in the order shown.
Note
• Left cylinder head cover bolt heads are round.
Tightening torque:
5.0—8.8 N m (50—90 kgf cm, 44—78 in-lbf}
6. Recheck the torque of the bolts indicated, and tighten then

if necessary.
36U0B2-113
RH: © , ©
LH: © , (7)
B 2-105
B2 ASSEMBLY
TIMING BELT
Torque Specification
44—60 14.4—6.2, 32—44)
19—25 11.9—2.6, 14—181
7.9—10.7 N-m
(80—110 kgf-cm,
70—95 In-lbf)
7.9—10.7 N-m
80—110 kgf-cm,
7 0 -9 5 in-lbf)
~Mbi
BOLT
THREADS
Tl
W oO-RING,
NEW
7.9—10.7 N-m (80—110 kgf-cm,
70—95 In-lbf)
N-m (kgf-m, ft-lbf)
16E0B2-365
Timing Belt Pulley

2. Install the crankshaft key and the timing belt pulley on the
crankshaft.
3. Temporarily tighten the timing belt pulley bolt.
16E0B2-366
B 2-106
ASSEMBLY B2
No.2 Idler Pulley
Install the No.2 idler pulley to the cylinder block.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf}
16A0B2-097
Timing Belt Auto Tensioner
1. Set a flat washer under the tensioner body to prevent dam
age to the body plug.
16E0B2-368
2. Press in the tensioner rod slowly, using a press or vise.
Caution
• Do not press the tensioner rod to more than 9,807
N {1,000 kgf, 2,200 Ibf}. It will damage the ten
sioner.
46U0B2-223
3. Insert a pin to hold the tensioner rod in the body.
16E0B2-370
4. Install the auto tensioner to the cylinder block and hand tight
en the upper tensioner bolt so that the tensioner can move.
Note
• This must be done to reduce the timing belt resistance
when the idler pulley is installed.
5. Temporarily install the tensioner pulley.
46U0B2-224
B 2-107
B2 ASSEMBLY
Timing Belt
1. Align the matching marks of the pulleys.
16E0B2-372
2. Install the timing belt on the pulleys in the order described
below.
© Timing belt pulley
© No.2 idler pulley
© LH camshaft pulley
@ Tensioner pulley
© RH camshaft pulley
16A0B2-098
3. Verify that the belt has no looseness at the tension side.
4. Install the No.1 idler pulley while applying the pressure on
the timing belt.
Tightening torque:
38—51 N-m {3.8—5.3 kgf m, 28—38 ft Ibf)
46U0B2-114
5. Push the auto tensioner in the direction of the arrow and
install the lower bolt.
6. Tighten the upper and lower tensioner bolts to the speci
fied torque.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf)
46U0B2-115
7. Remove the pin from the auto tensioner, and apply tension
to the belt.
8. Tighten the tensioner pulley.
Tightening torque:
38—44 N-m {3.8—4.5 kgf m, 28—32 ft Ibf)
46U0B2-116
B 2-108
ASSEMBLY B2
9. Turn the crankshaft twice in the direction of rotation, and
align the timing marks.
10. Verify that the timing marks are correctly aligned. If not, re
peat the procedure from Timing Belt Auto Tensioner.
46U0B2-117
11. Check the timing belt deflection. If it is incorrect, replace
the auto tensioner.
Deflection: 6.0—8.0mm [0.24—0.31 in)
98
22
46U0B2-118
Engine Mount Bracket
Install the engine mount bracket.
Tightening torque:
44—60 Nm {4.4—6.2 kgf m, 32—44 ft-lbf}
16E0B2-379
Timing Belt Cover
1. Install the right timing belt cover.
Tightening torque:
7.9—10.7 N m {80—110 kgf-cm, 70—95 in-lbf}
36U0B2-166
2. Install the left timing belt cover.
Tightening torque:
7.9—10.7 N-m {80—110 kgf cm, 70—95 in-lbf}
36U0B2-167
B 2-109
B2 ASSEMBLY
Crankshaft Position Sensor
Install the crankshaft position sensor.
Tightening torque:
7.9—10.7 N m [80—110 kgf-cm, 70—95 in lbf}
36U0B2-114
Dipstick and Pipe
Install the dipstick and pipe with the clip.
Tightening torque:
7.9—10.7 N m [80—110 kgf cm, 70—95 in lbf}
O-RING,
NEW
46U0B2-225
Water Pump Pulley
Install the water pump pulley.
Tightening torque:
7.9—10.7 N m [80—110 kgf cm, 70—95 in-lbf)
36U0B2-169
1if EESBMEl
frA
Crankshaft Pulley
1. Hold the flywheel (MTX) or drive plate (ATX) by using the
SST.
Caution
• Install the crankshaft pulley carefully. The crank
shaft position sensor rotor is on the rear of the pul
ley, and can be damaged easily.
3. Install the crankshaft pulley onto the crankshaft.

4. Apply clean engine oil to the bolt threads.
' 1 P 5. Tighten the crankshaft pulley.
Tightening torque:
1 5 7 -1 6 6 Nm [1 6 .0 -1 7 .0 kgf m, 116—122 ft Ibf)
B 2-110
ASSEMBLY B2
AUXILIARY PARTS
3 8 -5 1 [3.8—5 .3 ,2 8 —38)
N-m |kgf-m, ft-lbf)
16E0B2-386
Oil Filter
1. Apply a small amount of clean engine oil to the rubber seal
of the new oil filter.
2. Install the filter and tighten it by hand until the rubber seal
contacts the mounting base.
3. Tighten the filter 1-1/6 turns by using the SST.
16E0B2-387
B2-111
B2 ASSEMBLY
Spark Plug
Install the spark plugs.
Tightening torque:
15—22 N m (1.5—2.3 kgf m, 11—16 ft-lbf]
A/C Compressor Bracket (If equipped)

Install the A/C compressor bracket.
Tightening torque:
38—51 N m {3.8—5.3 kgf m 28—38 ft-lbf}
Engine Hanger
1. Install the front engine hanger and the ground harness.
Tightening torque:
19—25 N-m {1.9—2.6 kgf m, 14—18 ft-lbf]
2. Install the rear engine hanger.
Tightening torque:
38—51 Nm (3.8—5.3 kgfm, 28—38 ft-lbf]
Intake Manifold Assembly

1. Install new gaskets and the intake manifold assembly. Hand
tighten the bolts and nuts.
46U0B2-226
ASSEMBLY B2
2. Connect the stays, bracket, fuel pipe, and hoses in the order shown in the figure.
3. Tighten the intake manifold bolts and nuts in two or three steps.
N-m (kgf-m, ft-lbf)
46U0B2-227
Distributor
the distributor.
2. Apply engine oil to the drive blade.
3. Align the groove of the distributor body and shaft gear mark
as shown.
4. Install the distributor with the blade fit into the camshaft
groove.
16A0B2-074
B 2-113
B2 ASSEMBLY
5. Hand tighten the distributor mounting bolts.
6. Connect the high-tension leads.
Note
• Adjust the ignition timing after engine installation. (Refer
to section G.)
46U0B2-120
Exhaust Manifold Assembly (Left)
1. Place the new gasket in position.
2. Install the left exhaust manifold.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf}
16E0B2-395
Exhaust Manifold Insulator (Left)
Install the left exhaust manifold insulator.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95 in-lbf}
36U0B2-170
Bracket and Tensioner
1. Install the bracket and tensioner.
2. Hand tighten bolt 1, then bolt 2.
3. Tighten bolt 2, then bolt 1 to the specified torque.
Tightening torque:
19—25 N-m {1.9—2.6 kgf-m, 14—18 ft-lbf}
Alternator
Install the alternator and the bracket.
Tightening torque
A: 38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf}
B: 1 9 -2 5 Nm {1.9—2.6 kgf m, 14—18 ft Ibf}
16E0B2-398
B 2-114
ENGINE STAND DISMOUNTING B2
ENGINE STAND DISMOUNTING
PROCEDURE
1. Remove the engine from the engine stand.
2. Remove the SST from the engine in the reverse order of
installation. (Refer to page B2-52.)
46U0B2-229
3. Install the new gasket and the right exhaust manifold togeth
er with the EGR valve and pipe.
Tightening torque:
19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf}
4. Tighten the EGR valve bolts.
Tightening torque:
19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf}
16E0B2-400
5. Install the right exhaust manifold insulator.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95 in lbf}
36U0B2-171
B 2-115
B2 INSTALLATION
INSTALLATION
PROCEDURE
Tighten all bolts and nuts to the specified torques.
Step 1
N-m {kgf-m, ft-lbf)

16E0B2-402
No.2 Engine mount rubber and bracket

1. Install the mount rubber bracket.
Tightening torque:
38—51 N m [3.8—5.3 kgf m, 28—38 ft-lbf)
16A0B2-099
B2—116
INSTALLATION B2
2. Install the engine mount No.2 rubber and hand tighten the
through bolt.
Starter
Install the starter to the transaxle housing.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf)
B 2-117
B2 ASSEMBLY
Step 2
Warning
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip
or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not
securely supported on safety stands.
67—93 I
67—93
67—93 [6.8—9.5, 50—68]
N-m [kgf-m, ft-lbf)
46U0B2-121

1. Suspend the engine and transaxle assembly.
2. Slowly lower the engine and transaxle assembly as a unit.
3. Install the engine and transaxle assembly in the engine com
partment.
4. Align the engine mounts with the engine mount member
mounting holes.
46U0B2-122
B 2-118
INSTALLATION B2
Engine mount member
Install the bolts and nuts (A) as shown and hand tighten the
nuts (§).
Tightening torque:
67—93 N-m (6.8—9.5 kgf m, 50—68 ft-lbf}
Engine mount
1. Install the engine mount No.1 mounting bolts.
Tightening torque:
67—93 Nm {6.8—9.5 kgfm, 50—68 ft-lbf]
Tightening torque
® : 74—102 Nm (7.5—10.5 kgf m, 55—75 ft-lbf}
(§): 86—116 N m {8.7—11.9 kgf m, 63—86.0 ft-lbf}
3. Install the engine mount No.4 bracket.

4. Hand tighten bolts ® .
5. Tighten bolts ® .
6. Tighten bolts ® .
Tightening torque
® : 59—80 Nm {6.0—8.2 kgf m, 44—59 ft-lbf}
(§): 59—80 Nm {6.0—8.2 kgf m, 44—59 ft-lbf}

(ATX)
Tightening torque
® : 67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf}
(S): 86—116 Nm {8.7—11.9 kgf m, 63—86 ft-lbf}
8. Remove the chain block from the engine hangers.

9. Tighten the engine mount No.2 rubber mounting bolt.
Tightening torque:
86—116 N m {8.7—11.9 kgf-m, 63—86 ft-lbf}
36U0B2-175
B 2-119
B2 INSTALLATION
10. Tighten the engine mount No.2 nuts B.
Tightening torque:
75—104 Nm {7.6—10.7 kgf m, 55—77 ft-lbf)
Tightening torque
A: 67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf)
B: 44—60 Nm {4.4—6.2 kgf m, 3 2 - 4 4 ft Ibf)
36U0B2-176
Step 3
Torque specifications
16E0B2-413
Drive shaft
1. Apply grease to the ends of the drive shafts.
46U0B2-234
B 2-120
INSTALLATION B2
2. Install new clips with the end gap upward and install the
drive shafts.
3. Install the joint shaft.
Tightening torque:
43—61 Nm [4.3—6.3 kgf m, 32—45 ft-lbf}
5. Coat the ball joints with grease.

6. Install the lower arm ball joints to the knuckles and tighten
the through bolts.
Tightening torque:
44—58 Nm {4.4—6.0 kgfm, 32—43 ft-lbf)
16A0B2-047
Tie rod end
1. Install the tie rod ends to the knuckles and tighten them.
Tightening torque:
43—56 Nm {4.3—5.8 kgfm , 32—41 ft-lbf)
2. Install new cotter pins.
16E0B2-417
Install the stabilizer control link.
Tightening torque:
44—60 Nm {4.4—6.2 kgfm, 32—44 ft-lbf)
36U0B2-177
Extension bar (MTX)
Install the extension bar to the transaxle.
Tightening torque:
32—46 Nm {3.2—4.7 kgfm, 24—33 ft-lbf)
Shift control rod (MTX)

Install the shift control rod to the transaxle.
Tightening torque:
16—22 N m {1.6—2.3 kgfm, 12—16 ft-lbf)
B2-121
B2 INSTALLATION
Front exhaust pipe
1. Connect the front exhaust pipe to the exhaust pipe with a
new gasket. Loosely tighten the new nuts.
2. Install the exhaust pipe to the vehicle body with mount
rubbers.
3. Tighten the nuts.
Tightening torque:
64—89 Nm {6.5—9.1 kgf m, 48—65 ft-lbf)
4. Install the front exhaust pipe with new gaskets.
Tightening torque:
38—51 N m {3.8—5.3 kgfm, 28—38 ft-lbf)
46U0B2-248
Transverse member
Install the transverse member.
Tightening torque:
94—126 Nm {9.5—12.9 kgf m, 69—93 ft-lbf)
16E0B2-422
1. Install the clutch release cylinder.
Tightening torque:
16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf)
2. Mount the pipe in the brackets and install the clips.
Fuel filter
I J
sS '
Install the harness bracket and the fuel filter.
•M Tightening torque:
7.9—10.7 Nm {80—110 kgf-cm, 70—95.4 in-lbf)
pv-J
rl
r(
46U0B2-235
INSTALLATION B2
Step 4
Connect the hoses shown in the figure.
HEATER HOSES
46U0B2-236
B 2-123
B2 INSTALLATION
Step 5
Connect the harness connectors shown in the figure.
B 2-124
INSTALLATION B2
Step 6
7.9—10.7 Nm {80—110 kgf cm, 70—95.4 In Ibf)
25
7.9—10.7 N-m
180—110 kgf-cm,
7 0 -9 5 .4 in Ibf)
7.9—10.7 N-m
180-110 kgf-cm,
70—95.4 In Ibf)
7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in Ibf)
CRUISE ACTUATOR SERVICE,

REFER TO SECTION T
N-m {kgf-m, ft-lbf)
16E0B2-427
B 2-125
B2 INSTALLATION
A/C compressor
Install the A/C compressor to the bracket.
Tightening torque:
24—35 N-m {2.4—3.6 kgf-m, 18—26 ft-lbf]
P/S oil pump and bracket

Tightening torque
A: 32—46 Nm {3.2—4.7 kgf m, 24—33 ft-lbf]
B: 19—25 Nm (1.9—2.6 kgf-m, 14—18 ft-lbf]
2. Tighten the bolts shown in the figure.
Tightening torque:
32—46 N m {3.2—4.7 kgf m, 24—33 ft-lbf]
c
3. Connect the P/S pressure switch connector.
4. Install the P/S oil pump pulley to the pump body and hand
tighten the nut.
5. Tighten the pulley nut by using a 12mm {0.47 in] socket
through the pulley hole.
Tightening torque:
63—93 N m {6.4—9.5 kgf m, 47—68 ft-lbf]
46U0B2-237
B 2-126
INSTALLATION B2
6. Install the P/S oil reservoir and the engine ground.
Tightening torque:
6.9—9.8 N-m {70—100 kgf-cm, 61—86 in-lbf)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflection. (Refer to page B2-6.)
Radiator and electric coolant fan assembly

1. Install the radiator.
Tightening torque:
19—25 Nm {1.9—2.6 kgfm, 14—18 ft-lbf)
2. Connect the ATF cooler hoses. (ATX)

3. Connect the upper and lower radiator hoses.
4. Install the coolant fan assembly.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in-lbf)
5. Connect the coolant reservoir hose.

6. Connect the coolant fan motor connector.
Accelerator cable
Inspection / Adjustment
Free play: 1.5—4.0mm {0.06—0.16 in)
3. If not as specified, turn stopper (§) while pressing lock but

ton (A) to release the lock.
UN LOCK
4. Push the spring in direction (5) and adjust the cable free
play.
46U0B2-123 5. Lock stopper ® after locking stopper (§).
Air cleaner housing assembly

1. Install the air cleaner housing assembly.
2. Connect the hoses.
Tightening torque:
19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf)
46U0B2-246
B 2-127
B2 INSTALLATION
Fresh air duct
Install the fresh air duct.
Tightening torque:
7.9—10.7 N m {80—110 kgf cm, 70—95.4 in lbf)
46U0B2-247

1. Fill the engine with the specified amount and type of engine oil. (Refer to section D2.)
3. If the transaxle was drained, fill it with the specified amount and type of transaxle oil.
(MTX: Refer to section J, ATX: Refer to section K1.)
4. Install the front wheels.
5. Start the engine and
(1) Check the engine oil, transaxle oil, and engine coolant leakage.
(2) Check the ignition timing and idle speed (Refer to section F2.)
(3) Check the operation of the emission control system.
6. Turn off the engine and check drive belt deflection. (Refer to page B2-6.)
7. Perform a road test.
8. Recheck the oil and coolant levels.
46U0B2-124
Electrical Troubleshooting Manual; see section S for air bag system
service warnings and section J for audio antitheft system alarm conditions.
LUBRICATION SYSTEM
(FS)
INDEX...............................................................D 1 - 2
OUTLINE..........................................................D 1 - 3
SPECIFICATIONS........................................ D 1 - 3
TROUBLESHOOTING GUIDE....................... D 1 - 3
OIL PRESSURE...............................................D 1 - 4
PREPARATION............................................ D 1 - 4
INSPECTION................................................D 1- 4
ENGINE OIL.....................................................D 1- 6
INSPECTION................................................D 1 - 6
REPLACEMENT...........................................D 1 - 6
OIL FILTER...................................................... D 1 - 7
PREPARATION............................................ D 1- 7
REPLACEMENT........................................... D 1- 7
OIL PAN...........................................................D 1- 8
REMOVAL /INSTALLATION....................... D 1 - 8
OIL PUM P....................................................... D1-11
DISASSEMBLY/ASSEMBLY....................... D1-11
INSPECTION................................................ D1-12
36U0D1-001
D1 INDEX
INDEX
ENGINE OIL SPECIFICATION

API SERVICE SG, SH (ECU)
ILSAC
TOTAL CAPACITY
3.7 L (3.9 US qt, 3.3 Imp qt)
36UOD1-002
1. Oil pressure 4. Oil pan

Inspection............. .................... page D1-4 Removal / Installation.............. page D 1- 8
2. Engine oil 5. Oil pump
Inspection.................................. page D1-6 Disassembly / Assembly......... page D 1-1 1
Replacement.............................. page D1-6 Inspection................................ page D1-12
3. Oil filter
Replacement.............................. page D1-7
D 1 -2
OUTLINE, TROUBLESHOOTING GUIDE D1
OUTLINE
SPECIFICATIONS
_ Engine
Item FS
Lubrication system Force-fed type
Type Trochoid gear
Oil pump
Relief pressure kPa (kgf/cm2, psi) 4 4 2 -5 3 9 (4 .5 -5 .5 , 6 4 -7 8 )
Type Full-flow, paper element
Oil filter Relief pressure differential
7 9 -1 1 7 (0 .8 -1 .2 , 1 2 -1 7 )
kPa (kgf/cm2, psi)
Oil pressure switch activation pressure kPa {kgf/cm2, psi) 14.8—27.4 (0.15—0.28, 2.14-3.98)
Total (dry engine) L [US qt, Imp qt) 3.7 (3.9, 3.3)
Engine oil replacement
3.3 (3.5, 2.9)
Oil capacity L (US qt, Imp qt)
Engine oil replacement (with oil filter)
3.5 (3.7, 3.1)
L (US qt, Imp qt)
Engine oil API Service SG, SH (EC II)
ILSAC
46U0D1-001
Recommended SAE Viscosity

CM
o _
CO
O_
-1 0 0 10 20 30 40 50
1
1
(°C ) I I i i i i
Temperature 1 1 I I i i i I !
( °F)
-2 0 0 20 40 60 80 100 120
5W-30 >
Engine oil
< 10W-30
Anticipated ambient temperature range before the succeeding oil change, °C (°F)
Problem Possible Cause Remedy Page
Engine hard starting Improper engine oil Replace D1— 6

Insufficient engine oil Add oil D 1- 6
Excessive oil Oil working up or down in cylinder Refer to Section B1
consumption Oil leakage Repair _
Oil pressure drop Insufficient oil Add oil D 1- 6
Oil leakage Repair
Worn and/or damaged oil pump rotor Replace D 1-12
Worn plunger (inside oil pump) or weak spring Replace D 1-12
Clogged oil strainer Clean
Excessive main bearing or connecting rod bearing Refer to Section B1
clearance
Warning lamp Oil pressure drop As described above
illuminates while Malfunction of oil pressure switch Refer to Section T
engine is running Malfunction of electrical system Refer to Section T
36U0D1-004
Warning
46U0D1-002
D1 OIL PRESSURE
OIL PRESSURE
PREPARATION
SST
INSPECTION
1. Remove the intake manifold bracket.
2. Remove the oil pressure switch.
3. Screw the SST into the oil pressure switch installation hole.
5. Run the engine at 3,000 rpm and note the gauge readings

{4.0—5.0 kgf/cm2, 57—71 psi}-3,000 rpm
6. If the pressure is not as specified, check for the cause and

repair. (Refer to Troubleshooting Guide p. D1-3.)
7. Apply sealant to the oil pressure switch threads as shown.
16E0D1-009
D1—4
OIL PRESSURE D1
8. Remove the SST and install the oil pressure switch.
Tightening torque:
11.8— 17.6 N m {120— 180 kgf-cm, 105— 156 in-lbf}
D1
9. Install the intake manifold bracket.
Tightening torque:
38—51 N-m {3.8—5.3 kgf-m, 28—38 ft-lbf}
16EQD1-039
D 1 -5
D1 ENGINE OIL
ENGINE OIL
INSPECTION
stop it.
5. Add or replace oil as necessary.
Note
REPLACEMENT
Warning
• When the engine and the oil are hot, they can bad
ly burn. Don’t burn yourself with either.
2. Drain the oil into a container.
46U0D1-005
3. Install the drain plug.
Tightening torque:
30—41 N m {3.0—4.2 kgf m, 22—30 ft Ibf}
gine oil.
Oil capacity
L (US qt, Imp qt)
Total (dry engine) 3.7 (3.9, 3.3)
Engine oil replacement 3.3 (3.5, 2.9)
46U0D1-006 Engine oil replacement (with oil filter) 3.5 (3.7, 3.1)
5. Refit the oil filler cap.

6
46U0D1-014
D 1 -6
OIL FILTER D1
OIL FILTER
PREPARATION
SST
49 G014 001 For

removal and
Oil filter installation of
wrench oil filter
16E0D1-015
REPLACEMENT
1. Remove the oil filter by using the SST.
engine.
the new filter.
36U0D1-005
tacts the cylinder block
5. Tighten the filter 1 and 1/6 turns by using the SST.
Tightening torque:
13.8— 17.6 N m (140— 180 kgf cm, 122— 156 in lb f)

7. Check the oil level and add if necessary.
Oil filter capacity: 0.2 L (0.21 US qt, 0.18 Imp qt)

46UQD1-007
D1 OIL PAN
OIL PAN
REMOVAL / INSTALLATION
2. Drain the engine oil. (Refer to page D1-6.)
GASKET, REPLACE
7.9— 10.7 N-m

(80— 110 kgf cm, 70—95.4 in-lbf)
19—25 (1.9—2.8, 14— 18)
7.9— 10.7 N m (80— 110 kgf cm, 70—95.4 in-lbf)
N m (kgf m, ft-lbf)
46UOD1-O15
1. Undercover 5. Oil strainer
2. Heated oxygen sensor connector Removal Note... page D1-9
3. Front exhaust pipe Installation Note. page D1-9
4. Oil pan
Removal Note............................page D1-9
Installation Note..........................page D1-9
D 1 -8
OIL PAN D1
Removal Note
Oil pan
Caution
• Pry tools can easily scratch the oil pan stiffener and
oil pan contact surfaces. Prying off the oil pan can
also easily bend the oil pan flange. Refer to the fol
lowing instructions before removing the oil pan.
D1
2. Remove the sealant on the bolt threads.

3. Screw in an oil pan bolt in the weld nut hole to make a small
gap between the oil pan upper block and the oil pan.
4. Insert a screwdriver or suitable tool as shown in the figure.
36U0D1-008
Oil strainer
1. Remove bolt (§).
2. Remove bolts ® .
3. Remove the oil strainer and gasket.
36U0D1-0Q9
Installation Note
Oil strainer
1. Install the oil strainer with a new gasket.
2. Tighten the bolts marked ® first.
Tightening torque:
7.9— 10.7 N m [80— 110 kgf cm, 70—95 in lbf)
46UOD1-OQ9
Oil pan
Caution
46U0D1-010
D 1 -9
D1 OIL PAN
2. Apply silicone sealant to the oil pan as shown in the figure.
4. Install the oil pan.
Tightening torque:
19—25 N m [1.9—2.6 kgf m, 14—18 ft-lbf)

1. Fill with the specified amount and type of engine oil. (Refer to page D1-6.)
46U0D1-016
OIL PUMP D1
OIL PUMP
DISASSEMBLY / ASSEMBLY
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.
53—78 In-lbf)
36U0D1-012
1. Oil seal 5. Snap ring

Disassembly Note, .......... below 6. Spring seat
Assembly Note .... page D1-13 7. Pressure spring
2. Pump cover Inspection................................page D1-12
Disassembly Note page D1-12 8. Control plunger
Assembly Note.... page D1-13 Inspect for wear or damage
3. Outer rotor 9. Pump body
Assembly N ote.... page D1-13 Inspect for distortion or damage
4. Inner rotor
Assembly Note.... page D1-13
Disassembly Note
Oil seal
Remove the oil seal with a screwdriver protected with a
rag.
16E0D1-Q29
D1-11
D1 OIL PUMP
Pump cover
1. Remove the pump cover mounting bolts with an impact
screwdriver.
2. Remove the pump cover.
46U0D1-017
INSPECTION
Pressure spring
1. Inspect the spring for weakness and damage.
2. Measure the free length. Replace the spring if necessary.
Free length: 46.79mm [1.842 in)
46U0D1-018
Rotor Clearance
Measure the following clearance. Replace the rotor if
necessary.
Tooth tip clearance:

0.02—0.18mm [0.0008—0.0071 in)
Maximum: 0.200mm [0.0118 in)
46U0D1-020
Outer rotor to pump body clearance:
0.113—0.186mm [0.0044—0.0073 in)
Maximum: 0.210mm [0.0083 in)
46U0D1-021
Side clearance:
0.035—0.095mm [0.0014—0.037 in)
Maximum: 0.120mm [0.0047 in)
46U0D1-022
D 1 -1 2
OIL PUMP D1
Assembly Note
Inner and outer rotor
1. Apply a small amount of clean engine oil to the contact sur
face of the pump body.
2. Install the inner and outer rotors into the oil pump body with
the marks aligned as shown.
Pump cover
1. Install the pump cover.
Tightening torque:
5.9—8.8 N m (60—90 kgf cm, 53—78 in Ibf)
2. Verify that the inner rotor turns smoothly when turned by

hand.
Oil seal
oil seal.
the edge of the oil pump body.
Note
• Oil seal outer diameter: 54.5mm (2.15 in)
• Oil seal inner diameter: 42.5mm (1.67 in)
46U0D1-013
LUBRICATION SYSTEM
(KL)
INDEX........................................................... D 2- 2
OUTLINE.......................................................D 2- 3
SPECIFICATIONS.......................................D2- 3
TROUBLESHOOTING GUIDE...................... D2- 3
OIL PRESSURE............................................ D 2- 4
PREPARATION.......................................... D2- 4
INSPECTION..............................................D2- 4
ENGINE OIL.................................................. D2— 5
INSPECTION............................................. D 2- 5
REPLACEMENT.........................................D2- 5
OIL FILTER................................................... D2- 6
PREPARATION.......................................... D2- 6
REPLACEMENT.........................................D2- 6
OIL COOLER................................................D2- 7
PREPARATION.......................................... D2- 7
REMOVAL/INSTALLATION...................... D 2- 7
OIL PAN........................................................ D2- 8
REMOVAL / INSTALLATION...................... D 2- 8
INSPECTION............................................. D2- 9
OIL PUMP.....................................................D2-11
DISASSEMBLY/ASSEMBLY...................... D2-11
INSPECTION............................................. D2-12
36U0D2-001
D2 INDEX
INDEX
ILSAC
TOTAL CAPACITY
4.9 L (5.2 US qt, 4.3 Imp qt)
16A0D2-007
1. Oil pressure 4. Oil cooler

Inspection.................................. page D2-4 Removal / Installation.............. page D 2- 7
2. Engine oil 5. Oil pan
Inspection.................................. page D2-5 Removal / Installation.............. page D2- 8
Replacement..............................page D2-5 Inspection.............................:.. page D 2- 9
3. Oil filter 6. Oil pump
Replacement............................ page D2-6 Disassembly / Assembly......... page D 2-11
Inspection................................ page D2-12
D 2 -2
OUTLINE, TROUBLESHOOTING GUIDE D2
OUTLINE
SPECIFICATIONS
---------------------------- Engine
Item ------------ ---------- KL
Lubrication system Force-fed type
Type Trochoid gear
Oil pump
Relief pressure kPa (kgf/cm2, psi) 5 00 -5 80 (5.0—6.0, 7 2 -8 5 )
Type Full-flow, paper element
Oil filter Relief pressure differential
7 9 -1 1 0 (0.8—1.2, 1 1 -1 7 )
kPa |kgf/cm2,psi)
Total (dry engine) L (US qt, Imp qt) 4.9 (5.2, 4.3)
Engine oil replacement
3.7 (3.9, 3.3)
Oil capacity L (US qt, Imp qt)
Engine oil replacement (with oil filter)
4.0 (4.2, 3.5)
L (US qt, Imp qt)
Engine oil API service SG, SH (EC H)
ILSAC
46U002-001
Recommended SAE Viscosity

CM
o
CO
o
-1 0 0 10 20 30 40 50
I
(°C ) i i
_
I 1 i i i
T e m p e ra tu re I I 1 1 i i i i
(°F )
-2 0 0 20 40 60 80 100 120
5W-30 " >

E n g in e o il
< 10W-30
Anticipated ambient temperature range before the succeeding oil change, °C (°F)
Engine hard staring Incorrect oil viscosity Replace D 2- 5
Insufficient oil Add oil D 2- 5
Excessive oil Oil working up or down in cylinder Refer to Section B2
consumption Oil leakage Repair or replace _
Oil pressure drop Insufficient oil Add oil D 2- 5
Oil leakage Repair or replace
Worn and/or damaged oil pump Replace D2-11, 12
Worn plunger (inside oil pump) or weak spring Replace D 2 -1 1 ,12
Clogged oil strainer Clean
Excessive main bearing or connecting rod bearing Refer to Section B2
clearance
36U0D2-006
Warning
46U0D2-002
D2 OIL PRESSURE
OIL PRESSURE
PREPARATION
SST
16E0D2-005
INSPECTION
1. Remove the oil pressure switch.
16E0D2-006
2. Screw the SST into the oil pressure switch installation hole.
4. Run the engine at the specified, and note the gauge
readings.
Oil pressure
1.000 rpm:200 kPa (2.0 kgf/cm2, 28 psi)
3.000 rpm: 340—490 kPa
{3.4—5.0 kgf/cm2, 49—71 psi)
5. If the pressure is not as specified, check for the cause and

46U0D2-003 repair as necessary.
(Refer to Troubleshooting Guide p. D2-3.)
6. Apply sealant to the oil pressure switch threads as shown.
16E0D2-008
7. Remove the SST and install the oil pressure switch.
Tightening torque:
11.8—17.6 Nm {120—180 kgf-cm, 104—156 Inlbf)
36U0D2-101
D 2 -4
ENGINE OIL D2
ENGINE OIL
INSPECTION
stop it.
5. Add or replace oil as necessary.
Note
REPLACEMENT
Warning
• When the engine and the oil are hot, they can bad
ly burn. Don’t burn yourself with either.
3. Install a new gasket and the drain plug.
Tightening torque:
46U0D2-005 30—41 N m {3.0—4.2 kgf m, 22—30 ft-lbf)
gine oil.
Oil capacity
L [U S qt, Im p q t)
T otal (d ry e n g in e) 4 .9 (5 .2 , 4 .3 )
E n g in e oil re p la c e m e n t 3 .7 [3 .9 , 3 .3 )
Engine oil replacement (with oil filter) 4 .0 (4 .2 , 3 .5 )
46U0D2-006 5. Refit the oil filler cap.

D2 OIL FILTER
OIL FILTER
PREPARATION
SST
4 9 G 0 1 4 001 F or
re m o va l /
W re n c h , in sta lla tio n of
oil filte r oil filte r
16E0D2-012
REPLACEMENT
oil cooler base.
the new filter.
16E0D2-013
tacts the oil cooler base.
49 GO 14 001
Tightening torque:
13.8—17.6 N m (140—180 kgf-cm, 122—156 in-lbf ]

Oil filter capacity: 0.3 L (0.3 US qt, 0.3 Imp qt)

46U0D2-0Q7
OIL COOLER D2
OIL COOLER
PREPARATION
SST
D2
3. Remove in the order shown in the figure.
REPLACE
N-m (kgf-m, ft-lbf)
46U0D2-011
1. Oil filter 4. Oil pressure switch

Replacement........ ..................... page D2-6 5. Oil filter body
2. Oil cooler hoses 6. Gasket
3. Oil cooler

1. Fill with the specified amount and type of engine coolant. (Refer to Section E2-6.)
2. Check for leaks.
D 2 -7
D2 OIL PAN
OIL PAN
2. Drain the engine oil. (Refer to page D2-5.)
GASKET,
REPLACE
Short: 7.9— 10.7 N m (80— 110 kgf cm, 70—95.4 in-lbf)

Long: 19—25[ 1.9—2.6, 14— 18)
N m (kgf m, ft-lbf)
46U0D2-012
1. Undercover 4. Oil pan

2. Transverse member Removal Note........................... page D2-9
3. Front exhaust pipe Inspection...................................page D2-9
Installation Note......................... page D2-9
5. Oil strainer
D2—8
OIL PAN D2
Removal Note
Oil pan
Caution
• Pry tools can easily scratch the lower cylinder block
and oil pan contact surfaces. Prying off the oil pan
can also easily bend the oil pan flange. Refer to the
following instructions before removing the oil pan.
2. Remove the sealant from the bolt threads.

Screw on oil pan bolt into the oil pan (arrow) to make a small
gap between the block and oil pan.
3. Insert a screwdriver or suitable tool shown in the figure and
pry loose the oil pan.
INSPECTION
Oil Pan
Visually check for cracks, deformation and damage.
Repair or replace if necessary.
16E0D2-020
Installation Note
Oil pan
Caution
46U0D2-009
16E0D2-022
D 2 -9
D2 OIL PAN
flange as shown in the figure.
4. Install the oil pan.
Tightening torque
® : 7.9—10.7 N m
(80—110 kgf cm, 70—95.4 inlbf)
(I): 1 9 -2 5 N m (1 .9 -2 .6 kgf m, 1 4 -1 8 ft-lbf)

1. Fill with the specified amount and type of engine oil. (Refer to page D2-5.)
16E0D2-025
_____________________________OIL PUMP________ ________________ D2
OIL PUMP
DISASSEMBLY / ASSEMBLY
53—78 In-lbf)
-----------0 57—68 15.8—7.0, 42—50)
N m (kgf m, ft-lbf)
16E0D2-026
1. Pump cover 5. Spring seat

Disassembly Note...............................below 6. Pressure spring
Assembly Note.........................page D2-13 Inspection.................................page D2-12
2. Outer rotor 7. Control plunger
Assembly Note.........................page D2-12 Inspect for wear and damage
3. Inner rotor 8. Pump body
Assembly Note.........................page D2-12 Inspect for distortion and damage
4. Blind plug
Disassembly Note
Pump cover
1. Remove the pump cover mounting bolts with an impact
screwdriver.
2. Remove the pump cover.
46U0D2-013
D2-11
D2 OIL PUMP
INSPECTION
Pressure Spring
1. Inspect the spring for weakness and damage.
2. Measure the spring free length. Replace the spring if
necessary.
Free length: 46.79mm (1.842 in)
46U0D2-014
Rotor Clearance
Measure the following clearances. Replace the rotor if
necessary.
Tooth tip clearance:

0.02—0.18mm (0.0008—0.0070 in}
46U0D2-015
Outer rotor to pump body clearance:
0.113—0.186mm (0.0045—0.0073 in)
46U0D2-016
Side clearance: 0.03—0.09mm (0.0012—0.0035 in)
46U0D2-017
Assembly Note
Inner and outer rotor
1. Apply a liberal amount of clean engine oil to the friction sur
face of the pump body and the rotors.
2. Install the inner rotor and outer rotor with the markings fac
ing upward.
16E0D2-032
D 2-1 2
OIL PUMP D2
Pump cover
1. Install the pump cover.
Tightening torque:
5.9—8.8 N-m (60—90 kgf-cm, 53—78 in-lbf)
2. Verify that the oil pump rotates smoothly when turned by

hand.
16E0D2-033
D 2-1 3
E1
COOLING SYSTEM
(FS)
INDEX........................................................... E1- 2
OUTLINE.......................................................E1- 3
SPECIFICATIONS.......................................E1- 3
TROUBLESHOOTING GUIDE...................... E1- 3
ENGINE COOLANT.......................................E1- 4
PREPARATION........................................... E1- 4
INSPECTION...............................................E1- 4
REPLACEMENT.........................................E1- 5
RADIATOR CAP........................................... E1- 7
PREPARATION........................................... E1- 7
INSPECTION...............................................E1- 7
RADIATOR.....................................................E1- 8
REMOVAL / INSTALLATION....................... E1- 8
INSPECTION...............................................E1- 8
THERMOSTAT............................................. E1- 9
INSPECTION...............................................E1— 9
WATER PUMP...............................................E1-11
REMOVAL / INSTALLATION....................... E1-11
COOLANT FAN MOTOR.............................. E1-12
INSPECTION...............................................E1-12
REPLACEMENT.........................................E1-13
COOLANT FAN RELAY............................... E1-14
REMOVAL.................................................. E1-14
INSPECTION...............................................E1-14
46U0E1-001
E1 INDEX
INDEX
1. Engine coolant 5. Water pump

Inspection.................................page E1- 4 Removal / Installation............... page E 1-11
Replacement.............................page E1- 5 6. Coolant fan motor
2. Radiator cap Inspection................................ page E1-12
Inspection.................................page E1- 7 Replacement............................ page E1-13
3. Radiator 7. Engine coolant temperature sensor
Removal / Inspection / Removal / Inspection / MTX: Section F1
Installation...............................page E1- 8 Installation ..... ATX: Section F3
4 Thermostat 8. Coolant fan relay
Removal / Inspection / Removal................................... page E1—14
Installation...............................page E1- 9 Inspection................................ page E1-14
E 1-2
OUTLINE, TROUBLESHOOTING GUIDE E1
OUTLINE
•*
SPECIFICATIONS
' ------------------------ Engine FS
Item ~ ~ -------------- MTX ATX
Cooling system Water-cooled, fcirced circulation
Coolant capacity L (US qt, Imp qt) 7.0 (7.4, 6.2)
Type Centrifugal, V-ribbed belt-driven
Water pump
Water seal Unified mechanical seal
Type Wax, bottom-bypass
Opening temperature °C (°F ) 8 0 -8 4 (1 7 6 -1 8 3 )
Thermostat
Full-open temperature °C (°F ) 95 (203)
Full-open lift mm (in) 8.5 (0.33) min.
Type Corrugated fin
Radiator
Cap valve opening pressure kPa (kgf/cm2, psi) 9 3 -1 2 3 (0.95-1.25, 13.5-17.8)
Type Electric
Outer diameter mm (in) 340 (13.4)
Blade
Coolant fan Number 4 5
8 .0-14 .0 (LOW)
Motor Current A 5.6—7.6
11.5-17.5 (HIGH)
46U0E1-003
Overheating Coolant level insufficient Add E 1- 4

Coolant leakage Repair or replace
Radiator fins clogged Clean E 1- 8
Radiator cap malfunction Replace E1- 7
Coolant fan malfunction Replace E1-12
Thermostat malfunction Replace E1- 9
Water passage clogged Clean E1- 5
Water pump malfunction Replace E1-11
Corrosion Impurities in coolant Replace E1- 5
36U0E1-003
E 1 -3
E1 ENGINE COOLANT
ENGINE COOLANT
PREPARATION
SST
49 9200 145 For 49 9200 146 For

inspection of inspection of
Adapter set, Jjf /g v ^ y cooling system Adapter A // \\ cooling system
radiator cap ^ pressure (Part of iL pressure
tester 49 9200 145)
16E0E1-005
INSPECTION
Warning
• Removing the radiator cap or the radiator drain plug
steam may shoot out and cause serious injury. It
may also damage the engine and cooling system.
sure escapes.
down on the cap - still using a cloth-turn it, and re
move it.
46U0E1-004

radiator.
L marks. Add coolant if necessary.
46U0E1-0Q5
Note
• The distance between the L and F mark on dipstick
Coolant Quality
radiator cap and filler neck.
2. Verify that the coolant is free of oil. Replace the coolant if
necessary.
36U0E1 -004 Coolant Leakage

1. Connect a radiator tester (commercially available) and the
2. Apply 123 kPa {1.25 kgf/cm2, 17.8 psi) pressure to the
system.
3. Verify that the pressure is held. If not, check for coolant
leakage.
Caution
• Applying more than 123 kPa (1.25 kgf/cm2, 17.8 psi)
can damage the hoses, fittings and other compo
nents, and cause leaks.
46U0E1-017
ENGINE COOLANT E1
Coolant Protection
COOLANT PROTECTION Caution

SPECIFIC
GRAVITY • The engine has aluminum parts that can be
damaged by alcohol or methanol antifreeze. Do not
use alcohol or methanol in the cooling system. Use

shown.
as necessary.

Volume percentage Gravity at
Coolant protection
COOLANT TEMPERATURE °C |°F| Water Coolant 20°C |68°F)
Above -16°C (3°F) 65 35 1.054
Above -26°C (—15°F) 55 45 1.066
46U0E1-006
Above -40°C {-40°F) 45 55 1.078
REPLACEMENT
Draining
Warning
• Removing the radiator cap or the radiator drain plug
sure escapes.
move it.
1. Remove the radiator cap and loosen the radiator drain plug.
3. Drain the coolant into a container.
are gone.
5. Let the system drain completely.
6. Tighten the drain plug.
46U0E1-008
E 1 -5
E1 ENGINE COOLANT
Refilling
Use the proper amount and mixture of ethylene-glycol based
coolant. (Refer to Coolant Protection, page E1-5.)
1. Slowly pour the coolant into the radiator up to the coolant
filler port.
Filling pace:
1.0 L (1.1 US qt, 0.9 Imp qt}/min. max.
2. Fill the coolant reservoir up to the F mark.

3. Fully install the radiator cap.
4. Start the engine and let it idle until it warms up.
5. If the temperature increases beyond normal, there is exces
sive air in the system. Stop the engine and allow it to cool;
then repeat Step 1—3.
6. Run the engine at 2,200—2,800 rpm for five minutes.
7. Stop the engine and allow it to cool.
8. Repeat steps 1—7; then go to step 9.
Warning
• Removing the radiator cap while the engine is run
ning, or when the engine and radiator are hot is dan
gerous. Scalding coolant and steam may shoot out
and cause serious injury. It may also damage the
engine and cooling system.
-f
sure escapes.
move it.
9. Remove the radiator cap and verify that the engine coolant
level is near the filler neck. If not, repeat steps 1—9.
10. Fill the reservoir up to the F mark.
46U0E1-009
RADIATOR CAP E1
RADIATOR CAP
PREPARATION
SST
49 9200 145 For 49 9200 147 For

Adapter set,
({
JL
\
/y \
/X
,4 ^ radiator cap Adapter B J ' radiator cap
radiator cap valve (Part of wOAV' valve
tester 49 9200 145)
16E0E1-014
INSPECTION
Radiator Cap Valve
Warning
49 92 00 147 engine and cooling system. Turn off the engine and
wait until it is cool. Even then, be very careful when
removing the cap. Wrap a thick cloth around it and
46U0E1-018 slowly turn it counter clockwise to the first stop.
Step back while the pressure escapes.
move it.
1. Remove all foreign material (such as water residue) from

between the radiator cap valve and the valve seat.
2. Attach the radiator cap to a radiator cap tester (commer
cially available) with the SST. Apply pressure gradually to
93—123 kPa {0.95—1.25 kgf/cm2, 13.5—17.8 psi).
3. Verify that the pressure is held for at least 10 seconds.
Negative Pressure Valve

1. Pull the negative pressure valve to open it. Verify that it
closes completely when released.
2. Check for damage of the contact surfaces and for cracked
and deformed seal packing.
3. Replace the radiator cap if necessary.
16E0E1-016
E1 RADIATOR
RADIATOR
2. Drain the engine coolant. (Refer to page E1-5.)
N-m {kgf-m, ft-lbf)

46UOE1-010
1. Resonance chamber No.1 6. Oil cooler hose (ATX)

2. Fresh air duct 7. Radiator bracket
3. Coolant fan motor connector 8. Radiator
4. Coolant reservoir pipe Inspection............................................below
5. Upper and lower, radiator hose 9. Coolant fan and radiator cowling assembly
INSPECTION
Radiator
Check for the following and repair or replace as necessary.
1. Cracks, damage, and water leakage
2. Bent fins (Repair with a screwdriver.)
3. Distorted and bent radiator inlet and outlet

1. Fill the radiator with the specified amount and type of en
gine coolant. (Refer to page E1-6.)
2. Check for leaks.
46U0E1-019
E 1 -8
THERMOSTAT E1
THERMOSTAT
E1
14—18)
N-m {kgf m, ft-lbf)

46U0E1-020
1. Radiator hose, lower 3. Thermostat

2. Thermostat cover Inspection............................................below
Installation Note....................... page E1-10
INSPECTION
Thermostat
1. Visually check that the thermostat valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Heat the water and check the following.
Initial-opening temperature:
80—84°C {176—183°F)
Full-open temperature: 95°C {203°Fj
Full-open lift: 8.5mm {0.33 in} min.
36U0E1-015
E 1 -9
E1 THERMOSTAT
4. If the gasket of the thermostat is damaged, replace the ther
mostat assembly.
16E0E1-021
Installation Note
Thermostat
1. Verify that the jiggle pin is aligned with the projection of the
thermostat gasket as shown.
36U0E1-006
2. Install the thermostat and gasket into the thermostat hous
ing, aligning the tab to the housing, as shown in the figure.
16E0E1-023

1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E1-6.)
2. Check for leaks.
46UQE1-021
E1—10
WATER PUMP E1
WATER PUMP
2. Drain the coolant. (Refer to page E1-5.)
N-m (kgf-m, ft-lbf)

46U0E1-022
1. Timing belt 4. Water pump rubber seal

Removal / Installation...... ............Section B1 Inspect for damage
2. P/S oil pump adjuster
3. Water pump assembly
Inspect for cracks, damaged mounting sur
face, bearing condition, and leakage

2. Check for leaks.
E1 COOLANT FAN MOTOR
COOLANT FAN MOTOR
INSPECTION
Single-Speed Type (MTX)
1. Verify that the battery is fully charged.
2. Disconnect the coolant fan motor connector.
3. Connect battery positive voltage and an ammeter to the cool
ant fan motor connector.
4. Verify that current draw is as specified.
Current: 5.6—7.6A
46U0E1-011
5. If current is not within the specification or the coolant fan
does not turn smoothly, replace the coolant fan motor.
Two-Speed Type (ATX)

ant fan motor connector for low-speed inspection.
4. Verify that the coolant fan motor operates smoothly at the
standard current draw. w
Current: 8.0—14.0A
46U0E1-Q12
ant fan motor connector for high-speed inspection.
standard current draw.
Current: 11.5—17.5A
7. If not as specified, replace the coolant fan motor.
46U0E1-013
E1—12
COOLANT FAN MOTOR E1
REPLACEMENT
2.7—3.7 N-m (27—38 kgf-cm, 24—32 In-lbf)
46U0E1-014
1. Resonance chamber No.1 4. Radiator cowling

2. Fresh air duct 5. Coolant fan blade
3. Coolant fan motor connector 6. Coolant fan motor
E 1 -13
E1 COOLANT FAN RELAY V
COOLANT FAN RELAY

REMOVAL
2. Remove the coolant fan relay as shown in the figure.
46U0E1-015
INSPECTION
1. Check continuity of the coolant fan relay as shown.
Terminal Continuity
A -C No
B -D Yes
2. Apply battery positive voltage between terminals B and D.

Check for continuity between terminals A and C.
3. If not as specified, replace the coolant fan relay.
E1—14
COOLING SYSTEM
(KL)
INDEX............................................................E2- 2
OUTLINE.......................................................E2- 3
SPECIFICATIONS...................................... E2- 3
TROUBLESHOOTING GUIDE...................... E2- 3
ENGINE COOLANT.......................................E2- 4
PREPARATION........................................... E2- 4
INSPECTION...............................................E2— 4
REPLACEMENT.........................................E2- 5
RADIATOR CAP........................................... E2- 7
PREPARATION........................................... E2- 7
INSPECTION...............................................E2- 7
RADIATOR.....................................................E2— 8
INSPECTION...............................................E2- 8
THERMOSTAT..............................................E2- 9
INSPECTION...............................................E2-10
WATER PUMP...............................................E2-11
REMOVAL / INSTALLATION....................... E2-11
COOLANT FAN MOTOR.............................. E2-12
INSPECTION...............................................E2-12
REPLACEMENT.........................................E2-13
COOLANT FAN RELAY............................... E2-14
REMOVAL.................................................. E2-14
INSPECTION...............................................E2-14
46U0E2-001
E2 INDEX
INDEX
46U0E2-002
1. Engine coolant 5. Water pump
Inspection......................... ....... page E2- 4 Removal / Installation...... ........ page E2-11
Replacement.................... ....... page E2- 5 6. Coolant fan motor
2. Radiator cap Inspection....................... .......page E2-12
Inspection......................... ....... page E2- 7 Replacement................... ....... page E2-13
3. Radiator 7. Engine coolant temperature sensor
Removal / Installation....... ....... page E2- 8 Removal / Inspection /
Inspection......................... ....... page E2- 8 Installation..................... .......... Section F2
4. Thermostat 8. Coolant fan relay
Removal / Installation....... ....... page E2- 9 Removal.......................... ....... page E2-14
Inspection......................... ....... page E2-10 Inspection....................... ....... page E2-14
OUTLINE, TROUBLESHOOTING GUIDE E2
OUTLINE
SPECIFICATIONS
Engine
Item KL
Cooling system Water-cooled, forced circulation
Coolant capacity L (US qt, Imp qt) 7.5 (7.9, 6.6)
Type Centrifugal
Water seal Unified mechanical seal
Type Wax, bottom-bypass
Opening temperature °C ( °F) 8 0 -8 4 (1 7 6 -1 8 3 )
Thermostat
Full-open temperature °C (°F) 95 (203)
Full-open lift mm (in) 8.5 (0.33) min.
Type Corrugated fin
Radiator Cap valve opening pressure kPa E2
(kgf/cm2, psi) 7 4 -1 0 2 (0.75-1.05, 10.7-14.9)
Type Electric
Outer diameter mm (in) 340 (13.4)
Blade
Coolant fan Number 5
MTX 11.5-17.5 (High) 8 .0-14 .0 (Low)
Motor Current A
ATX 13.7-19.7 (High) 9 .0 -1 5 .0 (Low)
46U0E2-003
Overheating Coolant level insufficient Add E2- 4
Coolant leakage Repair or replace
Radiator fins clogged Clean E 2- 8
Radiator cap malfunction Replace E2- 7
Coolant fan malfunction Repair or replace E2-12
Thermostat malfunction Replace E2-10
Water passage clogged Clean E 2- 4
Water pump malfunction Replace E2-11
Corrosion Impurities in coolant Replace coolant E2- 4
46U0E2-004
E2—3
E2 ENGINE COOLANT
ENGINE COOLANT
PREPARATION
SST
49 9200 145 For 49 9200 146 _____ For

Adapter set, // \\ cooling system Adapter A If \\ cooling system
radiator cap (Part of X A
tester 49 9200 145) gQ
46U0E2-005
INSPECTION
Warning
sure escapes.
move it.
36U0E2-010

1. Verify that the coolant level is at the filler neck.
2. Verify that the coolant level on the coolant dipstick is be
tween the F and L marks.
Note
• The distance between the L and F mark on dipstick
Coolant Quality
radiator cap, filler cap or filler neck.
2. Verify that coolant is free of oil. Replace the coolant if
necessary.
16E0E2-008 Coolant Leakage

1. Connect a radiator tester (commercially available) and the
2. Apply 102 kPa {1.05 kgf/cm2, 14.9 psi) pressure to the
system.
3. Verify that the pressure is held. If not, check the system for
coolant leakage.
Caution
• Applying more than 102 kPa {1.05 kgf/cm2, 14.9 psi}
can damage the hoses, fittings, and other compo
nents, and cause leaks.
46U0E2-017
E 2 -4
ENGINE COOLANT E2
Coolant Protection
COOLANT PROTECTION Caution

SPECIFIC • The engine has aluminum parts that can be
GRAVITY
damaged by alcohol or methanol antifreeze. Do not
use alcohol or methanol in the cooling system. Use

shown.
as necessary.

|6 8 ) |8 6 J 1 1 0 4 )11 2 2 )(1 4 0 )11 5 8 1 (1 7 6 )1194)
Volume percentage Gravity at
Coolant protection
COOLANT TEMPERATURE °C ( " F | Water Coolant 20°C (68°Fj
Above -16°C (3°F) 65 35 1.054
Above -26°C (-15°F) 55 45 1.066
46U0E2-007
Above -40°C (-40°F) 45 55 1.078
16E0E2-011
REPLACEMENT
Draining
o Warning
46U0E2-008 may also damage the engine and cooling system.
sure escapes.
move it.
1. Remove the filler cap and loosen the radiator drain plug.
2. Disconnect the oil cooler hose.
3. Drain the coolant into a container.
are gone.
5. Let the system drain completely.
6. Tighten the drain plug and connect the oil cooler hose.
Caution
• Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good fit.
E 2 -5
E2 ENGINE COOLANT, RADIATOR CAP
Refilling
Use the proper amount and mixture of ethylene-glycol based
coolant. (Refer to Coolant Protection, page E2-5.)
1. Slowly pour the coolant into the radiator up to the coolant
filler port.
Filling pace:
1.0 L (1.1 US qt, 0.9 Imp qt]/min. max.
2. Fill the coolant reservoir up to the F mark.

3. Fully install the filler cap.
4. Start the engine and let it idle until it warms up.
5. If the temperature increases beyond normal, there is exces
sive air in the system. Stop the engine and allow it to cool;
then repeat Step 1—3.
6. Run the engine at 2,200—2,800 rpm for five minutes.
7. Stop the engine and allow it to cool.
8. Repeat steps 1—7; then go to step 9.
Warning
sure escapes.
move it.
9. Remove the filler cap and verify that the engine coolant level
is near the filler neck. If not, repeat step 1—9.
10. Fill the reservoir to the F mark.
46U0E2-010
____________________________RADIATOR CAP________ _______________ E2
RADIATOR CAP
PREPARATION
49 9200 145 For 49 9200 147 For

Adapter set, If .ii. Z \ radiator cap Adapter B j) radiator cap
radiator cap rw l (Part °f
tester ^ 49 9200 145)
16E0E2-015
INSPECTION
Radiator Cap Valve
Warning
46U0E2-018 a thick cloth around it and slowly turn it counter
sure escapes.
move it.
1. Remove all foreign material (such as water residue) from

between the radiator cap valve and the valve seat.
2. Attach the radiator cap to a radiator cap tester (commer
cially available) with the SST. Apply pressure gradually to
74—102 kPa [0.75—1.05 kgf/cm2, 10.7—14.9 psi).
3. Verify that the pressure is held for at least 10 seconds.
Negative Pressure Valve

1. Pull the negative pressure valve to open it. Verify that it
closes completely when released.
2. Check for damage on the contact surfaces and for cracked
or deformed seal packing.
3. Replace the radiator cap if necessary.
16E0E2-017
E2—7
E2 RADIATOR
RADIATOR
1. Fresh air duct 5. Radiator bracket

2. Coolant fan motor connector 6. Radiator
3. Coolant reservoir hose Inspection............................................below
4. Radiator hose (upper and lower) 7. Condenser fan and radiator cowling assembly
INSPECTION
1. Cracks, damage, and water leakage.
2. Bent fins, (repair with a screwdriver.)
3. Distorted and bent radiator inlet and outlet.

1. Fill the radiator with the specified amount and type of en
gine coolant. (Refer to page E2-6.)
2. Check for leaks.
46U0E2-019
E2—8
THERMOSTAT E2
THERMOSTAT
19—25 (1.9—:
O-RING, REPLACE
19—25 11.9—2.6, 14— 18)
N m (kgfm , ft-lbf|
46U0E2-020
1. Water inlet pipe 4. Thermostat

2. Engine harness bracket Inspection................................ page E2-10
3. Thermostat cover Installation Note....................... page E2-10
E 2 -9
E2 THERMOSTAT
INSPECTION
1. Visually check that the thermostat valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Heat the water and check the following.
Initial-opening temperature:
80—84°C (176—183°F}
Full-open temperature: 95°C (203°F)
Full-open lift: 8.5mm (0.33 in) min.
4. If the gasket of the thermostat is damaged, replace the ther

mostat assembly.
Installation Note
Thermostat
Install the thermostat into the cylinder head with the left jig
gle pin and projection at the top.
16E0E2-022

2. Check for leaks.
46UQE2-021
WATER PUMP E2
WATER PUMP
_______________________________________________________________________________________________________________________ N m (kgf-m, ft-lbf t

46U0E2-022
1. Timing belt 3. Water pump assembly

Removal / Installation.................. Section B2 Inspect for cracks, damages mounting sur-
2. No.3 Engine mount bracket face, bearing condition, and leakage
4. Water pump rubber seal

2. Check for leak.
E2—11
E2 COOLANT FAN MOTOR
COOLANT FAN MOTOR

INSPECTION
ant fan motor connector for low-speed inspection.
Current
46U0E2-012 MTX: 8.0—14.0A
ATX: 9.0—15.0A

ant fan motor connector for high-speed inspection.
Current
MTX: 11.5—17.5A
ATX: 13.7—19.7A
46U0E2-Q13
7. If not as specified, replace the coolant fan motor.
COOLANT FAN MOTOR E2
REPLACEMENT
7.9—10.7 N m {BO— 110 kgf-cm, 70—95.4 in Ib f)
(8 0 -1 1 0 kgf cm, 7 0 -9 5 .4 In Ibf)

19—25 (1.9—2.6, 14— 18).
1.5—2.4 N m
(15—25 kgf cm, 14—21 In Ib f)
APPLY LOCKING
COMPOUND
1.8—2.1 N m (18—22 kgf cm, 16— 19 In lbf)
4.0—4.9
(40—50 kgf cm, 35—43 In lbf) APPLY LOCKING COMPOUND
4.3—5.1 N m (43—53 kgf cm, 38—46 in Ibf)
N m (kgf m, ft-lbf)
46U0E2-014
1. Fresh air duct 7. Condenser fan motor connector

2. Radiator bracket 8. Radiator cowling
3. Coolant reservoir hose 9. Condenser fan
4. Radiator hose (upper and lower) 10. Coolant fan
5. Radiator 11. Condenser fan motor
6. Coolant fan motor connector 12. Coolant fan motor

2. Check for leak.
E2—13
E2 COOLANT FAN RELAY
COOLANT FAN RELAY

REMOVAL
2. Remove the coolant fan relay from the place shown in the
figure.
46U0E2-015
INSPECTION
1. Check continuity of the coolant relay as shown.
Terminal Continuity
A -C No
B -D Yes
2. Apply battery positive voltage between terminals B and D.

Check for continuity between terminals A and C.
46U0E2-016
F1
Before beginning any service procedure, refer to the Body Electrical
Troubleshooting Manual; see section S for air bag system
precautions and J1 for audio antitheft system precautions.
FUEL AND EMISSION

CONTROL SYSTEMS (FS MTX)
IN D EX.................................................................. F 1 - 2 EXHAUST GAS RECIRCULATION
OUTLINE............................................................. F 1 - 5 (CALIFORNIA)..................................................F 1 - 66
SYSTEM DIAGRAM........................................ F 1 - 5 DESCRIPTION................................................ F 1 - 66
VACUUM HOSE ROUTING DIAGRAM......... F 1 - 7 SYSTEM OPERATION.................................... F 1 - 66
WIRING DIAGRAM......................................... F 1 - 8 SYSTEM INSPECTION...................................F 1 - 67
SPECIFICATIONS............................................ F 1 - 10 EGR SOLENOID VALVE (VACUUM).............F 1 - 67
COMPONENT DESCRIPTIONS..................... F 1 - 11 EGR SOLENOID VALVE (VENT)...................F 1 - 67
ENGINE TUNE-UP.............................................. F 1 - 14 EGR CONTROL VALVE..................................F 1 - 67
PREPARATION................................................F 1 - 14 EGR FUNCTION SENSOR.............................F 1 - 68
BASIC INSPECTION.......................................F 1 - 14 POSITIVE CRANKCASE VENTILATION
ADJUSTMENT.................................................F 1 - 15 (PCV) SYSTEM................................................ F 1 - 69
ON-BOARD DIAGNOSIS SYSTEM...................F 1 - 17 DESCRIPTION................................................ F 1 - 69
DESCRIPTION.................................................F 1 - 17 PCV VALVE.................................................... F 1 - 69
PREPARATION................................................F 1 - 18 FUEL EVAPORATIVE SYSTEM...................... F 1 - 70
DIAGNOSTIC TROUBLE CODE NUMBER... F 1 - 18 DESCRIPTION................................................ F1— 70
SWITCH MONITOR FUNCTION.................... F 1 - 38 SYSTEM OPERATION.................................... F 1 - 71
HEATED OXYGEN SENSOR MONITOR PURGE CONTROL SOLENOID VALVE........F 1 - 71
FUNCTION.....................................................F1— 39 FUEL VAPOR VALVE.................................... F 1 - 71
INTAKE AIR SYSTEM .......................................F 1 - 42 CHECK VALVE (TWO-WAY).......................... F 1 - 72
COMPONENT PARTS.................................... F 1 - 42 CHARCOAL CANISTER................................ F 1 - 72
THROTTLE BODY...........................................F 1 - 43 FUEL-CUT CONTROL SYSTEM...................... F 1 - 73
INTAKE MANIFOLD.......................................F 1 - 43 DESCRIPTION................................................ F 1 - 73
RESONANCE CHAMBER No.2..................... F 1 - 43 PREPARATION............................................... F 1 - 74
ACCELERATOR PEDAL.................................F 1 - 44 SYSTEM OPERATION.................................... F 1 - 75
ACCELERATOR CABLE.................................F 1 - 44 A/C CUTOFF SYSTEM..................................... F 1 - 76
IDLE-SPEED CONTROL SYSTEM................... F 1 - 45 DESCRIPTION................................................ F 1 - 76
DESCRIPTION.................................................F 1 - 45 SYSTEM OPERATION.................................... F 1 - 76
PREPARATION................................................F 1 - 46 DECHOKE CONTROL SYSTEM...................... F 1 - 77
SYSTEM OPERATION.................................... F 1 - 46 SYSTEM OPERATION.................................... F 1 - 77
IDLE AIR CONTROL VALVE......................... F 1 - 46 COOLANT FAN CONTROL SYSTEM..............F 1 - 77
AIR VALVE...................................................... F 1 - 46 DESCRIPTION................................................ F 1 - 77
FUEL SYSTEM ................................................... F 1 - 47 SYSTEM OPERATION.................................... F 1 - 78
DESCRIPTION.................................................F 1 - 47 CONTROL SYSTEM.......................................... F 1 - 79
SYSTEM OPERATION.................................... F 1 - 48 PREPARATION............................................... F 1 - 79
FUEL TANK.....................................................F 1 - 50 STRUCTURAL VIEW.......................................F 1 - 80
FUEL FILTER.................................................. F 1 - 51 POWERTRAIN CONTROL MODULE
FUEL PUMP................................................... F 1 - 52 (ENGINE)...................................................... F 1 - 81
FUEL PUMP RELAY.......................................F 1 - 55 MASS AIRFLOW SENSOR.............................F 1 - 90
PRESSURE REGULATOR.............................. F 1 - 55 CRANKSHAFT POSITION SENSOR..............F 1 - 90
INJECTOR....................................................... F 1 - 57 ENGINE COOLANT TEMPERATURE
PRESSURE REGULATOR CONTROL SENSOR........................................................F 1 - 91
SYSTEM ............................................................ F1— 60 INTAKE AIR TEMPERATURE SENSOR........F 1 - 92
PRESSURE REGULATOR CONTROL SOLENOID THROTTLE POSITION SENSOR.................... F 1 - 92
VALVE............................................................ F 1 - 61 HEATED OXYGEN SENSOR......................... F 1 - 93
EXHAUST SYSTEM............................................F 1 - 62 IDLE SWITCH..................................................F 1 - 94
COMPONENT PARTS.................................... F 1 - 62 MAIN RELAY..................................................F 1 - 94
OUTLINE OF EMISSION CONTROL COOLANT FAN RELAY.................................. F 1 - 94
SYSTEM ............................................................ F 1 - 63 CLUTCH SWITCH.......................................... F 1 - 94
STRUCTURAL VIEW.......................................F 1 - 63 NEUTRAL SWITCH........................................F 1 - 95
EXHAUST GAS RECIRCULATION STEERING PRESSURE SENSOR................. F 1 - 95
(EXCEPT CALIFORNIA)..................................F 1 - 64 TROUBLESHOOTING GUIDE.......................... F 1 - 96
DESCRIPTION.................................................F1— 64 QUICK DIAGNOSIS CHART.......................... F 1 - 96
SYSTEM OPERATION.................................... F 1 - 64 RELATIONSHIP CHART................................ F 1-1 00
SYSTEM INSPECTION................................... F 1 - 64 USING THIS SECTION...................................F1-102
EGR CONTROL VALVE..................................F 1 - 65 DIAGNOSTIC INDEX..................................... F 1-1 04
EGR FUNCTION CONTROL.......................... F 1 - 65 SYMPTOM TROUBLESHOOTING................. F 1 -1 07
EGR SOLENOID VALVE................................ F 1 - 65 SERVICE POINTS.............................................. F1-142
EGR FUNCTION SENSOR.............................F 1 - 65 OUTLINE......................................................... F 1-142
WIRING DIAGRAM......................................... F 1-146
ELECTRICAL DIAGNOSIS SUPPORT........... F 1-1 48
46U0F1-001
F1 INDEX
INDEX
CALIFORNIA
INDEX F1
1. Fresh air duct 19. EGR solenoid valve (Vacuum-California)
Inspection / Replacement......... page F1-42 Inspection............................. ... page 1-67
2. Air cleaner element 20. EGR solenoid valve (Vent-California)
Inspection.................................page F1-15 Inspection............................. ... page 1-67
Replacement.............................page F1-42 21 . Purge control solenoid valve
3. Resonance chamber No.1, No.2 Inspection............................. ... page 1-71
Inspection / Replacement......... page F1-42 22. Charcoal canister
4. Throttle body Inspection............................. ... page 1-72
Inspection.................................page F1-43 23. Powertrain control module (Engine)
Replacement.............................page F1-42 Removal / Installation............ ... page 1-81
5. Idle air control valve Inspection............................. ... page 1-81
Inspection.................................page F1-46 24. Mass airflow sensor
Replacement.............................page F1-42 Inspection............................. ... page 1-90
6. Air valve (In BAC valve) Replacement......................... ... page 1-42
Inspection.................................page F1-46 25. Crankshaft position sensor
7. Intake manifold 26. Engine coolant temperature sensor
Removal / Installation............... page F1-42 Removal................................ ... page 1-91
8. Accelerator cable Inspection............................... ... page 1-91
Inspection / Adjustment............ page F1-44 Installation............................. ... page 1-92
9. Fuel filter (High-pressure side) 27. Intake air temperature sensor
10. Fuel pump relay Replacement......................... ... page 1-92
Inspection.................................page F1-55 28. Throttle position sensor
11. Pressure regulator Adjustment............................ ... page 1-92
Inspection.................................page F1-55 Replacement......................... ... page 1-93
Replacement.............................page F1-56 29. Heated oxygen sensor
12. Injector Inspection............................. ... page 1-93
Removal....................................page F1-57 30. Idle switch
Installation.................................page F1-57 Inspection............................. ... page 1-94
13. Pressure regulator control solenoid valve 31. Main relay
14. EGR control valve 32. Coolant fan relay
15. EGR function sensor 33. Clutch switch
16. EGR function control (Except California) Replacement......................... ... page 1-95
Inspection.................................page F1-65 34. Neutral switch
17. PCV valve Inspection............................. ... page 1-95
18. EGR solenoid valve (Except California) 35. Steering pressure sensor
Replacement......................... page F1-95
46U0F1-002
F 1 -3
F1 INDEX
ja>
CALIFORNIA
c©
46U0F1 -003
1. Fuel tank 5. Check valve (Two-way)

Removal / Inspection / Inspection................................ page F1-72
Installation...............................page F1-50 6. Exhaust system
2. Fuel filter Removal / Inspection /
Replacement.............................page F1-51 Installation.............................. page F1-62
3. Fuel pump 7. Three-way catalyst
Inspection.................................page F1-52 Removal / Inspection I
Removal / Installation............... page F1-54 Installation.............................. page F1-62
4. Fuel vapor valve 8. Warm-up three-way catalyst
Inspection.................................page F1-71 Removal / Inspection I
Installation.............................. page F1-62
F1—4
CO
•< o
w c
H
PRESSURE REGULATOR CONTROL m
CHARCOAL CANISTER SOLENOID VALVE
o z
m
>
o
3)
>
m
x
o
m
TJ
H
O
>
*—TO PCME
SYSTEM
PRESSURE REGULATOR CONTROL
CHARCOAL CANISTER SOLENOID VALVE
DIAGRAM
PRESSURE REGULATOR
FUEL VAPOR VALVE PURGE CONTROL

SOLENOID VALVE
CRANKSHAFT POSITION
SENSOR
(CALIFORNIA)
(IN DISTRIBUTOR)
THROTTLE
POSITION PCME
SENSOR
PCV VALVE
IDLE SWITCH
/ INJECTOR = = * MASS AIRFLOW SENSOR

INTAKE AIR
TEMPERATURE
SENSOR
FUEL FILTER
(LOW-PRESSURE SIDE)
FUEL ru M r
WARM-UP THREE-WAY CATALYST
BAC VALVE VALvI°<(VENT)

VALVE vI n t !D Al” CLEANER
FILTER
ENGINE COOLANT EGR FUNCTION SENSOR EGR SOLENOID VALVE
TEMPERATURE
(VACUUM)
SENSOR
EGR CONTROL VALVE
THREE-WAY CATALYST
HEATED OXYGEN SENSOR

46U0F1-005
*—TO PCME
OUTLINE F1
VACUUM HOSE ROUTING DIAGRAM
EXCEPT CALIFORNIA
EGR MODULATOR VALVE

SOLENOID VALVE
(PURGE CONTROL) R
SOLENOID VALVE
(PRESSURE REGULATOR)
SOLENOID VALVE (EGR)
VACUUM HOSE COLOR

B: BLACK CHARCOAL CANISTER
G: GREEN
L: BLUE
O: ORANGE
R: RED EGR CONTROL VALVE
W: WHITE
Y: YELLOW
PRESSURE REGULATOR
16E0F1-006
F 1 -7
FI_________________ _________ OUTLINE
WIRING DIAGRAM
46U0F1-006
F1—8
OUTLINE F1
0©
F 1 -9
FI________________ OUTLINE
SPECIFICATIONS
Engine FS
Item
Idle speed*1 rpm 6 50 -7 50 (700 ± 50)
Ignition timing*1 BTDC 11—13° (12 ± 1°)
Throttle body
Type Horizontal draft
Throat diameter mm [in) 55 (2.2)
Fuel pump
Maximum output pressure kPa (kgf/cm2, psi) 640 (6.5, 92)
Fuel filter
Low-pressure side Nylon element (in fuel pump)
Type
High-pressure side Paper element
Pressure regulator
Regulating pressure kPa (kgf/cm2, psi) 2 60 -3 20 (2.6—3.3, 3 7 -4 6 )
Injector
Type High-ohmic
Type of drive Voltage
Resistance 12 [20°C [ 68°F)] 1 2 -1 6
Volume m (cc, fl oz)/15 sec. 4 7 -6 8 (4 7 -6 8 , 1 .4 -2 .0 )
Idle air control valve
Resistance Q [23°C (73°F)] 7.7—9.3
Purge control solenoid valve
Resistance n [20°C {68°F) ] 30—34
Pressure regulator control solenoid valve
Resistance J2 [20°C (68°F)] 3 6 -4 3
EGR solenoid valve (Except California)
Resistance n [20°C (68°F)] 3 3 -3 9
EGR solenoid valve (Vent and vacuum) (California)
Resistance n [20°C (68°F)] 3 0 -4 5
Crankshaft position sensor
Type Hall sensor
Mass airflow sensor
Type Heat resistor
Engine coolant temperature sensor
-2 0 °C { -4 °F ) 13.5—16.5
20°C ( 68°F) 2.20-2.70
80°C (176°F) 0.29-0.35
Resistance kfl 91°C ( 196°F) 0.226—0.241
97°C (207°F) 0.193-0.205
108°C (226°F) 0.145-0.153
110°C (230°F) 0.137-0.146
Fuel tank
Capacity L (US gal, Imp gal) 58.5 (15.5, 12.9)
Air cleaner element
Element type Oil permeated
Fuel
Specification Unleaded—(R + M)/2 method 87 or higher
* x TEN te rm in a l o f data lin k c o n n e c to r g ro u n d e d 46U0F1-007
F 1 -1 0
OUTLINE F1
COMPONENT DESCRIPTIONS
Component Function Remark
A/C relay Controls A/C compressor magnetic clutch —
Air cleaner housing Filters air entering throttle body • Intake air temperature sensor mounted in
housing
Air valve Supplies bypass air into intake manifold • Engine speed increased to shorten warm-up
(engine cold) period
• Thermowax type
• Installed in BAC valve
Bypass air control Supplies bypass air into intake manifold • Consist of air valve and idle air control valve
(BAC) valve
Charcoal canister Stores fuel tank fumes (engine stopped) —
Check valve Controls pressure in fuel tank

—
(two-way)
Clutch switch Detects clutch condition; sends signal to • Switch OFF when clutch pedal released
PCME
Crankshaft position Detects No. 1 cylinder TDC;sends signal to • Installed in distributor

sensor PCME (G signal)
[G signal, NE signal] Detects crank angle at 180° intervals;
sends signal to PCME (NE signal)
Data link connector Concentrated service connector terminals for • 25-pin (located near battery)
serviceability
1. CIS self-diagnosis 1. FEN terminal

2. Initial set 2. TEN terminal
3. Fuel pump check 3. FIP terminal
4. Engine speed output 4. IG - terminal
5. Switch and heated oxygen sensor monitor 5. MEN terminal
6. Supply battery positive voltage 6. + B terminal
7. Ground 7. GND terminal
EGR control valve Recirculates portion of exhaust gas —
EGR function control Controls vacuum acting on EGR control valve

—
(Except California)
EGR solenoid valve Controls vacuum to EGR control valve —
EGR function sensor Detects EGR control valve position • Installed in EGR control valve
(California)
EGR function sensor Detects EGR gas temperature to detect EGR • Installed in EGR control valve
(Except California) control valve open condition; sends signal to
PCME
Engine coolant Detects coolant temperature;sends signals to • Installed in engine

temperature sensor PCME
F u e l filter Filters particles from fuel —
Fuel pump Provides fuel to injectors • Operates while engine is running

• Installed in fuel tank
Fuel pump relay Voltage for fuel pump while engine is running,
—
controlled by PCME
F1 —11
F1 OUTLINE
Fuel vapor valve Prevents fuel from flowing into charcoal

—
canister
Heated oxygen Detects oxygen concentration;sends signal to • Zirconic and platinum coating
sensor PCME • With heater
Idle air control valve Supplies bypass air to intake manifold • Controlled by duty signal from PCME
Idle switch Detects idle condition;sends signal to PCME • Installed in throttle body
Igniter Receives spark signal from PCME and gener • Installed in distributor
ates high voltage in ignition coil
Ignition switch Sends engine cranking signal to PCME

—
(START position)
Injector Injects fuel into intake port • Controlled by signals from PCME
Intake manifold Supplies intake air to all cylinders —
Intake air Detects intake air temperature;sends signal to • Installed in air cleaner housing
temperature senser PCME
Idle air control valve Controls bypass air amount • Controlled by duty signal from PCME
Main relay Supplies current to output devices and PCME —
Mass airflow sensor Detects amount of intake air;sends signal to • Heat resistor type
PCME
Neutral switch Detects in-gear condition;sends signal to • Switch ON in neutral

PCME
PCV valve Controls blowby gas introduced into engine —
Powertrain control Detects the following:

module (Engine) 1. A/C operation 1. Air conditioning sensor
2. Air/fuel ratio (oxygen concentration) 2. Heated oxygen sensor
3. Braking signal 3. Stoplight switch
4. Cranking signal 4. Ignition switch (START position)
5. E/L operation 5. Blower motor switch, coolant fan relay,
headlight switch, and rear window
defroster switch
6. Engine coolant temperature 6. Engine coolant temperature sensor
7. Engine speed 7. Crankshaft position sensor (NE signal)
8. Ignition ON signal 8. Ignition switch
9. In-gear condition 9. Neutral and clutch switch
10. Intake air amount 10. Mass airflow sensor
11. Intake air temperature 11. Intake air temperature sensor
12. No.1 piston TDC (compression stroke) 12. Crankshaft position sensor (G signal)
13. P/S operation 13. Steering pressure sensor
14. Diagnostic test mode signal (ignition tim 14. Data link connector (TEN terminal)
ing, idle speed, diagnostic trouble code
no.)
15. Throttle valve opening angle 15. Throttle position sensor
16. Throttle valve fully closed 16. Idle switch
17. Vehicle speed 17. Vehicle speed sensor
F 1 -1 2
OUTLINE F1
Powertrain control Controls operation of following;

module (Engine) 1. A/C (cut-off) 1. A/C relay
-cont’d 2. On-board diagnosis system 2. Self-Diagnosis Checker
3. Fuel injection system 3. Injector
4. Idle speed control 4. Idle air control valve
5. Ignition system 5. Igniter
6. Monitor function 6. Monitor lamp
7. Purge control system 7. Purge solenoid valve
8. Exhaust gas recirculation 8. EGR solenoid valve
9. PRCV control system 9. PRC solenoid valve
10. Coolant fan control 10. Coolant fan relay
11. Fuel pump control 11. Fuel pump relay
Pressure regulator Adjusts fuel pressure supply to injectors —
Pressure regulator Controls vacuum to pressure regulator control

control solenoid valve —
valve
Purge solenoid valve Controls evaporative fumes from charcoal • Controlled by duty signal from PCME
canister to intake manifold
Resonance chamber Reduces intake air suction noise and

—
increases engine torque
Steering pressure Detects P/S operation;sends signal to PCME • Steering pressure sensor ON when steering
sensor wheel turned
Stoplight switch Detects braking;sends signal to PCME —
Three way catalyst Reduces HC, CO, NOx by chemical reaction • Monolith type
Throttle body Controls intake air amount —
Throttle position Detects throttle valve opening angle;sends • Installed on throttle body
sensor signal to PCME
Vehicle speed sensor Detects vehicle speed;sends signal to PCME • Installed in instrument cluster
46UOF1-008
F 1-1 3
F1 ENGINE TUNE-UP
ENGINE TUNE-UP
PREPARATION
SST
16E0F1 -011
BASIC INSPECTION
Engine Oil
1. Remove the engine oil dipstick and check the engine oil
level and oil-condition.
2. Add or change oil as necessary.
Note
represents 1.0 L (1.1 US qt, 0.9 Imp qt).
Coolant (Engine cold)
Warning
• Removing the radiator cap or the coolant drain plug
sure escapes.
remove it.
1. Verify that the coolant level is near the radiator filler neck.
L marks.
Battery
Removing the label on the top of the battery or removing the
vent caps will void the battery’s warranty.
1. Remove any corrosion on the clamps or battery posts.
2. Verify that the battery top is clean. If necessary, clean with
baking soda and water.
3. Verify that cables are in good condition and not frayed or
corroded. Repair or replace if necessary.
4. Verify that cable clamps are tight.
Note
• Because this is a maintenance free battery, it is not neces
sary to check the fluid level.
F 1 -1 4
ENGINE TUNE-UP F1
Air Cleaner Element
Inspection
and damage.
Caution
duce the element’s ability to filter the air. Don’t use

46UQF1-012
ADJUSTMENT
Preparation
2. Shift the selector lever to Neutral.
• Headlight
• Blower
• Power steering
46U0F1-013
Ignition Timing
1. Perform Preparation. (Refer to above.)
IG - as shown.
Idle speed: 650—750 (700 ± 50) rpm
4. If not within the specification, adjust the idle speed.

(Refer to page F1 -16.)
5. Connect the SST to the data link connector.

TEN terminal and GND terminal of the data link connector.
Idle speed (Ground the terminal TEN): 500—800 rpm
46U0F1-015
10. Connect a timing light to the engine.
11. Verify that the timing mark (yellow) on the crankshaft pully
and the mark on the timing belt cover are aligned.
Ignition timing: BTDC 11—13° (12 ± 1°)
46U0F1-016
F 1-1 5
F1 ENGINE TUNE-UP
12. If the marks are not aligned, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
13. Tighten the distributor lock bolts to the specified torque.
Tightening torque:
19—25 N m [1.9—2.6 kgf m, 14—18 ft-lbf}
46U0F1-017
15. Verify that the ignition timing is within the specification.
Ignition timing: BTDC 6—18°

46U0F1-018
Idle Speed
1. Perform Preparation. (Refer to page F1-15.)
IG - as shown.
46U0F1-019
4. If not within specification, connect the SST to the data link
connector.
nector.
46U0F1-020
Idle speed (Groud the terminal TEN):

650—750 (700 ± 50) rpm
46U0F1-021
F 1 -1 6
ON-BOARD DIAGNOSIS SYSTEM F1
ON-BOARD DIAGNOSIS SYSTEM
DESCRIPTION
When trouble occurs in the main input or output devices, check for the cause by using the SST. Malfunc
tions of each input and output device are indicated and retrieved from the PCME as diagnostic trouble
code numbers.
For input devices, the PCME continuously checks for malfunctions. For output devices, it checks for mal
functions only in a three-second period after the ignition switch is turned to ON, or the TEN terminal of
the data link connector is grounded.
46U0F1-022
F 1 -1 7
F 1 ON-BOARD DIAGNOSIS SYSTEM
PREPARATION
SST
DIAGNOSTIC TROUBLE CODE NUMBER

Inspection Procedure
1. Connect the SST (System Selector) to the data link con
nector.
3. Set the test switch to SELF TEST.
4. Connect the SST (Self-Diagnosis Checker) to the System

Selector and a ground.
5. Set the select switch to position A.
6. Turn the ignition switch ON.
7. Verify that 88 flashes on the digital display and the buzzer
sounds for 3 seconds after turning the ignition switch ON.
8. If 88 does not flash, check the main relay (refer to page
F1-94), power supply circuit, and data link connector
wiring.
9. If 88 flashes and the buzzer sounds continuously for more
than 20 seconds, check for a short circuit between the
PCME terminal 1F and the data link connector. Replace the
PCME if necessary and perform Steps 3 through 7 again.
10. Note any code numbers and check for the causes by refer
ring to the check sequences shown on pages F 1-22
8B through F1-37, Repair as necessary.
11. After repairs, cancel the code numbers by performing the
“ After-repair procedure” (Refer to page F1-38.)
46U0F1-025
ON-BOARD DIAGNOSIS SYSTEM F 1
Principle of Code Cycle
Diagnostic trouble codes are determined as shown below.
1. Code cycle break

The time between diagnostic trouble code cycles is 4.0 seconds.
DIAGNOSTIC TROUBLE CODE

1 C YCLE
CYCLE BREAK
ON
OFF
4.0 SEC.
36U0F1-018
2. Second digit of diagnostic trouble code (ones position)

The digit in the ones position of the diagnostic trouble code represents the number of times the checker
buzzer sounds 0.4 second during one cycle.
DIAGNOSTIC TROUBLE CODE DIAGNOSTIC TROUBLE

1 CYCLE
CODE: 03
1 2 3 CYCLE BREAK
ON
OFF
0.4 0.4 4.0 SEC.

SEC. SEC.
36U0F1-019
3. First digit of diagnostic trouble code (tens position)

The digit in the tens position of the diagnostic trouble code represents the number of times the checker
buzzer sounds 1.2 seconds during one cycle.
The buzzer remains off for 1.6 seconds between the long and short pulses.
DIAGNOSTIC
1 CYCLE TROUBLE
1 2 CODE. 22
nr | i 0.4
•1.2 S EC . SEC 1.6

1 2 C YCLE
BREAK
4.0 S EC .
n
h ---------------- S FC
F IR S T D IG IT SECOND
D IG IT
36U0F1-020
F1—19
FI___________________ SELF-DIAGNOSIS FUNCTION
Diagnostic Trouble Code Number
No. Indicator flashing pattern Diagnosted circuit Condition Fail-safe Memorized Page
Ne signal No Ne signal while de
(Crankshaft position tecting 12 G signals
02 Yes F1-22
sensor)
G signal No G signal for 1.5 Cancels sequen

(Crankshaft position sec. tial injection
03 Yes F1-23
sensor)
Mass airflow sensor Measures intake

air amount by
08 Yes F1-24
throttle valve
opening angle
Engine coolant tem Maintains con

perature sensor stant 34°C
09 Yes F1-25
(93°F)
command
Open or short circuit
Intake air tempera Maintains con
ture sensor stant 20°C
11 Yes F1-26
(68°F)
command
Throttle position Maintains con

sensor stant command
12 Yes F1-27
of throttle valve
fully open
Heated oxygen Sensor output con Cancels engine

sensor tinues less than 0.55V closed loop
15 Yes F1-28
(Inactivation) 75 sec. after engine ex operation
ceeds 1,500 rpm
EGR function sensor Open or short circuit

EGR valve stuck
16 Yes F1-29
Heated oxygen Sensor output con Cancels engine

sensor tinues unchanged 40 closed loop
17 Yes F1-30
(Inversion) sec. after engine ex operation
ceeds 1,500 rpm
Pressure regulator
control solenoid
25 No F1-31
valve
Purge control sole

noid valve
26 No F1-32
Open or short circuit
• EGR solenoid valve

(Except California)
F1-33
28 • EGR solenoid No
F1-34
valve (vacuum)
(California)
F1—20
No. Indicator flashing pattern Diagnosted circuit Condition Fail-safe Memorized Page
EGR solenoid valve

(vent)
29 No F1-35
(California)

34 Open or short circuit No F1-36
Coolant fan relay

67 No F1-37
46U0F1-026
F1 ON-BOARD DIAGNOSIS SYSTEM
Troubleshooting
If a diagnostic trouble code number is shown on the SST, check for the cause by using the chart related
to the code number shown.
CODE No. 02 (DISTRIBUTOR NE-SIGNAL)
STEP INSPECTION ACTION

1 Are there any poor connections in distributor Yes Repair connector and/or wiring
circuit?
No Go to next step
2 Is Code No. 03 also present? Yes Go to next step
No Go to Step 5
3 Does wire between distributor terminal 2A and Yes Go to next step

ground have continuity?
No Repair or replace
4 Does battery positive voltage exist at distributor Yes Go to next step

terminal 2B with ignition switch ON?
No Check for open circuit in wiring
(Distributor—Main relay)
5 Does wire between distributor terminal 2C and Yes Go to next step

PCME terminal 2E have continuity?
6 Is PCME terminal 2E voltage OK? Yes Replace PCME c r page F1-81

c r page F1-81
No Go to next step
7 Does approx. 0V or approx. 5V exist at distribu Yes Replace distributor

tor terminal 2C?
No Go to next step
8 Does approx. 5V exist at PCME terminal 2E? Yes Check for short circuit in wiring
(with distributor connector disconnected) (Distributor—PCME)
c r page F1-81
No Replace PCME c r page F1-81
46U0F1-Q27
Circuit Diagram
16E0F1-034
F1—22
CODE No. 03 (DISTRIBUTOR G SIGNAL)

1 Are there any poor connections in distributor Yes Repair connector and/or wiring
circuit?
No Go to next step
2 Is Code No. 02 also present? Yes Go to next step
No Go to Step 5
3 Does wire between distributor terminal 2A and Yes Go to next step

ground have continuity?
4 Does battery positive voltage exist at distributor Yes Go to next step

terminal 2B with ignition switch ON?
(Distributor—main relay)
5 Does wire between distributor terminal 2D and Yes Go to next step
PCME terminal 2G have continuity?
6 Is PCME terminal 2G voltage OK? Yes Replace PCME c r page F1-81

c r page F1-81
No Go to next step
7 Does approx. 0V or approx. 5V exist at distribu Yes Replace distributor

tor terminal 2D?
No Go to next step
8 Does approx. 5V exist at PCME terminal 2G? Yes Check for short circuit in wiring
(with distributor connector disconnected) (Distributor—PCME)
c r page F1-81
No Replace PCME c r page F1-81
46U0F1-028
Circuit Diagram
DISTRIBUTOR
1C 1B 1A
2F 2E 2D 2C 2B 2A
16E0F1-036
F1—23
CODE No. 08 (MASS AIRFLOW SENSOR)

1 Are there any poor connections in mass airflow Yes Repair connector and/or wiring
sensor circuit?
No Go to next step
2 Is voltage of mass airflow sensor OK? Yes Go to next step

c r page F1-90
No Replace mass airflow sensor
3 Does wire harness between mass airflow sensor Yes Go to next step
and PCME have continuity?
No Repair wire harness
Mass airflow sensor PCME
B 20
C 2C
4 Are PCME 1B, 2C, and 2 0 terminals voltages Yes Replace PCME c r page F1-81
OK?
c r page F1-81 Check for short circuit in wiring
No
(Mass airflow sensor—PCME)
46U0F1-029
Circuit Diagram
MASS AIRFLOW SENSOR
16E0F1-040
F 1-2 4
CODE No. 09 (ENGINE COOLANT TEMPERATURE SENSOR)

1 Are there any poor connections in engine cool Yes Repair connector and/or wiring
ant temperature sensor circuit?
No Go to next step
2 Does wire harness between engine coolant tem Yes Go to next step
perature sensor and PCME have continuity?
No Repair wiring
Engine coolant
PCME
temperature sensor
A 2Q
B 2D
3 Is resistance of engine coolant temperature sen Yes Go to next step

sor OK?
No R e p la ce e n g in e c o o la n t te m p e ra tu re
Coolant temp. Resistance (k0) sensor
20°C ( 68°F) 2.2—2.7
80°C ( 176°F) 0.29-0.35
4 Is same Code No. present following after-repair Yes Go to next step

procedure?
c r page F1-38
No Engine coolant temperature sensor and
circuit OK
5 Are PCME terminals 2D and 2Q voltages OK? Yes Replace PCME c r page F1-81
c r page F1-81
No Check for short circuit in wiring
(Engine coolant temperature
sensor—PCME)
46UOF1-030
Circuit Diagram
IGNITION SWITCH
ENGINE COOLANT
TEMPERATURE SENSOR €B A
16E0F1-042
F1—25
CODE No. 11 (INTAKE AIR TEMPERATURE SENSOR)

1 Are there any poor connections in intake air tem Yes Repair connector and/or wiring
perature sensor circuit?
No Go to next step
2 Does wire harness between intake air tempera Yes Go to next step
ture sensor and PCME have continuity?
No Repair wiring
Intake air
PCME
thermosensor
A 2L
B 2D
3 Is resistance of intake air temperature sensor be Yes Go to next step

tween terminals A and B OK?
No Replace intake air temperature sensor
Temperature Resistance (kfi)
25°C (77°F) 29.7-36.3
85°C ( 185°F) 3.3—3.7

procedure?
c r page F1-38 No Intake air temperature sensor and cir
cuit OK
5 Are PCME terminals 2D and 2L voltages OK? Yes Replace PCME c r page F1-81
c r page F1-81
(Intake air temperature sensor—PCME)
46U0F1-031
Circuit Diagram
16E0F1-Q44
CODE No. 12 (THROTTLE POSITION SENSOR)
1 Are there any poor connections in throttle posi Yes Repair connector and/or wiring
tion sensor circuit?
No Go to next step
2 Does wire harness between throttle position sen Yes Go to next step
sor and PCME have continuity?
No Repair wiring
Throttle position
PCME
sensor
A 2K
B 2M
C 2D
3 Are resistance between terminals B and C OK? Yes Go to next step
Throttle valve Resistance No Replace throttle body c r page F1-42

Closed throttle position Below 1 kO
Wide open throttle Approx. 5 kfi
4 Is PCME terminal 2M voltage OK? Yes Replace PCME c r page F1-81

c r page F1-81
(Throttle position sensor—PCME)
46U0F1-032
Circuit Diagram
F 1 -2 7
CODE No. 15 (HEATED OXYGEN SENSOR-INACTIVATION)

Note
• If Code Nos. 15 and 17 are both present, first perform the checking procedure for Code No. 17.
1 A re th e re a n y p o o r c o n n e c tio n s in h e a te d o xy- Y es R e p a ir c o n n e c to r a n d /o r w irin g
a e n s e n s o r c irc u it?
No G o to n e xt step
2 Is h e a te d o x y g e n s e n s o r h e a te r O K ? Y es G o to n e xt ste p
C7 oaae F1-93
No R e p a ir o r re p la c e re la te d pa rts
3 Is h e a te d o x y g e n s e n s o r o u tp u t v o lta g e O K ? Y es G o to n e xt ste p
c r naae F1—93
No R e p la ce h e a te d o x y g e n s e n so r cr page F I-9 3
4 D o e s w ire h a rn e s s b e tw e e n h e a te d o x y g e n se n Y es G o to n e xt ste p
sor anti P O M P term inal ? N have eontinuitv?
No R e p a ir o r re p la ce
5 Is P C M E te rm in a l 2 N v o lta g e O K ? Y es G o to n e xt ste p
c r naae F1—81
No C h e c k fo r sh o rt c irc u it in w irin g
(H e a te d o x y g e n s e n s o r— PC M E)
6 Is s e n s itiv ity o f h e a te d o x y g e n s e n so r O K ? Y es R e p la ce P C M E cr page F1-81

i~7 naae F1—93
No T ry a k n o w n g o o d h e a te d o x y g e n se n
s o r a n d c h e c k if c o n d itio n im p ro ve s, cr page F1-93
46UQF1-034
Circuit Diagram
IGNITION SWITCH
__i.
C A
B
---- - T
16E0F1-049
CODE No. 16 (EGR FUNCTION SENSOR)
1 Does EGR function sensor circuit have a poor Yes Repair connector and/or wiring harness
connection?
No Go to next step (California)
Go to Step 3 (Except California)
2 Is EGR function sensor terminal C voltage OK Yes Go to next step
with EGR function sensor connector discon-
neciea <
No Check for short or open circuit in wiring
harness (EGR function sensor terminal
Condition Voltage
C—PCME terminal 21)
Ign switch ON Approx. 5.0V
=> If OK, replace PCME
=> If not OK, repair wiring harness
3 Is there continuity between EGR function sensor Yes Check for short circuit in wiring harness
and PMCE? (EGR function sensor terminal A—
PCME terminal 2J)
California
EGR function sensor PCME ■=> If OK, go to next step
A 2J =!> If not OK, repair wiring harness
B Ground No Repair wiring harness
Except California
EGR function sensor PCME
A 2J
B 2D
4 Is resistance of EGR function sensor Yes Check for short circuit in wiring
(EGR function sensor—PCME)
No Replace EGR function sensor
46U0F1-035
(EXCEPT CALIFORNIA) CALIFORNIA
SENSOR
EGR FUNCTION EGR FUNCTION SENSOR
SENSOR
F1—29
CODE No. 17 (HEATED OXYGEN SENSOR-INVERSION)

procedure?
c r page F1-38
No Check heated oxygen sensor circuit for
poor connection
=> If OK, perform troubleshooting
Code No. 15 c r page F1—28
==> If not OK, repair or replace con
nector
2 Does monitor lamp of Self-Diagnosis Checker il Yes Go to next step
luminate at idle after engine has been warmed Note
up and run at 2,500—3,000 rpm for 3 min? • A/F mixture rich
No Go to Step 5
Note
• A/F mixture is lean or misfire
occurring
3 Is fuel line pressure correct at idle? Yes Go to next step
c r page F1-55
No High pressure
Fuel line pressure:
Check if fuel return hose is clogged or
255—314 kPa {2.6—3.2 kgf/cm2, 37—46 psi) restricted
(vacuum hose to pressure regulator dis ■=> If OK, replace pressure regulator c r page F1-56
connected) => If not OK, repair or replace hose
4 Is there fuel leakage from injectors? Yes Replace injector c r page F1-57
c r page F1-58 No Check if engine coolant temperature
sensor is OK c r page F1-81
"=> If OK, try a known good PCME
=> If not OK, replace engine coolant c r page F1-91
temperature sensor
5 Disconnect each high-tension lead at idle; does Yes Go to next step
engine speed decrease equally at each cylinder?
No Go to Step 8

c r page F1-55
No Low pressure
Fuel line pressure: Check fuel line pressure while pinching
255—314 kPa {2.6—3.2 kgf/cm2, 37—46 psi) fuel return hose
(vacuum hose to pressure regulator dis <=> If it quickly increases, check pres
connected) sure regulator c r page F1-55
=> If it gradually increases, check for
clogging between fuel pump and
pressure regulator
If hose not clogged, check fuel
pump maximum pressure c r page F1-53
7 Is there leakage of intake air system com Yes Try a known good PCME, and check if
ponents? condition improves c r page F1-81
No Replace
8 Is there misfire of dead cylinder from Step 5 in Yes Repair or replace ignition system com
spection? ponents) c r Section G
No Go to next step
9 Is there injector operating sound at idle of dead Yes Try a known good injector and check if
cylinder from Step 5 inspection? condition improves c r page F1-57
No Check for battery positive voltage at in
jector connector terminal A
■=> If there is, replace injector c r page F1-57
=> If there is not, check circuit in for
short or open
46U0F1-037
F1—30
CODE No. 25 (PRESSURE REGULATOR CONTROL SOLENOID VALVE)
Does solenoid valve circuit have a poor con Yes Repair connector and/or wiring harness
nection?
No Go to next step
Is connector terminal A voltages OK with sole Yes Go to next step

noid valve connector disconnected?
Condition Voltage
No Check for open or short circuit in wiring
Ign switch ON Battery positive harness (Solenoid valve terminal A—Main
voltage relay terminal F)
Is there continuity between solenoid valve termi Yes Check for short circuit in wiring from
nal B and PCME terminal 2T? solenoid valve terminal B to PCME ter
minal 2T
■=J> If OK, go to next step

■=> If not OK, repair wiring harness
No Repair wiring harness
Is solenoid valve OK? Yes Replace PCME a - page F1-81

cr page F1-61
No Replace solenoid valve
46U0F1-038
Circuit Diagram
IGNITION
SWITCH BATTERY
PRESSURE REGULATOR
MAIN CONTROL SOLENOID
RELAY VALVE
PRESSURE REGULATOR
MAIN RELAY
CONTROL SOLENOID VALVE
E A
X
■ rtn
16E0F2-C163
F1-31
CODE No. 26 (PURGE CONTROL SOLENOID VALVE)

nection?
No Go to next step

Condition Voltage
No Check for open or short circuit wiring har
Ign switch ON Battery positive ness (Solenoid valve terminal A—Main re
voltage lay terminal F)
nal B and PCME terminal 2X? solenoid valve B to PCME terminal 2X
<=> If OK, go to next step

Is solenoid valve OK? Yes Replace PCME cr page F1-81

o- page F1-71
No Replace EGR solenoid valve
46U0F1-039
Circuit Diagram
IGNITION
SWITCH BATTERY
E{a===gi B
PURGE CONTROL
SOLENOID VALVE
PURGE CONTROL
MAIN RELAY
SOLENOID VALVE
16E0F2-063
F 1-3 2
CODE No. 28 (EGR SOLENOID VALVE-EXCEPT CALIFORNIA)
nection?
No Go to next step

Condition Voltage
No Check for open or short circuit wiring har
Ign switch ON Battery positive ness (Solenoid valve terminal A—Main re
voltage lay terminal F)
nal B and PCME terminal 2S? solenoid valve teminal B to PCME ter
minal 2S
■=> If O K, g o to n e xt ste p
Is solenoid valve OK? Yes Replace PCME cr page F1-81

a - page F1-65
46U0F1-040
Circuit Diagram
F 1-33
F 1 ON-BOARD DIAGNOSIS SYSTEM
CODE No. 28 (EGR SOLENOID VALVE-VACUUM) (CALIFORNIA)

1 Does EGR solenoid valve circuit have a poor Yes Repair connector and/or wiring harness
connection?
No Go to next step
2 Is connector terminal A voltages OK with sole Yes Go to next step

Condition Voltage No Check for open or short circuit in wiring
Ign switch ON Battery positive relay terminal F)

voltage
3 Is there continuity between solenoid valve termi Yes Check for short circuit in wiring from
nal B and PCME terminal 2S? solenoid valve terminal B to PCME ter
minal 2S
=> If OK, go to next step

4 Is EGR solenoid valve (vacuum) OK? Yes Replace PCME c r page F1-81
c r page F1-67
46U0F1-041
Circuit Diagram
IGNITION SWITCH BATTERY
MAIN RELAY
EGR SOLENOID VALVE

(VACUUM)
EGR SOLENOID
VALVE (VACUUM)
____ Q.
-c r
16E0F2-063
F 1 -3 4
CODE No. 29 (EGR SOLENOID VALVE-VENT) (CALIFORNIA)

1 Does EGR solenoid valve (vent) circuit have a Yes Repair connector and/or wiring harness
poor connection?
No Go to next stop
2 s connector terminal A /oltage OK with solenoid Yes Go to next step

valve connector disconn ected?
Condition Voltage
Ign switch ON Battery positive harness (Solenoid valve terminal A—Main
3 Is there continuity between solenoid valve Yes Check for short circuit in wiring harness
terminal B and PCME terminal 2R? (Solenoid valve terminal B—PCME
terminal 2R)

4 Is EGR solenoid valve (vent) OK? Yes Replace PCME cr page F1-81
cr page F1-67
No Replace EGR solenoid valve (vent)
46U0F1-042
Circuit Diagram
IGNITION SWITCH BATTERY
MAIN RELAY
EGR SOLENOID VALVE

(VENT)
MAIN RELAY
E > < A
16E0F2-065
CODE No. 34 (IDLE AIR CONTROL VALVE)

Does the idle air control valve circuit have a Yes Repair connector and/or wiring harness
poor connection?
No Go to next step
Is connector terminal A voltages OK with control Yes Go to next step

valve connector disconnected?
Condition Voltage
Ign switch ON Battery positive harness (Control valve terminal A—Main
Is there continuity between control valve terminal Yes Check for short circuit in wiring from
B and PCME terminal 2W? solenoid valve terminal B to PCME ter
minal 2W
=> If O K , g o to n e xt ste p
Is control valve OK? Yes Replace PCME cr page F1-81

c=r page F1-46
No Replace control valve
46U0F1-043
Circuit Diagram
CODE No. 67 (COOLANT FAN RELAY)

1 Disconnect connector from PCME; is there bat Yes Check PCME terminal connector for
tery positive voltage at PCME terminal 1S wire poor connection
with ignition switch ON?
■=> If OK, replace PCME c r page F1-81
■=> If not OK, repair or replace con
nector
No Go to next step
2 Is same condition as Step 1, is there battery Yes Repair wire

positive voltage at coolant fan relay terminal wire
BV No Go to next step
3 In same condition as Step 1, is there battery Yes Go to next step

positive voltage at coolant fan relay terminal wire
A? No Look for short circuit in wiring
(main relay—coolant fan relay)
4 Is there continuity at coolant fan relay connector Yes Look for short circuit in wiring
B and A? (coolant fan relay—PCME)
No Replace coolant fan relay
46UOF1-044
Circuit Diagram
IGNITION
SWITQH BATTERY
COOLANT FAN
RELAY 9 -1
PCME
TERMINAL 1S
COOLANT F A N ( m )
MOTOR V /
COOLANT FAN RELAY
------- L_
c A
D B
16E0F1-061
F 1 -3 7
After-repair procedure
Cancel the memory of malfunctions by disconnecting the
negative battery cable and depressing the brake pedal for
at least 20 sec. Reconnect the negative battery cable.
Self-Diagnosis checker
nector.
2. Set the switch A to position 1.

5. Set the select switch of the Self-Diagnosis Checker to posi
tion A.
7. Start and warm up the engine; then run it at 2,000 rpm for
3 min.
8. Verify that no diagnostic trouble code numbers are dis
played.
36U0F1-041
SWITCH MONITOR FUNCTION

Individual switches can be inspected by the SST (Self-Diagnosis Checker).
Preparation
The TEN terminal of the data link connector must be grounded and the ignition switch turned to ON (en
gine off). If either switch remains activated, the monitor lamp will be illuminated.
46U0F1-045
Self-Diagnosis Checker (Monitor lamp)
Switch Remarks
Light ON Light OFF
Clutch switch Pedal released Pedal depressed In gear
Neutral switch In gear Neutral Clutch pedal released
Idle switch Pedal depressed Pedal released —
Air conditioning sensor ON OFF Blower switch 1st

Stoplight switch Pedal depressed Pedal released —
Parking brake applied
Headlight switch ON OFF
(Canada)
Blower switch 3rd or 4th position OFF, 1st, or 2nd position —
Rear window defroster switch ON OFF —
TEN terminal grounded and
Coolant fan relay Fan operating Fan not operating
Idle switch OFF
46U0F1-046
HEATED OXYGEN SENSOR MONITOR FUNCTION

With the System Selector test switch set to 02 Monitor, the heated oxygen sensor is monitored as described.
Condition
Item monitored Function
Engine System Selector Switch
Heated oxygen sensor out
put more than 0.45V moni
Heated oxygen sensor tor lamp ON
Running O2 monitor
output signal Heated oxygen sensor at
put less than 0.45V monitor
lamp OFF
46U0F1-199
1. Perform preparation (Refer to page F1-38.)
nector.

tion A.
8. Check if Monitor Lamp illuminates when each switch is made
to function as described below.
46U0F1-048
F 1-3 9
Procedure
46U0F1-049
Neutral and Clutch switches
46U0F1-050
Idle switch
46U0F1-051
Air conditioning sensor (ACS)
46U0F1-052
Stoplight switch
46U0F1-053
Headlight switch
46U0F1 -054
Blower switch
46U0F1-055
Rear window defroster switch
46U0F1-056
Coolant fan relay
46U0F1-Q57
F1-41
F1 INTAKE AIR SYSTEM
INTAKE AIR SYSTEM

COMPONENT PARTS
2. Inspect the intake air system components and repair or replace them as necessary.
2.S—3.5 Nm (25—36 kgf-cm, 22—31 Inlbf]
N-m (kgf-m, ft-lbf)

46U0F1-Q58
1. Fresh air duct 7. Resonance chamber No.2

Inspect for damage Inspect for damage
2. Resonance chamber No.1 Installation note................... page F1-43
Inspect for damage 8. Accelerator cable
3. Air cleaner housing Inspection / Adjustment ... page F1-44
Inspect for excessive dirt and damage 9. Throttle body
4. Air cleaner element Inspection........................... page F1-43
Inspection............................... page F I—15 10. BAC valve
5. Mass airflow sensor Inspection........................... .... page F1-46
Inspection............................... page F1-90 11. Intake manifold bracket
6. Air hose 12. Intake manifold
Inspect for damage Installation note................... .... page F1-43
F 1 -4 2
INTAKE AIR SYSTEM F1
THROTTLE BODY
Inspection
1. Check the throttle body for wear, deposits, and coolant
leakage.
2. Verify that the throttle valve moves smoothly when the throttle
lever is moved from fully closed to fully open.
3. Replace the throttle body if necessary.
Caution
• Do not remove the thin seal coating from the throt
tle valve or bore. It is necessary for proper
operation.
INTAKE MANIFOLD
Installation Note
1. Tighten the bolts in the order shown in the figure.
Tightening torque:
1 9 -2 5 Nm { 1 .9 -2 .6 kgf m, 1 4 -1 9 ftlbf)
2. Refill the radiator with the specified engine coolant.

(Refer to page F1-14.)
3. Check for engine coolant leakage.
46U0F1-060
RESONANCE CHAMBER No.2
Installation Note
1. Slide the hose clamp onto the hose and push it onto reso
nance chamber No.2.
16E0F1-360
2. Rotate the hose and hook it securely onto the locating knob.
16E0F1-362
F 1-43
ACCELERATOR PEDAL
1. Accelerator cable 3. Retainer

Inspection / Adjustment...................... below 4. Clip
2. Cruise actuator cable 5. Accelerator pedal
Adjustment.. 1994 626/MX-6 body electrical 6. Return spring
troubleshooting manual Section Q 7. Bracket
ACCELERATOR CABLE
Free play: 1.5—4.0mm {0.06—0.16 in)

per B while pressing lock button A with the throttle valve
fully closed.
F 1 -4 4
IDLE-SPEED CONTROL SYSTEM F1
IDLE-SPEED CONTROL SYSTEM
DESCRIPTION
36U0F1-246
The idle-speed control system controls the bypass air amount that passes through the throttle body to
improve startability, warm-up, idle smoothness, and drivability.
This system replaces the dashpot to control deceleration.
F1 IDLE-SPEED CONTROL SYSTEM
PREPARATION
SST
49 B019 9A0 For

inspection of idle
System Selector // air control valve
and air valve
36U0F1-247
SYSTEM OPERATION
Air Valve
{68°Fj
3. Set switch A to position 1 and the test switch to SELF TEST.
5. Verify that the idle speed decreases gradually as the en
gine warms up.
46U0F1-063
Idle Air Control Valve
2. Set switch A to position 1 and the test switch to SELF TEST.
3. Verify that the idle speed is within specification.
4. Disconnect the idle air control valve connector with the test
switch SELF TEST.
5. If the engine speed decreases, replace the BAC valve.
6. Perform the after-repair procedure. (Refer to page F1-38.)
46U0F1-064
IDLE AIR CONTROL VALVE
Inspection
1. Disconnect the idle air control valve connector.
2. Measure resistance of the valve.
Resistance: 7.7—9.3 (at 23°C {73°Fj)
3. If not as specified, replace the BAC valve.
36U0F1-248
AIR VALVE
Inspection
1. Remove the BAC valve. (Refer to page F1-42.)
2. Cool the BAC valve to below 0°C {32°F}.
3. Heat the BAC valve at point A by using a blow drier, and
verify that part B moves in the direction of the arrow in the
figure.
46U0F1-065
F 1-4 6
FUEL SYSTEM F1
FUEL SYSTEM
DESCRIPTION
PRESSURE REGULATOR
INJECTOR
^ ► T O FUEL TANK
FROM FUEL PUMP
FUEL FILTER
(HIGH-PRESSURE SIDE)
FHFl PUMP
FUEL FILTER
VALVE (TWO-WAY)
FUEL TANK
36U0F1-249
This system supplies the fuel to the fuel injectors at a constant pressure. Fuel is metered and injected
into the intake manifold according to injection control signals from the PCME. The system consists of the
fuel tank, fuel pump, fuel filters, pressure regulator, pressure regulator control solenoid valve, fuel injec
tors, and fuel pump relay.
F 1-4 7
F1 FUEL SYSTEM
Fuel Pressure and Servicing Fuel System
FUEL PUMP
(GREEN)
Warning
Warning
46U0F1-066 • Fuel line spills and leaks are dangerous. Fuel can
this, always complete the following “ Fuel Line Safe
ty Procedures” .

3. After the engine stalls, turn the ignition swicth to OFF.
B. Avoid leakage
1. When disconnecting a.fuel line hose, wrap a rag around
2. Plug the hose after removal.
C. Use a fuel pressure gauge correctly; install hose clamps
to secure the fuel pressure gauge to the fuel filter and the
main hose to prevent leakage.
Priming Fuel System

After the fuel pressure has been released for repairs or inspec
tion, the system must be primed to avoid excessive cranking
when the engine is first started. Follow the steps below.
1. Connect the data link connector terminals F/P and GND
with a jumper wire.
2. Turn the ignition switch ON for approx. 10 sec. and check
for fuel leaks.
3. Turn the ignition switch OFF and remove the jumper wire.
36U0F1-065
SYSTEM OPERATION
FUEL PUMP
(GREEN)
Fuel Pressure Hold Inspection
Warning
this, always complete the “ Fuel Line Safety Proce
dures” above.
46U0F1-068
F 1 -4 8
FUEL SYSTEM F1
1. Disconnect the negative battery terminal.
2. Install a fuel pressure gauge between the fuel filter and the
main fuel hose. (Install clamps as shown.)
3. Connect the negative battery terminal.

with a jumper wire.
INSTALL CLANMPS 5. Turn the ignition switch ON for 10 sec. to operate the fuel
46U0F1-069 pump.
6. Turn the ignition switch OFF and disconnect the jumper wire.
7. Observe the fuel pressure after 5 min.
nws
Fuel pressure:
GND F/P More than 150 kPa {1.5 kgf/cm2, 21 psi)
DATA LINK
\CONNECTOR
8. If not as specified, perform the following inspections.
• Fuel pump hold pressure. (Refer to page F1-52.)
• Pressure regulator hold pressure.
• Injector fuel leakage. (Refer to page F1-58.)
46U0F1-070
Fuel Line Pressure Inspection
FUEL PUMP
RELAY (GREEN)
Warning
dures” on page F1-48.
46U0F1-071
2. Install a fuel pressure gauge between the fuel filter and the
main fuel hose. (Install clamps as shown.)
4. Connect data link connector terminals F/P and GND with

INSTALL CLANMPS a jumper wire.
46U0F1-072 5. Turn the ignition switch ON.
6. Measure the fuel line pressure.
Fuel line pressure:

260—320 kPa {2.6—3.3 kgf/cm2, 37—46 psi)

• Fuel pump maximum pressure. (Refer to page F1-53.)
• Fuel line clogging and restriction.
• Fuel filter clogging and restriction.
46U0F1-073
F 1-4 9
F1 FUEL SYSTEM
FUEL TANK
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
Warning
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel
Line Safety Procedures” on page F1-48.
Warning
• Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion
or fire may cause death or serious injury. Always properly steam clean a fuel tank before repair
ing it.
1. Drain the fuel from the fuel tank.

3. Inspect all parts and repair or replace as necessary.
Nm I kgfm, ft-lbf]
46U0F1-074
1. Connector 4. Fuel tank straps

2. Fuel hoses 5. Fuel tank
Installation Note........................page F1-51 Inspect for cracks and corrosion
3. Evaporative hoses Removal Note.......................... page F1-51
Installation Note........................page F1-51
F 1 -5 0
FUEL SYSTEM F1
Removal Note
1. Remove the filler cap and insert a hose into the fuel tank
through the filler pipe.
2. Start the pump and suck up the fuel into a container.
Note
• For easier work, prepare a hose of following size.
Outer diameter: 13mm [0.51 in)

Length: 2160mm [85.0 in)
Installation Note
1. Push the ends of the main fuel hose, fuel return hose, and
evaporative hoses onto the fuel tank fittings at least 25mm
[1.0 in).
2. Push the fuel filler hoses onto the fuel tank pipes and filler
pipes at least 35mm [1.4 in).
16E0F1-105
FUEL FILTER
Replacement
Low-pressure side (in-tank filter)
46U0F1-075
High-pressure side
The fuel filter must be replaced at the intervals outlined in the
maintenance schedule.
1. Disconnect and plug the fuel hoses from the fuel filter.
Tightening torque:
7.9—10.7 N m [80—110 kgf cm, 70—95.4 in-lbf}
4. Verify that the fuel hoses are pushed fully onto the fuel filter
nipples.
5. Secure the fuel hoses with clips.
6. Start the engine and verify that the fuel line joints do not leak.
F1—51
F1 FUEL SYSTEM
FUEL PUMP
Inspection
Fuel pump operation
1. Connect the data link connector terminals F/P and GND with
a jumper wire.
2. Remove the fuel filler cap.
4. Listen at the filler inlet for the operational sound of the fuel
pump.
5. Install the fuel filler cap.
6. If no sound was heard, measure the voltage between the

fuel pump connector of wiring harness side terminal A to
a ground.
Voltage: Approx. 12V
7. If not correct, check the fuel pump relay and related wiring
harness. (Refer to page F1-55.)
8. If the voltage is normal, check for continuity between fuel
pump connector of fuel pump side terminal A and D.
9. If there is continuity, replace the fuel pump.
10. If there is none, repair the ground circuit.
FUEL PUMP
Hold pressure
(GREEN)
Perform this inspection if the fuel pressure hold inspection
is not as specified. (Refer to page F1-48.)
Warning
• Fuel line spills and leaks can be dangerous. Fuel can
age the vehicle. Fuel can also irritate skin and eyes.
To prevent this, always complete the “ Fuel Line
Safety Procedures” on page F1-48.
46U0F1-078
2. Connect a fuel pressure gauge to the fuel filter and plug
the outlet of the gauge as shown. (Install clamps as shown.)
16E0F1-111
a jum per wire.
\
DATA LINK
5. Turn the ignition switch ON for 10 sec. to operate the fuel
pump.
7. Observe the fuel pressure after 5 min..
Fuel pressure:
More than 340 kPa {3.5 kgf/cm2, 50 psi)
8. If not as specified, replace the fuel pump.

36U0F1-070
F 1 -5 2
FUEL SYSTEM F1
FUEL PUMP
Fuel pump maximum pressure
(GREEN)
Warning
46U0F1-079
the outlet of the gauge as shown. (Install clamps as shown.)
16E0F1-114
a jumper wire.
5. Turn the ignition switch ON to operate the fuel pump.
6. Measure the pump maximum pressure.
Fuel pump maximum pressure:

450—630 kPa {5.0—6.5 kgf/cm2, 64—92 psi)
36U0F1-071
F1 FUEL SYSTEM
1. Remove the fuel tank.
2. Remove the fuel pump, referring to Removal Note.
Note
• Replace the fuel pump as an assembly.
FUEL PUM P RING

INSTALLATION
REMOVAL
FUEL TANK
/F L A N G E
46U0F1-080
1. Fuel hose 3. Fuel pump

2. Fuel pump ring 4. Fuel pump gasket
Removal / Installation Note. below
Removal Note
Rotate the fuel pump ring counterclockwise and remove it.
Installation Note
Rotate the fuel pump ring clockwise until the flange touches
the stopper.
F1—54
FUEL SYSTEM F1
FUEL PUMP RELAY
FUEL PUMP Inspection
RELAY (GREEN)
Operation check
Listen for clicking of the fuel pump relay while turning the
ignition switch from OFF of START.
36U0F1-073
Continuity inspection
Check continuity between the terminals of the relay.
B + : Battery positive voltage
Terminal A—B Terminal C—D
Apply B + Yes
B + not applied No
36U0F1-260
Replacement
FUEL PUMP
RELAY (GREEN)
1. Remove the relay from main fuse block No.1.
PRESSURE REGULATOR
Inspection
16E0F1-121 Fuel line pressure
FUEL PUMP
RELAY (GREEN)
Warning

2. Connect a fuel pressure gauge between the fuel filter and
the main fuel hose. (Install clamps as shown.)
46U0F1-081 3. Connect the negative battery terminal.
4. Start the engine and run it at idle.
Fuel line pressure:

210—260 kPa [2.1—2.7 kgf/cm2, 30—38 psi)
6. Disconnect the vacuum hose from the pressure regulator

and measure the fuel line pressure.
Fuel line pressure:

INSTALL CLAMPS
260—320 kPa [2.6—3.3 kgf/cm2, 37—46 psi)
46U0F1-082
F 1 -5 5
F1 FUEL SYSTEM
Hold pressure
Perform this inspection if the fuel pressure hold inspection
is not as specified. (Refer to page F1-48.)
Warning
this, always complete the ‘‘Fuel Line Safety Proce

46U0F1-084
a jumper wire.
pump.
7. Pinch the fuel return hose with a plier.
8. Observe the fuel pressure for 5 min..
Fuel pressure:
More than 147 kPa (1.5 kgf/cm2, 21 psi)
36U0F1-074
9. If not as specified, replace the pressure regulator.
Replacement
Warning
46U0F1-085
1. Disconnect the vacuum hose.
2. Disconnect the fuel return hose.
3. Remove the pressure regulator.
4. Install a new O-ring.
Tightening torque:
7.8—10.7 Nm {80—110 kgf-cm, 70—95.4 inlbf)
F1—56
FUEL SYSTEM F1
INJECTOR
Inspection
Operation check
1. Warm up the engine and let it idle.
2. Listen for the operational sound of each injector with a screw
driver or a sound scope.
3. If no sound is heard, measure injector resistance.
4. If the injector resistance is OK, check wiring to the injector
and the voltages of the PCME terminals 2U, 2V, 2Y and
2Z. (Refer to page F1-81.)
Warning

N m (kgf m, ft-lbf)
46U0F1 -087
1. Negative battery cable 4. Fuel hose

2. Injector connector 5. Distribution pipe
3. Pressure regulator 6. Injector
Inspection............... page F1-55 7. Insulator
F 1 -5 7
F1 FUEL SYSTEM
Fuel leakage test
1. Remove the injectors together with the distribution pipe.
2. Fasten the injectors firmly to the pipe.
Warning
46U0F1-088
with a jumper wire.
GND F/P DATA LINK

\CO NNECTO R
36U0F1-075
5. Tilt the injectors approximately 60 degrees and verify that
no fuel leaks from the injector nozzles.
Leakage Specification
If there is more than one drop per 2 minutes, replace the
injector.
6. Turn the ignition switch to OFF and remove the jumper wire.
46U0F1-089
Volume test
2. Affix the injectors to the distribution pipe with wire.
3. Fasten the injectors firmly to the pipe.
Warning
46UQF1-090
4. Connect the SST to the battery and an injector.
49 L 0 1 8 901
5. Check the injection volume with a graduated container.
Injection volumes:
47—68 ml [47—68 cc, 1.4—2.0 fl oz}/15 sec.
6. If not as specified, replace the injectors.
46 UOF1-091
F 1 -5 8
FUEL SYSTEM F1
Installation
Install in the reverse order of removal, referring to Installa
tion Note.
Tightening torque
Delivery pipe
A: 1 9 -2 5 Nm {1.9—2.6 kgf m, 14—18 ft-lbf}
B: 7.8—10.7 N m
(80—110 kgf-cm, 70—95.4 in-lbf)
Installation note
-T f
O-RING 1. Use new injector O-rings.
ml
INJECTOR c o r« c t 2. Apply a small amount of clean engine oil to the O-rings be
fore installing them.
t f
GROMMET DELIVERY
PIPE
, as
W RONG
16E0F1-137
3. Install new injector insulators.
4. Install the injectors.
16E0F1-138
Inspection
Injector resistance
1. Disconnect the injector harness.
2. Measure resistance of the injector.
Resistance: 12— 16Q (at 20°C (68°F))
3. If not as specified, replace the injector.
16E0F1-139
FI___________ PRESSURE REGULATOR CONTROL SYSTEM
PRESSURE REGULATOR CONTROL SYSTEM
DISTRIBUTOR (NE-SIGNAL)
ENGINE COOLANT
TEMPERATURE SENSOR
INTAKE AIR PCME

TEMPERATURE SENSOR
PRC SOLENOID VALVE

IDLE SWITCH
ir
MAIN RELAY
IGNITION SW ITCH-
<b
FUEL
(FROM DISTRIBUTION I
PIPE) ▼
VACUUM
© ©
I
FUEL
(TO FUEL TANK)
Operating condition
Operating time
Coolant temperature Intake air temperature Engine condition
Idle switch ON and engine
Above 70°C [158°F| Above 20°C (68°F) Approx. 102 sec.
speed below 1,500 rpm
16E0F1-140
To prevent vapor lock of the fuel during hot restart idle, vacuum to the pressure regulator is momentarily
cut and the fuel injection pressure is increased to slightly more than 284 kPa {2.9 kgf/cm2, 41.2 psi}.
F1—60
PRESSURE REGULATOR CONTROL SYSTEM F1
PRESSURE REGULATOR CONTROL SOLENOID VALVE
Inspection
On-vehicle
2. Disconnect the vacuum hose (yellow) from the pressure
regulator. Verify that vacuum is felt.
46U0F1-092
3. Ground the solenoid valve terminal B with a jumper wire.
Verify that no vacuum is felt.
4. If vacuum exists, check the solenoid valve.
46U0F1 -093
Solenoid Valve
1. Remove the solenoid valve.
2. Blow through the solenoid valve from port A.
3. Verify that air flows from port B.
16E0F1-143
4. Apply battery positive voltage to solenoid valve terminal.
6. Verify that air flows from the valve air filter.
7. If not as specified, replace the solenoid valve.
36U0F1-266
F1 EXHAUST SYSTEM
EXHAUST SYSTEM
COMPONENT PARTS
REPLACE
38—51 13.8—5.3, 28—38)
REPLACE
20—28 {2.0—2.9, 15—20) 7.8—11 N-m {80—110 kgf-cm, 70—96 ln-lbf)
GASKET, REPLACE
7.8—11 Nm
GASKET, REPLACE (80—110 kgf-cm, 70—96 Inlbf)
\ REPLACE
GASKET, REPLACE,
CALIFORNIA
GASKET, REPLACE
46U0F1-094
1. Main silencer 5. Warm-up three-way catalyst (California)

Inspect for deterioration and restriction Inspect for deterioration and restriction
2. Pre-silencer 6. Exhaust manifold
Inspect for deterioration and restriction Inspect for deterioration and cracks
3. Three-way catalyst 7. Exhaust manifold insulator
Inspect for deterioration and restriction 8. Heated oxygen sensor
4. Front pipe assembly Inspection................................ page F1-93
Inspect for deterioration and restriction
F 1 -6 2
OUTLINE OF EMISSION CONTROL SYSTEM F1
OUTLINE OF EMISSION CONTROL SYSTEM
STRUCTURAL VIEW
The following systems are employed to reduce CO, HC, and NOx emissions.
1. Exhaust gas recirculation.
2. Positive crankcase ventilation (PCV) system
3. Fuel evaporative system
4. Three way catalyst
FUEL PUMP
FUEL FILTER
(LOW-PRESSURE SIDE) CHECK VALVE (TWO-WAY)
FUEL VAPOR VALVES
FUEL TANK
PURGE VALVE
CATALYST
CHARCOAL CANISTER
EGR SOLENOID VALVE (VENT)
SOLENOID VALVE (VACUUM)
46U0F1-095
F1—63
F1 EXHAUST GAS RECIRCULATION
EXHAUST GAS RECIRCULATION (EXCEPT CALIFORNIA)

DESCRIPTION
The exhaust gas recirculation (EGR) recirculates a portion of the exhaust gas through the EGR control
valve and the intake manifold into the combustion chamber. This lowers the combustion temperature and
reduces NOx emissions.
SYSTEM INSPECTION
2. Place a finger against the EGR control valve diaphragm.
3. Increase the engine speed to about 2,000 rpm.
4. Verify that the diaphragm moves.
Cold engine: Diaphragm does not move

Warm engine (coolant temperature above 50°C
(122°F)): Diaphragm moves
46U0F1-097
F1—64
EXHAUST GAS RECIRCULATION F1
EGR CONTROL VALVE
Inspection/Replacement
1. Let the engine idle.
2. Disconnect the vacuum hose from the EGR valve.
3. Connect a vacuum pump to the valve.
4. Apply 150 mmHg {5.91 inHg) vacuum and verify that the
engine runs roughly or stops.
5. Replace the EGR valve if not as specified.
Tightening torque:
7.8—10.7 Nm {80—110 kgf-cm, 70—95.4 inlbf}
EGR FUNCTION CONTROL

Inspection
1. Remove the EGR function control.
2. Plug the No.2 port and attach a vacuum pump to the No.1
port.
3. Blow into the exhaust gas port. Operate the vacuum pump
and verify that the vacuum is held at the No.3 port.
4. Release the exhaust gas port and verify that the vacuum
is released at the No.3 port.
5. Replace the EGR function control if not as specified.
EGR SOLENOID VALVE

Inspection
2. Verify that air flows between each part as below.
Port Airflow
A -B No
A -C No
B -C Yes
46U0F1-100
3. Connect the positive and negative battery terminals to the
solenoid valve terminals.
4. Verify that air flows between each part as below.
Port Airflow
A -B Yes
A -C No
B -C No
46U0F1-101
EGR FUNCTION SENSOR
Inspection / Replacement
1. Disconnect the EGR function sensor connector under the
engine cold condition.
2. Measure resistance of the sensor.
Resistance: 182—336 kfl (at 20°C {68°F}>
3. If not as specified. Replace the EGR control valve.
Tightening torque:
7.8—10.7 N m {80—110 kgf/cm2, 70—95.4 inlbf)
F1-65
EXHAUST GAS RECIRCULATION (CALIFORNIA)
DESCRIPTION
This system recirculates a small amount of exhaust gas into the intake manifold to reduce the combustion
temperature and reduce the NOx emissions.
This system consists of the EGR control valve, EGR function sensor, two duty-solenoid valves, PCME,
and input devices.
EGR SOLENOID fg r SOLENOID
POSITION
SENSOR
1: DETECTION OF ENGINE RUNNING CONDITION

2: DETERMINATION OF EGR GAS AMOUNT
46U0F1-102
SYSTEM OPERATION
Cold engine (coolant temperature: below 55°C {131 °F})
EGR operation is stopped to improve driveability when the engine is cold.
Warm engine
The ECU controls the solenoid valves (vacuum side and vent side) to supply EGR gases as described below.
Operating condition EGR operation Remark

Idle
Idle switch: ON
Deceleration
Stopped
High speed/Low speed Above 4,250/Below 1,000 rpm
Heavy load —
Acceleration —
Warming up Reduced EGR gas amount Coolant temperature: Between
55°C (131°F) and 60°C (140°F)
Other Controls supplied EGR gas amount by using sig
—
nal from EGR function sensor
F 1 -6 6
EXHAUST GAS RECIRCULATION F1
SYSTEM INSPECTION
ISE CONNECTOR A
1. Connect the SSTs to the PCME as shown.
3. Drive the vehicle and verify that PCME terminals 2S and
2R voltage is battery positive voltage (B+) while the engine
is still cold.
5. Drive the vehicle and verify that the Engine Signal Monitor
green and red lamps flash when the SST is set to 2S and 2R.
49 G 01 8 904
46U0F1-103
6. Stop the vehicle and let it idle.
7. Ground the PCME terminal 2R by using a jumper wire.
8. Verify that the engine runs roughly or stalls at idle.
46U0F1-104
EGR SOLENOID VALVE (VACUUM)

Inspection
1. Disconnect the vacuum hoses.
2. Blow into the solenoid valve and verify that air does not flow.
3. Disconnect the solenoid valve connector.
4. Apply battery positive voltage and a ground to the solenoid
valve as shown.
5. Blow through the solenoid valve and verify that air flows.
6. If not as specified, replace the solenoid valve assembly.
46U0F1-105
Inspection
2. Blow through the solenoid valve and verify that air flows.
EGR SOLENOID 3. Disconnect the solenoid valve connector.
VALVE (VENT)
4. Apply battery positive voltage and a ground to the solenoid
valve as shown.
5. Blow into the solenoid valve and verify that air does not flow.
46U0F1-106
EGR CONTROL VALVE
Inspection
2. Connect a vacuum pump as shown and apply vacuum.
3. Verify that the engine runs roughly or stalls at more than
the specified vacuum.
Specification:
5.4—7.7 kPa [40—60 mmHg, 1.6—2.3 inHg}
4. If not as specified, replace the EGR control valve.

46U0F1-107
F 1 -6 7
Replacement
Plug the water hoses after disconnecting them.
1. Remove the EGR control valve in the sequence shown
below.
(1) EGR hoses
(2) Vacuum hose
(3) EGR function sensor connector
(4) EGR control valve and gasket
2. Install a new gasket, and then install the EGR in the reverse
order of removal.
46U0F1-108
EGR FUNCTION SENSOR
ISE CONNECTOR A
Inspection of output voltage
1. Disconnect the PCME connector.
2. Connect the SST to the PCME as shown and connect a
vacuum pump to the EGR control valve.
4. Measure voltage at the terminals as shown in the table.
49 GO 18 903 Vacuum
Terminal PCME 0 kPa 20.0 kPa
49 G 0 1 8 9 04
{0 mmHg, 0 inHgj (150 mmHg, 5.90 inHgj
B 2K 4.5—5.5V
46U0F1-109
A 2D OV
C 2J Approx. 0.8V Approx. 4.9V
5. If not correct at 2J terminal, check the wiring harness and

2K terminal of the PCME.
Inspection of resistance
1. Disconnect the EGR function sensor connector, and con
nect an ohmmeter.
2. Disconnect the vacuum hose from the EGR control valve,
and connect a vacuum pump.
3. Measure the resistance between the terminals as shown
while vacuum is applied.
Vacuum
Terminal 0 kPa 20.0 kPa
(0 mmHg, 0 inHgj (150 mmHg, 5.90 inHgj
A -B Approx. 2.7 Mi
46U0F1-110 Approx. 0.5 kQ Approx. 2.7 kfl
A -C
B -C Approx. 2.4 kt) Approx. 0.1 k$l
F1—68
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM F1
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
DESCRIPTION
The PCV valve is operated by the intake manifold vacuum.
When the engine is running at idle, the PCV valve is slightly open and a small amount of blowby gas is
drawn into the intake manifold to be burned.
As the engine speed rises, the PCV valve is opened further, allowing a larger amount of blowby gas to
be drawn into the intake manifold.
16E0F1-153
PCV VALVE
Inspection
1. Verify that the engine coolant temperatuer is below 20°C
{68°F}.
3. Disconnect the PCV valve with the ventilation hose from the
46U0F1-111
out of port B.
46U0F1-112
F 1 -6 9
F1 FUEL EVAPORATIVE SYSTEM
FUEL EVAPORATIVE SYSTEM

DESCRIPTION
The fuel evaporative system consists of fuel vapor valve, two-way check valve, charcoal canister, purge
control solenoid valve, PCME, and input devices. The amount of evaporative fumes introduced into the
engine and burned is controlled by the solenoid valve to correspond to the engine’s operating conditions.
To obtain the best engine performance, the solenoid valve is controlled by the PCME.
Operation
The solenoid valve (purge control) is controlled by duty signals from the PCME to perform purging of the
charcoal canister. Purging is done when these conditions are met;
(1) After warm-up (Coolant temperature above 80°C {176°F})
(2) Driving in gear
(3) Engine speed more than 1,000 rpm
(4) Accelerator pedal depressed (idle switch OFF)
(5) Heated oxygen sensor functioning normally
F 1-7 0
EVAPORATIVE EMISSION CONTROL SYSTEM F1
SYSTEM OPERATION
let it idle.
2. Disconnect the vacuum hose from the solenoid valve and
plug it as shown in the figure. Verify that no vacuum is felt
at the solenoid valve.
3. If not as specified, check the solenoid valve.
46U0F1-114
PURGE CONTROL SOLENOID VALVE
1
Inspection
J 1. Disconnect the vacuum hoses from the solenoid valve.
2. Verify that no air flows through the valve.
/■— \
{j' < / Ni .... 0
_ D
46U0F1-115
GROUND
3. Disconnect the solenoid valve connector and supply bat
tery positive voltage as shown in the figure.
4. Verify that air flows through the valve.
26U0F1-267
FUEL VAPOR VALVE
Inspection
1. Verify that air flows through the valve from port A as shown
in the figure.
16E0F1-160
2. Verify that no air flows through the valve from port A as
3. Replace the fuel vapor valve if necessary.
16E0F1 -161
F1-71
F1 EVAPORATIVE EMISSION CONTROL SYSTEM
CHECK VALVE (TWO-WAY)
Inspection
1. Remove the valve.
2. Check the operation of the valve by using a vacuum pump.
Apply approx. 3.5 kPa (26 mmHg,

Valve opens
1.0 inHgj vacuum at port A
Apply approx. 5.9 kPa (44 mmHg,
Valve opens
1.7 inHgj vacuum at port B
36U0F1-256
CHARCOAL CANISTER
Inspection
1. Visually check for damage.
2. Replace the charcoal canister if necessary,
T 16E0F1-163
FUEL-CUT CONTROL SYSTEM F1
FUEL-CUT CONTROL SYSTEM
DESCRIPTION
This system is used to improve the fuel economy, to prevent engine bucking during deceleration, and
to protect the engine from overreving.
Deceleration fuel-cut
(x 10* rpm)
(-40) (32) (104) (176) {°F}
16E0F1-164
F 1-73
F1 FUEL-CUT CONTROL SYSTEM
PREPARATION
SST
46U0F1-116
F 1-7 4
SYSTEM OPERATION
USE CONNECTOR A
49 92 00 162 IG -
2. Connect the SSTs to the PCME.
let it idle.
Warning
49 G 0 18 903
• Performing this test with the transaxle in any range
49 G 018 904 other than neutral can be dangerous. Before per
forming this test, verify that the transaxle is in
46U0F1-117 neutral.
4. Set the SST (Engine Signal monitor) to the terminal 2U, 2V,
2Y and 2Z and verify that the green and red lamps flash
alternately.
46U0F1-118
5. Increase the engine speed to 4,000 rpm and then suddenly
release the throttle.
6. Verify that the red indicator lamp illuminates while the en
gine speed is above approx. 1,500 rpm on deceleration.
Caution
• Holding the maximum rpm for more than 3 seconds
can damage the engine.
7. Increase the engine speed and verify that the maximum rpm
does not exceed approx. 6,800 rpm while the engine is
at normal operating temperature.
F1 A/C CUTOFF SYSTEM
A/C CUTOFF SYSTEM

DESCRIPTION
An A/C cutoff system is used to improve idle smoothness just after starting the engine and to improve
acceleration performance.
DISTRIBUTOR
(NE-SIGNAL)
PCME
THROTTLE
POSITION
SENSOR DETERMINATION
OF
AIR CONDITIONING
SENSOR A/C CUT OFF
A/C RELAY
IGNITION SWITCH
(START)
ENGINE COOLANT \ IGNITION SWITCH

TEMPERATURE SE N SO R ' O'
-D_
CONDENSOR ® ©
NEUTRAL FAN MOTOR
SWITCH
MAGNETIC BATTERY
CLUTCH SWITCH CLUTCH
46U0F1-120
Operation
The A/C clutch operation is cancelled under the conditions below.
Engine condition Purpose Cutoff period

After engine starting Improve engine starting Approx. 4 sec.
Throttle valve fully open Improve drivability Approx. 5 sec.
Coolant temp, above 116°C (241°F) Prevent engine overheat Until coolant temp, decrease below 113°C (235°F)
SYSTEM OPERATION
2. Turn the blower switch and AIR CONDITIONING SENSOR
ON.
4. Verify that the additional fan stops for approx. 4 sec. after
the engine starts.
F 1 -7 6
DECHOKE CONTROL SYSTEM/COOLANT FAN CONTROL SYSTEM F1
DECHOKE CONTROL SYSTEM

SYSTEM OPERATION
1. Turn the ignition switch to START and verify that the injec
tor operating sound is heard.
2. Depress the accelerator pedal fully and turn the ignition
switch to START. Verify that no injector operating sound is
heard.
COOLANT FAN CONTROL SYSTEM

DESCRIPTION
To improve reliability, the coolant fan is controlled by the PCME. This system consists of the coolant fan
motor, fan relays, PCME, and input devices.
PCME
46U0F1-121
Coolant fan operation

Engine condition Fan relay
Coolant temperature above 97°C (207°F) ON
Air conditioning sensor ON
TEN terminal ground and idle switch ON
ECTS malfunction ON
F 1 -7 7
F1 COOLANT FAN CONTROL SYSTEM
SYSTEM OPERATION
1. Connect the data link connector terminals TEN and GND
with a jumper wire.
36U0F1-088
3. Rotate the throttle link by hand and verify that cooling fan
operates.
16E0F1-176
CONTROL SYSTEM F1
CONTROL SYSTEM
PREPARATION
SST
46U0F1-122
F1 CONTROL SYSTEM
STRUCTURAL VIEW
46U0F1-123
1. Fuel pump relay 8. Heated oxygen sensor

Inspection.................................page F -5 5 Inspection.................................page F1-93
Replacement.............................page F -5 5 Replacement............................ page F1-93
2. Powertrain control module (Engine) 9. Idle switch
Removal / Installation............... page F -81 Inspection.................................page F1-94
Inspection.................................page F -81 10. Main relay
3. Mass airflow sensor Inspection................................ page F1-94
Inspection.................................page F -9 0 11. Coolant fan relay
Replacement.............................page F -4 2 Inspection.................................page F1-94
4. Crankshaft position sensor 12. Clutch switch
Inspection.....................................page F -9 0 Inspection.................................page F1-94
5. Engine coolant temperature sensor Replacement............................ page F1-95
Removal.................................... page F -91 13. Neutral switch
Inspection............... ................. page F -91 Inspection.................................page F1-95
Installation.................................page F -9 2 Replacement............................ page F1-95
6. Intake air temperature sensor 14. Steering pressure sensor
Inspection.................................page F -9 2 Inspection.................................page F1-95
Replacement.............................page F -9 2 Replacement............................ page F1-95
7. Throttle position sensor
Inspection.................................page F -9 2
Adjustment................................page F -9 3
F 1 -8 0
CONTROL SYSTEM F1
POWERTRAIN CONTROL MODULE (ENGINE)
1. Disconnect the battery negative terminal.
46U0F1-124
1. Console 2. PCME connector 3. PCME
Inspection
1. Disconnect the PCME connectors.
49 9 2 0 0 162 2. Connect the SSTs. (Engine Signal Monitor and Adapter)
to the PCME as shown.
49 G 0 18 903
46U0F1-125
3. Place the SST (sheet) on the Engine Signal Monitor.
4. Measure the voltage at each terminal. (Refer to pages
F1-82 through F1-89.)
5. If any PCME terminal voltage is incorrect, check the relat
ed input or output devices and wiring. If no problem is found,
replace the PCME. (Refer to above.)
46U0F1-126
T E R M IN A L S Caution
• Never apply voltage to SST terminals A and B be
cause it will damage the SST.
46U0F1-127
F1-81
F1 CONTROL SYSTEM
Terminal voltage (reference data) B+; <0|t>ge
Terminal Input Output Connected to Test condition Voltage (V) Remark
1A — — B a tte ry C o n sta n t B+ For b a c k u p
1B O M a in relay
Ig n itio n sw itch
O FF 0
—
ON B+
1C O Ignition switch W h ile c ra n k in g 10

(START) —
Ig n itio n s w itc h O N 0
1D o D a ta lin k T est sw itch a t S E LF TEST L a m p illu m in a t W ith Self-
c o n n e c to r e d fo r 3 se c. a fte r ig n itio n sw itch 5 D ia g n o sis C h e c k
(M E N O F F -O N e r a n d S ystem
te rm in a l) S e le cto r
L a m p n o t illu m in a te d a fte r 3 sec. B+
T est sw itch a t 0 2 M O N IT O R a t id le
5
L a m p illu m in a te d
T est sw itch at O 2 M O N IT O R at idle
B+
L a m p n o t illu m in a te d
1E o M a lfu n c tio n L a m p illu m in a te d fo r 3 sec. a fte r ig n itio n
B e lo w 2 .5 V
W ith S ystem
in d ic a to r sw itch O F F -*O N S e le cto r test
la m p (M IL ) sw itch at
L a m p n o t illu m in a te d a fte r 3 sec. B+
"S E L F -T E S T ”
L a m p illu m in a te d B e lo w 2 .5 V
L a m p n o t illu m in a te d B +
1F o D a ta lin k B u zze r s o u n d e d fo r 3 sec. a fte r ig n itio n
0.4
• W ith self-
c o n n e c to r s w itch O F F -*O N D ia g n o sis
(FE N
te rm in a l)
B u zze r n o t s o u n d e d a fte r 3 sec. B + C hecker and
S ystem S e le c to r
B u zze r s o u n d e d B e lo w 2 .5 • W ith S ystem
B u zze r n o t s o u n d e d B+ S e le cto r test
sw itch a t S E LF
TEST
1G — — — — — —
1H o Fuel p u m p Ig n itio n sw itch O FF B+
relay
D u rin g c ra n k in g o r a t idle 0 —
11 o D aytim e O N (P a rkin g b ra k e n o t a p p lie d ) B+ • Ig n itio n sw itch

running light ON
O F F (P a rkin g b ra k e a p p lie d ) 0
(Canada)
1J 0 A /C relay Ig n itio n sw itch O N B+

A /C s e n s o r O N a t id le 1.0
A /C s e n so r O FF at id le B+
—
1K o D a ta lin k S ystem S e le cto r te st sw itch at

B+
• W ith system
c o n n e c to r 0 2 M O N IT O R se le cto r
(TEN • Ig n itio n sw itch
S yste m S e le cto r te st sw itch at
te rm in a l) 0 ON
S E L F TEST
1L o R ear w in R ear w in d o w d e fro s te r sw itch O N 0 .2 Ig n itio n sw itch

dow ON
d e fro ste r
R ear w in d o w d e fro s te r sw itch O FF B+
relay
1M o V e h icle V e h ic le s to p p e d V o ltm e te r 4 .0 — 5 .0 o r 0
sp e e d —
s e n so r D riv in g (20 km /h) V o ltm e te r 2 .0 — 3 .0
46U0F1-128
F 1 -8 2
CONTROL SYSTEM F1
B -I-: Battery positive voltage
Incorrect voltage Possible cause
Always OV • ROOM 15A fuse burnt
• Open circuit in wiring from ROOM 15A fuse to PCME terminal 1A
Always OV • Main relay malfunction c r page F1-94
• Open or short circuit in wiring from main relay to PCME terminal 1B
Always OV (starter turns) • Open or short circuit in wiring from ignition switch to PCME terminal 1C

• Open circuit in wiring from ignition switch to data link connector terminal
+B
• Open or short circuit in wiring from data link connector terminal MEN to
PCME terminal 1D
Always B + • Poor connection at PCME connector
• PCME malfunction
Always 5V • PCME malfunction
Always below MIL always ON • Short circuit in wiring from combination meter to PCME terminal 1E
2.5V • PCME malfunction
MIL never ON • Open circuit in wiring from combination meter to PCME terminal 1E
Always below No display on Self- • Main relay malfunction c r page F1-94

2.5 V Diagnosis Checker • Open circuit in wiring from ignition switch to data link connector terminal + B
"8 8 ” displayed and • Open or short circuit in wiring from data link connector terminal FEN to
buzzer sounds PCME terminal 1F
continuously
— —
Always below 2.5V • Engine 15A fuse burnt
• Open or short circuit in wiring from fuel pump relay wire to PCME terminal 1H
Always B + • Daytime running relay malfunction

• Combination switch malfunction
Always OV • Open circuit in wiring from daytime running relay to PCME terminal 11
Always below A/C does not • A/C relay malfunction
2.5V operate • Open circuit in wiring from ignition switch to A/C relay
• Open circuit in wiring from A/C relay to PCME terminal 1J
Air conditioning sensor • Short circuit in wiring from A/C relay to PCME terminal 1J
OFF but A/C operates • PCME malfunction
Always below 1.0V • Short circuit in wiring from data link connector terminal TEN to PCME termi
nal 1K
Always B + • Open circuit in wiring from data link connector terminal TEN to PCME ter
minal 1K
• Open circuit in wiring from data link connector terminal GND to ground
Always OV • Short circuit in wiring from rear defroster switch to PCME terminal 1L
Always B + • Open circuit in wiring from rear defroster switch to PCME terminal 1L
Always OV, 0 km/h, or 4.0—5.0V • Open or short circuit in wiring from vehicle speed sensor to PCME terminal 1M
• Vehicle speed sensor malfunction
46U0F1-129
F 1 -8 3
F1 CONTROL SYSTEM
Terminal Input Output Connectedto Test condition Voltage (V) Remark

1N O Idle switch Accelerator pedal released 0 Ignition switch
Accelerator pedal depressed B+ ON
10 O Stoplight Brake pedal released Ignition switch

switch Brake pedal depressed B+ ON
1P O Steering Ignition switch ON B+

pressure P/S ON (at idle)
sensor
P/S OFF (at idle) B+
10 o Air condi A/C sensor ON Ignition switch

tioning ON and blower
A1C sensor OFF B+
sensor control switch ON
1R O Blower con Blower control switch OFF, 1st or 2nd

B+
Ignition switch
trol switch position ON
Blower control switch 3rd or 4th position Below 1.0
1S O Coolant fan Coolant fan relay ON TEN terminal

relay Coolant fan relay OFF B+ grounded and
idle switch OFF
1T
1U O Headlights Headlights ON B+
switch Headlight OFF
1V O Neutral and Neutral position or clutch pedal
Clutch depressed
switches Others B+
2A Ground Constant
2B Ground' Constant
2C Ground Constant
2D Ground Constant
2E O Distributor Ignition switch ON 0 or 5
(NE signal) Idle Oscilloscope Voltage (V)
ne;
Voltmeter 2.0
2F O Igniter Ignition switch ON
Idle Oscilloscope Voltage (V)
4V
2V f - --
OV I I1
Voltmeter 0.4
46U0F1-130
F 1 -8 4
CONTROL SYSTEM F1

Always OV • Idle switch malfunction
• Short circuit in wiring from idle switch to PCME terminal 1N
Always B + • Idle switch malfunction
• Open circuit in wiring from idle switch to PCME terminal 1N
Always OV (stoplights OK) • Open circuit in wiring from stoplight switch to PCME terminal 10
Always below 1.0V • Steering pressure sensor malfunction c r page F1-95

• Short circuit wiring from steering pressure sensor to PCME terminal 1P
Always B + • Steering pressure sensor malfunction c r page F1-95
• Open circuit in wiring from steering pressure sensor to PCME terminal 1P
• Open circuit in wiring from steering pressure sensor to ground
Always below 2.5V (blower fan OK) • Air conditioning sensor malfunction c r 1994 626/MX-6 body electrical
troubleshooting manual Section G
• Short circuit in wiring from air conditioning sensor to PCME terminal 1Q
• Poor connection at PCME connector
Always B + (blower fan OK) • Air conditioning sensor malfunction c r 1994 626/MX-6 body electrical
troubleshooting manual Section G
• Open circuit in wiring from air conditioning sensor to PCME terminal 10
• Open circuit in wiring from air conditioning sensor to blower control switch
Always below 1,0V (blower fan OK) • Short circuit in wiring from blower control switch to PCME terminal 1R
Always B + (blower fan OK) • Open circuit in wiring from blower control switch to PCME terminal 1R
Always below 1,0V • Open or short circuit in wiring from fan relay to PCME terminal 1S
(Coolant fan OK) • PCME malfunction
— —
Always below 1.OV (Headlights OK) • Open or short circuit wiring from headlights switch to PCME terminal 1U
Always below 1.OV • Neutral and Clutch switch malfunction c r page F1-94, 95
• Short circuit in wiring from PCME terminal 1V to neutral or clutch switch
Always B + • Neutral and Clutch switch malfunction c r page F1-94, 95
• Open circuit in wiring from PCME terminal 1V to neutral or clutch switch
Above OV • Poor contact at ground terminal

• Open circuit in wiring from PCME to ground
Always OV or 5V • Refer to Code No.03 Troubleshooting c r page F1-23
Always OV • Short circuit in wiring from igniter to PCME terminal 2F

Always 5V • Open circuit in wiring from igniter to PCME terminal 2F

• Open circuit in wiring from igniter to ground
46U0F1-131
F 1-8 5
F1 CONTROL SYSTEM
B +: Battery positive voltage
2G O Distributor Ignition switch ON 0 or 5

(G signal) Idle Oscilloscope Voltage (V)
—
20 ms
Voltmeter 1.1
2H — — — — — —
21 — — — — — —
2J o EGR function Idle 3.2—4.9
—
sensor
2K o Throttle Constant 4.5—5.5 Ignition switch
position ON
sensor
2L o Intake air Engine coolant temperature 20°C (68°F) 2.5 Ignition switch
temperature ON
After warmup 1.5
sensor
2M 0 Throttle Accelerator pedal released 0.5 Ignition switch
position Accelerator pedal fully depressed 4.2 ON
sensor (TVO)
2N o Heated Ignition switch ON 0
oxygen Idle (cold engine) 0
sensor
Idle (after warmup) 0 -1 .0 —
Increasing engine speed (after warmup) 0 .5 -1 .0
Deceleration 0
20 o Mass air Ignition switch ON 1.0-1.5
flow sensor —
Engine running 1 .5-5.0
2P — — — — — —
2Q o Engine Engine coolant temperature 20°C (68°F) 2.5 Ignition switch
coolant After warmup 0.5 ON
temperature
sensor
2R o EGR Idle B+ California only
solenoid
valve (vent) Driving B+
2S o EGR solenoid Idle (cold engine) B+ Except California
valve Engine speed 2,000 rpm (after warmup) 1.0
o EGR solenoid Idle B+ California only
valve (vacuum) Driving B+
2T o Pressure Solenoid valve ON
regulator 1.5
Refer to ON condition, page F1—60 —
solenoid
valve Solenoid valve OFF B+
2U o Injector Ignition switch ON B+ *Engine Signal
(No.1) Idle (after warmup) Oscilloscope von«fl«<v) Monitor: Green
and red lamps
flash
5m»
Voltmeter 13.8*
Engine speed Voltmeter B+
above 2,000 rpm
on deceleration
(after warmup)
46U0F1-132
F 1 -8 6
CONTROL SYSTEM F1
Always OV or 5V • Refer to Code No.03 troubleshooting cr page F1—23
— —
— —
— —
Always OV • Poor connection at PCME connector

• Short circuit in wiring from PCME terminal 2K to throttle position sensor
Always OV or 5V • Refer to Code No.11 Troubleshooting cr page F1-26
Always OV after warmup • Refer to Code No. 15 Troubleshooting cr page F1-28

Always 1V after warmup • Refer to Code No.17 Troubleshooting cr page F1-30
Always below 2V or 4V • Refer to Code No.08 Troubleshooting cr page F1-24
— —
Always OV or B + • Refer to Code No.28 Troubleshooting c r page F1-34

• Open or short circuit in wiring from injector to PCME terminal 2U
Always B + • PCME malfunction
46U0F1-133
F1 CONTROL SYSTEM
Terminal Input Output Connectedto Test condition Voltage (V) Remark
2V O Injector Ignition switch ON B+ 1Engine Signal

(No.2) Idle (after warmup) Oscilloscope Monitor: Green
and red lamps
flash
Voltmeter 13.8*
above 2,000 rpm
on deceleration
(after warmup)
2W O Idle air Ignition switch ON B+
control Idle Oscilloscope
valve Voltage (V)
Vb
2X O Purge Ignition switch ON B+

solenoid Voltage (V)
valve 40
20
V!
2Y O Injector Ignition switch ON B+ * Engine Signal

No.3 Idle Oscilloscope Voltage (V) Monitor: Green
go
and red lamps
I
flash
Voltmeter 13.8*
above 2,000 rpm
on deceleration
(after warmup)
2Z O Injector Ignition switch ON B+ * Engine Signal
No.4 Idle Oscilloscope Voltage (V) Monitor: Green
Ol-H-
and red lamps
0*-— flash
-
0-f—
Voltmeter 13.8*
above 2,000 rpm
on deceleration
(after warmup)
46U0F1-134
CONTROL SYSTEM F1

• Open or short circuit in wiring from injector to PCME terminal 2V

• Open or short circuit in wiring from injector to PCME terminal 2Y
Always OV • Main relay malfunction

• Open or short circuit in wiring from injector to PCME terminal 2Z
46U0F1-135
F1 CONTROL SYSTEM
MASS AIRFLOW SENSOR (HEAT RESISTOR TYPE)
Inspection
Caution
• Do not drop the sensor, subject it to sharp shocks,
put or allow anything in it. It is very sensitive and
easily damaged.
1. Disconnect the mass airflow sensor connector.
46U0F1-136
2. Remove the mass airflow sensor. (Refer to page F1-42.)
3. Check for damage of the sensor.
4. Install the mass airflow sensor. (Refer to page F1-42.)
46U0F1-137
6. Disconnect the PCME connectors.
USE CONNECTOR A 7. Connect the SSTs. Engine Signal Monitor and Adapter to
49 9 2 0 0 162 the PCME as shown.
8. Place the SST (Sheet) on the Engine Signal Monitor.
9. Check the voltage of terminal 20.
Specification
Ign—ON
49 G 01 8 903 Condition Engine running
(Engine stopped)
Terminal voltage 1—1.5V 1.5—5V
46U0F1-138
10. If not as specified, replace the mass airflow sensor.
Tightening torque:
7.9—10.7 Nm {80—110 kgfcm, 70—95.4 in-lbf)
CRANKSHAFT POSITION SENSOR

Inspection
1. Remove the distributor. (Refer to Section G.)
2. Disconnect the injector connector.
3. Verify that the distributor connector (6 pin) is disconnected.
4. Connect the distributor connector (4-pin) as shown in figure.

7. Connect the SSTs (Engine Signal Monitor and Adapter Har
ness) to the PCME as shown.
8. Set the SST (Engine Signal Monitor).
9. Rotate the distributor drive by hand and measure the out
put voltage.
46U0F1-140
F 1 -9 0
CONTROL SYSTEM F1
Specification
Signal Terminal Voltage

NE 2E Approx. 5V (4 pulses/rev)
NE 5V
SIGNAL ov JU TTU ^ G 2G Approx. 5V (1 pulse/rev)
G
SIGNAL o v - __________ t l
46U0F1-141
10. After the inspection, install the distributor.
(Refer to Section G.)
11. Start the engine and adjust the ignition tinning.
Tightening torque:
1 9 -2 5 Nm [1 .9 -2 .6 kgfm, 14—18 ft-lbf)
46U0F1-142
ENGINE COOLANT TEMPERATURE SENSOR
Removal
Note
• The engine coolant temperature sensor is at the rear of
the engine.
1. Disconnect the engine coolant temperature sensor con

nector.
2. Remove the engine coolant temperature sensor.
Inspection
ENGINE COOLANT 1. Place the sensor in water with a thermometer and heat the
TEMPERATURE SENSOR water gradually.
Water Resistance (kfl)

20°C I 68°F) 2 2 -2 .7
40°C ( 104°F) 1.0-1.3
60°C ( 140°F) 0.50-0.65
80°C (176°F) 0.29-0.35
36U0F1-120 3. If not as specified, replace the engine coolant temperature

sensor.
Installation
1. Install a new washer and the engine coolant temperature
sensor.
Tightening torque:
25—29 Nm {2.5—3.0 kgf m, 19—21 ft-lbf)
2. Connect the engine coolant temperature sensor connector.

3. Start the engine and check for coolant leakage.
F1-91
F1 CONTROL SYSTEM
INTAKE AIR TEMPERATURE SENSOR
Inspection
1. Disconnect the intake air temperature sensor connector.
2. Check resistance of the sensor.
Temperature Resistance
25°C ( 77°F) 29.7-36.3 kQ
85°C ( 185°F) 3.3—3.7 kO
3. If not as specified, replace the intake air temperature sensor.
46U0F1-201
Replacement
1. Disconnect the intake air temperature sensor connector.
2. Remove the sensor.
3. Install the sensor and tighten it to the specified torque.
Tightening torque:
7.9—11.7 Nm {80—120 kgf-cm, 70—104 in-lbf)
46U0F1-202
THROTTLE POSITION SENSOR
Inspection
1. Disconnect the connector from the throttle position sensor.
2. Connect an ohmmeter between throttle position sensor ter
minal B and C.
36U0F1-124 3. Verify that the resistance increase is linear according to the

( RESISTANCE throttle valve opening angle.
5 (Ml)
Throttle valve condition Resistance (kQ)
4 Closed throttle position Below 1
3 Wide open throttle Approx. 5
2 4. If not as specified, adjust the throttle position sensor.

1 THROTTLE VALVE
OPENING ANGLE
0
Adjustment
WIDE OPEN THROTTLE 1. Connect the SST to the PCME as shown.
46U0F1-144 2. Measure the voltage of terminal 2M.
3. Loosen the sensor screws.
4. Ignition switch ON.
5. Adjust the sensor output voltage by rotating the sensor.
Specification
Condition Terminal voltage (V)

Accelerator pedal released Approx. 0.5
Accelerator pedal fully depressed Approx. 4.1
6. If not as specified, replace the throttle position sensor.

46L10F1-204
F 1 -9 2
CONTROL SYSTEM F1
Replacement
1. Disconnect the throttle position sensor connector.
2. Remove the screws.
3. Remove the throttle position sensor.
4. Install the throttle position sensor.
5. Adjust the throttle position sensor output voltage.
46U0F1-145
Inspection of Terminal voltage
let it idle.
2. Disconnect the heated oxygen sensor connector.
3. Connect a voltmeter between the heated oxygen sensor ter
minal A and a ground.
4. Run the engine at 3,000 rpm until the voltmeter indicates
approx 0.55V.
46U0F1-146
5. Quickly increase and decrease the engine speed several
times. Verify that when the speed is increased, the meter
0
reads 0.5—1.0V, and when the speed is decreased it reads
0V—0.5V.
6. If not as specified, replace the heated oxygen sensor.
Voltmeter o
© ©
46U0F1-147
Inspection of Heated Oxygen Sensor Heater
1. Turn the ignition switch OFF.
3. Connect an ohmmeter between the heated oxygen sensor
terminals C and D as shown.
4. Measure the resistance of the heating element.
Specification: Approx 6fl (at 20°C {68°F})
Replacement
2. Remove the heated oxygen sensor.
Tightening torque:
30—49 N-m (3.0—5.0 kgf-m, 22—36 ft-lbf]
36U0F1-132
F1—93
F1 CONTROL SYSTEM
IDLE SWITCH
Inspection
1. Disconnect the idle switch connector.
2. Check continuity between the switch and a ground.
Throttle valve Continuity

Closed throttle position Yes
Open No
3. If not as specified, check the condition of the wiring har

ness of the idle switch. Replace the idle switch and the throt
tle body (as an assembly), if necessary.
MAIN RELAY
Inspection
1. Verify that main relay clicks when the ignition switch is turned
ON and OFF.
2. Apply battery positive voltage (B+) to terminal A and ground
terminal B of the relay.
3. Check continuity of the relay as shown.
Terminals B + not applied B+ applied
36U0F1-135 C -D No. Continuity Continuity
4. If not as specified, replace the main relay.
COOLANT FAN RELAY

Inspection
2. Ground the TEN terminal of the data link connector.
3. Rotate the throttle link by hand and verify that coolant fan
relays click.
4. Remove the relays.

5. Apply battery positive voltage (B+) to terminal A and ground
terminal B of the each relays.
Terminals B + not applied B+ applied
C -D No continuity Continuity
36U0F1-137
CLUTCH SWITCH
inspection
1. Disconnect the clutch switch connector.
2. Connect an ohmmeter to the switch.
3. Check continuity of the switch.
Pedal Continuity
Depressed Yes
Released No
4. If not as specified, replace the clutch switch.

16E0F1-231
F 1 -9 4
CONTROL SYSTEM F1
Replacement
2. Loosen the locknuts.
3. Remove the clutch switch.
5. Adjust the pedal height. (Refer to Section H.)
NEUTRAL SWITCH
Inspection
1. Disconnect the neutral switch connector.
2. Connect an ohmmeter to the switch.
Transmission Continuity
Neutral Yes
Other ranges No
4. If not as specified, replace the neutral switch.
Replacement
Replace the neutral switch as shown in the figure.
Tightening torque:
20—29 Nm {2.0—3.0 kgfm, 15—21 ft-lbf)
STEERING PRESSURE SENSOR

Inspection
1. Disconnect the steering pressure sensor connector.
2. Connect an ohmmeter to the sensor.
3. Start the engine and run it at idle. Check continuity of the
sensor while turning the steering wheel.
Steering wheel Continuity

Turning Yes
Not turning No
4. If not as specified, replace the steering pressure sensor.
Replacement
Replace the steering pressure sensor as shown in the figure.
Tightening torque:
17—22 N-m (1.7—2.3 kgf-m, 13—16 ft-lbf}
36U0F1-141
F 1-9 5
F1 TROUBLESHOOTING GUIDE
QUICK DIAGNOSIS CHART
Possible Darts and reference page Fuel system Intake

air system Emissioncontrol system Ignitionsystem Control system
.]
Section G
1—CM *
CM
I F1-93
I F1-90
I F1-69
I F1-72
I F1-72
F1-65
F1-62
F1-65
F1-43
F1-16
F1-42
F1-55
F1-55
F1-57
O) 03 §
F1-51
m
F1-15
l l I 1 1 ILH
t- y— T— U
LL LL LL LL ul LL CD
EGR control valve, EGR function control


Ignition coil (in distributor)
Idle speed misadjustment
Throttle position sensor

Heated oxygen sensor
Check valve (two-way)
Vehicle speed sensor

Igniter (in distributor)
Mass airflow sensor

EGR solenoid valve
Air cleaner element
Three-wav catalyst
Pressure regulator
High-tension lead
Charcoal canister
Fuel vapor valve
Fuel pump relay
Ignition timing
Throtle body
Air leakage
Spark plug
Fuel pump
PCV valve
Distributor
Fuel filter
Injector
Item
I
I
I
I
I
|
I
I
I
I
I
I
I
I
|
I
I
|
|
|
|
1 Melts main or other fuse O0 0 00 O O 0 0
2 Will not crank or cranks slowly
3 Cranks No combustion Oo O O
normally Partial combustion — when engine
4 but will not
cold
o 0 OO0 o
start Partial combustion — after
5
warm-up
o
7 Cranks nor Any engine temp. o o o
8 mally but When engine cold 0 o O
9 hard to start After warm-up o
10 Engine Idle at any engine temp. ooO O o 0O Oo o oo
11 stalls During fast idle 00o
12 Idle after warm-up 0 o
13 Idle with A/C, P/S, and/or E/L ON
Idle when shifted from N or P to
14
other ranges
15 Driveaway o o O oO o
16 On acceleration o Oo o o o
17 While cruising oO oo o
18 On deceleration oO OO o o o o
19 Engine Idle at any engine temp. o 0O 0 0 oo0 00 00 00
20 rough During fast idle O
21 Idle after warm-up o 0o
22 Idle with A/C, P/S, and/or E/L ON o
Idle when shifted from N or P to o
23
other ranges
24 On deceleration 0
25 Poor ac Driveaway o o o o o
26 celeration On acceleration o o o o o o
27 High idle speed after warm-up o 0O
*1 1994 626/MX-6 Body Electrical Troubleshooting Manual
F 1 -9 6
TROUBLESHOOTING GUIDE F1
Control system Possible parts and reference page
Section G
I 1-1-94,95
Section E
LO
*
CO
* * * *
F1-94
o> 2 ■*r co s 5 2 2 2 2
1— l 1 LU 1 h- l~
I LJJ I- I— \—
1— t— h- LU LU LU LU LU
LL CD LL LL CQ LL CD CD CD CD CD
I
I Starter, Starter interlock switch

I Coolant fan relay (Nos.1, 2)
Clutch and neutral switches
I Steering pressure sensor
I Air conditioning sensor
| Rear window defroster

I Idle air control valve
I PRC solenoid valve
Condeser fan relay
IHeadlight switch
I Stoplight switch
1 Blower switch
I Main relay
I A/C relay
I PCME
Item
OO O OO O oO
Melts main or other fuse
O oO 1
o Will not crank or cranks slowly 2
O O No combustion Cranks normally but will not start 3
O Partial combustion — when engine cold 4
O Partial combustion — after warm-up 5
O Any engine temp. Cranks normally but hard to start 7
O When engine cold 8
O After warm-up 9
O Idle at any engine temp. Engine stalls 10
During fast idle 11
O O Idle after warm-up 12
O OOO O Oo Idle with A/C, P/S, and/or E/L ON 13
OO Idle when shifted from N or P to other ranges 14
O Driveaway 15
O On acceleration 16
O O While cruising 17
O OO 0 On deceleration 18
OO Idle at any engine temp. Engine rough 19
0 During fast idle 20
O O Idle after warm-up 21
0 00 O o 00 Idle with A/C, P/S, and/or E/L ON 22
Idle when shifted from N or P to other ranges 23
On deceleration O 24
Dffiteaway O Poor acceleration 25
00 High idle speed after warm-up 27
F 1 -9 7
Possible parts and reference page Fuel system Intake

air ayatem Emissioncontrol system Ignitionsystem Control system
' ■
Section G
*
in in CVJ CD'CO m LO m CM o
1 F1-92
I F1-93
I F1-90
F1—72
I F1-69
I F1-62
F1-52
5> 05
F1-51
in in in T—^ i—CO CD h-
I I I I I J_ 7— 1 1 1 1 y— I I I I LU
T— T— T— i—
Li- U_ LL LL LL LL LL LL LL LL LL. LL LL LL CO
EGR control valve, EGR function control


I Idle speed misadjustment
Headted oxygen sensor

Throttle position sensor
Check valve (two-way)
Vehicle speed sensor

Igniter (in distributor)
Mass airflow sensor

EGR solenoid valve
Air cleaner element
Three-way catalyst
I Pressure regulator
Charcoal canister
High-tension lead
Fuel vapor valve
Fuel pump relay
Ignition tinning
>
■O
I Air leakage
Spark plug
I Fuel pump
o
PCV valve
Distributor
n
I Fuel filter
a)
Injector
o
x:
i-
Item \
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
|
f
f
28 Idle fluctuates/idle hunts O o 0 O O
29 Hesitates/Stumbles on acceleration OooO o O OO o 0 0
30 Surges while cruising 0 O O
31 Lack of power 0 O O o O o
32 Poor fuel economy O o O
33 A/C does not work
34 Knocking/Pinging
35 Fuel odor O ooO
36 Exhaust sulfur smell
37 High oil consumption 0
38 Self-Diagnosis Checker flashes 88
39 MIL never ON
F1—98
Control system Possible parts and reference page
I F1-94, 95
Section G
Section E
B E TM "
* * * ■K *
F1-95 2 ^r
F1-46
00 s 2 2 G)
i— I LU I ILU
— I— I-- I— I
LU I— LU LU LU
CO LL CD LL CD CD CD CD LL
|
Starter, Starter interlock switch

Coolant fan relay (Nos.1, 2)

Steering pressure sensor
Rear window defroster

Air conditioning sensor
PRC solenoid valve
Condeser fan relay
Headlight switch
Stoplight switch
Blower switch
Main relay
A/C relay
PCME
Item
I
[
I
I
I
I
I
I
I
|
|
|
oO Idle fluctuates/idle hunts 28

O Hesitates/Stumbles on acceleration 29
O Surges while cruising 30
Lack of power 31
Poor fuel economy 32
oo O o A/C does not work 33
Knocking/Pinging 34
Fuel odor 35
Exhaust sulfur smell 36
High oil consumption 37
Self-Diagnosis Checker flashes “ 88” 38
MIL never ON 39
*1 1994 626/MX-6 Body Electrical Troubleshooting Manual 46U0F1-153
F1 TROBLESHOOTING GUIDE
RELATIONSHIP CHART
'V OUTPUT DEVICE
VALVE
MALFUNCTION INDICATOR LIGHT (MIL)

CONTROL
INJECTOR
(DIAGNOSTIC TROUBLE CODE) AND

[IDLE AIR CONTROL VALVE]
PURGE CONTROL SOLENOID
SELF-DIAGNOSIS CHECKER
A/C RELAY (A/C CUT-OFF)
PRESSURE REGULATOR
VALVE
FAN RELAY
FUEL PUMP RELAY
SOLENOID VALVE
(MONITOR LAMP)
FUEL INJECTION
FUEL INJECTION
EGR SOLENOID
BAC VALVE
COOLANT
AMOUNT
IGNITER
TIMING
INPUT DEVICE
CRANKSHAFT
NE SIGNAL 0 0 O0 O OO O O
POSITION SENSOR
G SIGNAL 0 0
IDLE SWITCH o o O o 0 0 0 O
THROTTLE POSITION SENSOR o o O o 0 o
MASS AIRFLOW SENSOR 0 o o o o o
ENGINE COOLANT TEMPERATURE SENSOR o o o o o o o o o
INTAKE AIR TEMPERATURE SENSOR 0 o o o
HEATED OXYGEN SENSOR o o o o
AIR CONDITIONING SENSOR o o o 0
STEERING PRESSURE SENSOR o o
IGNITION SWITCH (START SIGNAL) o o 0 o o o o o o
STOPLIGHT SWITCH o
E/L SIGNAL* o o
NEUTRAL AND CLUTCH SWITCHES o o o o o
DATA LINK CONNECTOR (TEN TERMINAL) o o o o o o
VEHICLE SPEED SENSOR 0
DAYTIME RUNNING LIGHT (CANADA) o
EGR FUNCTION SENSOR 0
46U0F1-154
* E/L SIGNAL: Blower fan control switch third position or higher, headlight ON, rear window defroster ON or coolant
fan ON.
F 1-1 00
Output devices and Engine condition
\ E N G I N E CONDITION CRAN WAR IG: ON

KING MING MEDIUM LOAD (EN
UP ACCE DECE
HEAVY GINE
(COLD (DUR LERA LERA IDLE REMARK
LOAD NOT
EN ING TION TION
COLD WARM RUNN
GINE) IDLE) ING)
OUTPUT DEVICE \
FUEL
IN Fuel No Injec “Engine speed:
INJECTION Rich Normal Rich Normal
JECTOR cut* tion Above 1,500 rpm
AMOUNT
FUEL PUMP RELAY ON OFF
Fixed at
IGNITER BTDC Advanced: depends on engine condition
6°
PURGE CONTROL ON
OFF OFF
SOLENOID VALVE (Purge)
EGR SOLENOID VALVE 'Engine speed:

OFF ON* OFF
(EXCEPT CALIFORNIA) 1,300— 4,500 rpm
EGR SOLENOID VALVE ON*

O N* O N* •Engine speed:
(VACUUM) OFF (Closed OFF
(Fixed) (Fixed) 1 ,0 0 0 -4 ,2 5 0 rpm
(CALIFORNIA) loop)
ON
EGR SOLENOID VALVE ON
OFF (Closed OFF ON
(VENT) (CALIFORNIA) (Fixed)
loop)
PRESSURE REGULATOR OFF •During hot start
CONTROL SOLENOID O N* OFF
(Vacuum to presure regulator) only
VALLVE
ON
ON ON
IACV (Closed OFF
(Closed loop duty) (Fixed duty)
BAC oop duty)
VALVE
AIR VALVE OPEN CLOSED —
OFF OFF
A/C RELAY (A/C ON (A/C ON OFF
cut) cut)
46U0F1-155
F1-101
USING THIS SECTION
Introduction
Most of the fuel and emission control systems are electronically controlled, often making it difficult to diag
nose problems, especially intermittent problems. Before undertaking actual checks, take a few minutes
to talk with a customer who approaches with a drivabilitiy complaint. The customer is often a good source
of information on such problems, especially the intermittent ones. Through a talk with the customer, you
will usually find out what the symptoms are and under what conditions they occur.
Work flow
CHECK IN
LISTEN TO CUSTOMER COMPLAINTS
REFER TO TROUBLESHOOTING PAGE THAT- DIAGNOSTIC INDEX

CORRESPONDS TO ACTUAL SYMPTOM (Refer to page F1-104)
CHECK FOR WHAT IS BAD IN SYSTEM- INSPECTION
CHECK FOR WHAT PART IS BAD- ACTION
REPAIR/REPLACE-
— ----------DETERMINE IF TROUBLE HAS BEEN ELIMINATED

No Yes[
CHECK OUT
46U0F1-156
Diagnostic index
Description:
symptom.
F 1-102
Troubleshooting chart
ENGINE STA LLS • ID L E WITH A /C , P/S , a n d /o r E/L ON
| ‘ IDLE WHEN SHIFTED FROM N OR P TO OTHER
I RANGES
• Engine slops unexpectedly when A/C, P/S. and/or E/L turned ON at idle
DESCRIP • Engine stops unexpectedly when shifted from N or P to other ranges at idle
TION • Idle condition is normal when A/C. P/S. and E/L are OFF and in N and P
[TRO U BLESH O O TIN G HINTS]

© Monitor switch functions (SST) • Blower switch
• A/C sensor (2> Solenoid valve (ISC)
• Headlight switch • Solenoid valve stuck
• Rear w indow defroster
INSPECTION
Are switches correct when checked by using Self- Go to next step
Diagnosis Checker monitor lam p while ignition
switch ON?
r r page F 2 -4 4
Lamp not ON/OFF with specified switch
• Blower switch
C heck for cause (Refer to specified
• Headlight switch
check sequence) = page F 2 -4 S
• Rear w indow defroster switch
• Selector lever
SYSTEM SELECTOR
~ SE LE CT SW: A
Is " 0 0 " displayed on Sell-Diagnosis Checker with

ignition switch ON?
r r page F 2 -1 8
16E0F1-256
DESCRIPTION: ^
Further describes the system. Confirm that the chart addresses the actual symptom before beginning
troubleshooting.
TROUBLESHOOTING HINTS:
This describes the possible point of malfunction.
STEP:
This shows the order of troubleshooting. Proceed with troubleshooting as indicated.
INSPECTION:
This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is
necessary to perform the INSPECTION, refer to the page specified by the “ c r ” mark.
ACTION:
This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to per
form the action is described on the reference page specified by the “cr " mark.
16E0F1-257
F1-103
DIAGNOSTIC INDEX
TROUBLESHOOTING ITEM
D P ^ P R IP T IO N PAGE
No. TROUBLE
1 Melts main or other fuse F I—107
Will not crank or cranks slowly Starter does not work
2 Section G
Starter cranks engine at slow speed
Cranks normal No combustion Starter cranks engine at normal speed but engine
3 F1-108
ly but will not shows no indication of firing
start Partial combustion Starter cranks engine at normal speed and engine
— when engine coldz shows indication of firing but will not run when en
4 gine is cold or at initial starting F1-108
Engine will not continue running when cold when ig
nition switch is returned from STA to IG position
Partial combustion Starter cranks engine at normal speed and engine
— when engine warm shows indication of firing but will not run when en
5 gine is warm F1-110
Engine will not continue running when warm when
IGN switch is returned from STA to IG position
Cranks nor Any engine temp. Starter cranks engine at normal speed but engine re
mally but hard quires excessive cranking time before starting at any
6 to s tart engine temperature
Engine starts after stalling a few times at any engine
temperature
When engine cold Starter cranks engine at normal speed but engine re
quires excessive cranking time before starting when F1-111
7 engine is cold
Engine starts after stalling a few times when engine
is cold
After warm-up Starter cranks engine at normal speed but engine re
8 quires excessive cranking time before starting after
warm-up
Engine stalls Idle at any engine Engine stops unexpectedly at any engine temp.
9
temp.
F1-113
10 During fast idle Engine stops unexpectedly during fast-idle operation
11 Idle after warm-up Engine stops unexpectedly at idle after warm-up
Idle with A/C, P/S, Engine stops unexpectedly when A/C, P/S, and/or
12 F1-116
and/or E/L ON E/L turned ON at idle
13 Driveaway Engine stops unexpectedly upon driveaway F1-117
On acceleration Engine stops unexpectedly at begining of accelera
14
tion or during acceleration F1-118
15 While cruising Engine stops unexpectedly while cruising
On deceleration Engine stops unexpectedly at begining of decelera
16 F I—120
tion or recovery from deceleration exhaust afterburn
Engine rough Idle at any engine Engine speed fluctuates between specified idle
temp. speed and lower speed and excessive engine shake
17 at any engine temp.
Idle speed too slow and excessive engine shake at
any engine temp.
During fast idle F1-122
18 Fast idle speed too slow and excessive engine shake
during fast idle, but returns to normal after warm-up
Idle after warm-up Engine speed fluctuates between specified idle
19 speed and lower speed and excessive engine shake
at idle after warm-up
Idle with A/C, P/S, Engine speed fluctuates between specified idle
20 and/or E/L ON speed and lower speed and excessive engine shake F1-126
at idle when A/C, P/S, and/or E/L ON
On deceleration Engine shakes at begining of deceleration, during
21 deceleration, or recovery from deceleration F1-128
Exhaust afterburn
F 1-104
DESCRIPTION PAGE
No. TROUBLE
Poor Driveaway Engine speed increases normally but vehicle speed
22
acceleration slowly increases during driveaway
F1-130
On acceleration Engine speed increases normally but vehicle speed
23
slowly increases during acceleration
High idle speed after warm-up Idle speed continues at fast idle after warm-up Engine
24 F1-132
returns slowly to idle after acceleration is released
Idle fluctuates/idle hunts Engine speed changes back and forth between
25 F1-133
specified idle speed and higher speed
Hesitates/Stumbles on acceleration Momentary pause at begining of acceleration or dur
26 F1-135
ing acceleration
Surges while cruising Momentary minor irregularity in engine output at
27 F1-138
steady vehicle speed
Lack of power Performance poor under load (i.e., power down
28 F1-139
when climbing hills)
29 Poor fuel economy Fuel economy unsatisfactory F1-140
A/C does not work A/C compressor magnetic clutch does not engage
30 F1-140
when Air conditioning sensor
Knocking/Pinging Sound produced when air/fuel mixture is ignited by
31 something other than spark plug (i.e., hot spot in F1-140
combustion chamber)
32 Fuel odor Gasoline fuel smell or visible leaks F1-141
33 Exhaust sulfur smell Rotten egg smell from exhaust F1-141
34 High oil consumption Oil consumption excessive F1-141
35 Self-Diagnosis Checker flashes 88 Checker flashes 88 with test connector grounded F1-141
MIL never ON Self-Diagnosis Checker indicates Diagnostic Trouble
36 F I—141
Code No. but MIL never ON
46U0F1-157
F 1-105
Description of Drivability Problems
STUMBLE : Mildly irregular performance during acceleration.
HESITATION : A dip or flat spot in performance just after the accelerator pedal is depressed.
SURGE : Continuous irregular performance during cruising.
Fuel Pressure Release and Servicing Fuel System
Warning
Warning
this, always complete the following "Fuel Line Safe
ty Procedures” .

B. Avoid leakage.
C. Install hose clamps to secure the fuel pressure gauge to
the fuel filter and the main hose.
F 1-1 06
SYMPTOM TROUBLESHOOTING
MELTS MAIN OR OTHER FUSE

[TROUBLESHOOTING HINTS]
Check the condition of the fuse
Shorted harness Deterioration
Repair shorted harness and replace fuse Replace fuse

FUSE
Damaged Fuse Related Wiring Harness

MAIN (100A) Main fuse- Alternator
BTN (60A) BTN fuse- ROOM fuse
ROOM (15A) ROOM fuse- • PCME terminal 1A
EGI INJ (30A) Main relay- Injectors

PCME terminal 1B
Distributor
PRC solenoid valve
EGR solenoid valve
Mass airflow sensor
ENGINE (15A) ENGINE fuse- Main relay

Fuel pump relay
METER (15A) METER fuse- Data link connector terminal +B
WIPER (20A) WIPER fuse- Heated oxygen sensor
46U0F1-161
F 1-107
3 CRANKS NORMALLY BUT WILL NOT START •N O COMBUSTION

• Starter cranks engine at normal speed but engine shows no indication of firing
DESCRIP
TION
© Distributor
• Poor conection of connector
• Open in ignition coil C7- Section G
© Main relay
• Poor connection of connector
• Malfunction of relay c r page F1-94
© PCME
• No IGT signal output from PCME terminal 2F to igniter (in distributor) c r Section G
•N o START signal from ignition switch (Open in PCME 1C terminal circuit)
46U0F1-162
4 CRANKS NORMALLY BUT WILL NOT START •PARTIAL COMBUSTION - WHEN ENGINE COLD
• Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine is
cold at initial starting
DESCRIP • Engine will not continue running when cold when ignition switch is returned from STA to IG position
TION • Refer to "ENGINE STALLS” if this symptom appears after engine stalls
• Fuel in tank
• Battery in terminal condition
© BAC valve © Distributor
• Malfunction of air valve • Cap and/or rotor damaged
• Idle air cintrol valve stuck «Poor connection of connector
© Injector © Mass airflow sensor
• Poor connection • Poor connection of connector
© Fuel pump relay © PCME
•Poor connection «No START signal from ignition switch
© Fuel pump (Open in PCME 1C terminal circuit)
1 Is “ 00” displayed on SST with ignition switch Yes “ 00” or displayed
ON?
c r page F1-18 Go to next step
SYSTEM SELECTOR
No Diagnostic Trouble Code No.

displayed
Check for cause (Refer to specified
MONITOR check sequence)
LAMP c r page F1-20
SELECT SW: A
“ 88” flashes
Refer to "No.38 SELF-DIAGNOSIS
CHECKER FLASHES 88”
2 Does engine start when throttle valve held Yes Check air valve operation
q uarter open? c r page F1—46
No Go to next step
F 1-1 08

3 Do Engine Signal Monitor lamps flash for Yes Go to next step
specified terminals while cranking engine?
c r pages F1-86
No Check as follows according to results:
F1-88
Does not flash and OV indicated for
individual terminals
Terminal: 2U, 2V, 2Y, 2Z
• Continuity of injector
•Continuity between PCME and in
jectors)
• Condition of injector connector and
PCME connector female terminals
Repair or replace parts and/or wir
ing harness as necessary
4 Connect jumper w/ire betweer F/P and GND ter- Yes Check as follows:
minals of data link COnnector; will engine start? •1H terminal voltage at PCME c r page F1-82
• Continuity between 1H terminal
and fuel pump relay connector
• terminal
\ •Condition of PCME and fuel pump
m M
relay connector female terminals
GND F/P j \m jj
\ DATA LINK
\ CONNECTOR No Check if fuel pump operating sound
is heard
— f t • If yes, go to next step
• If no, check fuel pump and wiring
f \ harness c r page F1-52
I / V . _
5 Are mass airflow sensor terminal voltage at Yes Go to next step
PCME correct?
c r pages F1-86
No Check as follows:
• Ground of mass airflow sensor
2 0 terminal: 1.0—1.5V (Ign. ON) • Continuity between mass airflow
1.5—5.0V (Engine running) sensor and PCME connector
• Condition of mass airflow sensor
and PCME connector female ter
minals
6 Connect data link connector terminals F/P and Yes Go to next step
GND with a jumper wire; is fuel line pressure
correct with ignition switch ON? No Low pressure
c r page F1-49
Check fuel line pressure while
pinching fuel return hose
Fuel line pressure: • If pressure quickly increases,
260—320 kPa (2.7—3.3 kgf/cm2, 37—46 psi) check pressure regulator cr page F1-55
• If pressure gradually increases,
check for clogging between fuel
pump and pressure regulator
pump maximum pressure cr page F1-53
F1-109

7 Is a strong blue spark visible at each disconnect Yes Go to next step
ed high-tension lead while cranking engine?
No Check as follows
• Distributor cap and rotor c r Section G
• High-tension leads c r Section G
8 Are injectors OK? Yes Go to next step

• No fuel leakage c r page F1-58
• Injectors not clogged c r page F1-57
No Replace injector(s)
c r page F1-57
9 Try a known good PCME; does condition

improve? c r page F1-81
46U0F1-163
5 CRANKS NORMALLY BUT WILL NOT START •PARTIAL COMBUSTION — AFTER WARM UP
• Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine is warm
DESCRIP • Engine will not continue running when ignition switch is returned from STA to IG position
TION
© Pressure regulator
• Hold fuel pressure low c r page F1-56
© Throttle body
• Carbon ON throttle valve c r page F1 -4 3
46U0F1-164
F 1-1 10
TROUBLESHOOTING GUIDE F 1
6, 7, 8 CRANKS NORMALLY BUT HARD TO START •ANY ENGINE TEMP

•WHEN ENGINE COLD
•AFTER WARM-UP
• Starter cranks engine at normal speed but engine requires excessive cranking time before starting
DESCRIP • Engine starts after stalling a few times
TION • Battery in normal condition
• Engine runs normally at idle (if idle condition not OK, refer to “ Rough idle” [Nos. 19—23])
© Injector © EGR solenoid valve
• Fuel leakage from injector(s) • Solenoid valve stuck
© Fuel pump © EGR control valve
• Malfunction of pump •EGR control valve stuck
© Pressure regulator © EGR function control (Except California)
• Pressure regulator stuck • EGR function control stuck
© Spark plug ©PCME
• Dirty or worn spark plug(s) • No START signal from ignition switch
© PRC solenoid valve (Open in PCME 1C terminal circuit)
• PRC solenoid valve
© Throttle body
• Carbon on throttle plate
Is “ 00” displayed on SST with ignition switch Yes “ 00” displayed
ON?
SYSTEM SELECTO R

49 H 018 9A1 displayed
MONITOR-#--? Check for cause (Refer to specified
L A M P -5 .^ check sequence)
S E L E C T SW : A c r page F1-20
"8 8 ” flashes
Refer to “ No.38 SELF-DIAGNOSIS
Connect data link connector terminals F/P and Yes Go to next step
c r page F1-49 Check fuel line pressure while pinching
fuel return hose
260—320 kPa (2.6—3.3 kgf/cm2, 37—46 psij check pressure regulator c r page F1-55
check for clogging between fuel pump
and pressure regulator
If hose not clogged, check fuel pump
DATA LINK maximum pressure c r page F1-53
CONNECTOR
F1-111

3 Is fuel line pressure held after ignition switch Yes • If symptom occurs at any engine
turned OFF? temp., go to Step 6
c r page F1-48 • If symptom occurs when engine
cold, go to next step
Fuel line pressure: • If symptom occurs after warm-up,
More than 150 kPa [1.5 kgf/cm2, 21 psi) go to Step 6
for 5 min.
No Plug outlet of pressure regulator,
Is fuel line pressure held after
ignition switch turned OFF? c r page F1-48
• If yes, replace pressure regulator c r page F1-56
• If no, check fuel pump hold
pressure c r page F1-52
If fuel pump OK, check injectors for
fuel leakage c r page F1-58
4 Is throttle body clean internally? Yes Clean throttle body
No Go to next step
5 Disconnect vacuum hose from EGR valve and Yes Check as follows:
plug it; does condition improve? • EGR solenoid valve for sticking
• Condition of solenoid valve
connector female terminal(s)
• EGR function control for sticking
(Except California)
No Check if EGR control valve moves

EGR CONTROl' ^ ^ E ^ ^ ^ ^ ^ smoothly c r page F1-65
• If yes, go to next step
•If no, replace EGR valve c r page F1-65
6 Try a known good PCME; does condition
46U0F1-165
F 1-112
9, 10, 11 ENGINE STALLS •IDLE AT ANY ENGINE TEMP
•DURING FAST IDLE
•IDLE AFTER WARM-UP
• Engine stops unexpectedly at idle and/or during fast idle operation
DESCRIP
TION
© Injector (D Distributor (8) EGR control valve
• Fuel leakage from injector(s) • Cap and/or rotor damaged • EGR control valve stuck
• Injector(s) clogged • Poor connection of connector (D BAC valve
@ Fuel pump © Mass airflow sensor • Air valve stuck
• Maximum pressure low • Poor connection of connector @ EGR function control
(3 ) Fuel pump relay @ Engine coolant temperature sensor (Except California)
• Poor connection of connector • Poor connection of connector • EGR modulator valve stuck
@ Air leakage in intake air system
STEP __________________ INSPECTION_________ ACTION
Is "0 0 ” displayed on SST with ignition switch Yes ‘00” displayed
ON? * If symptom occurs at idle at any
c r page F1-18 engine temp., go to next step
* If symptom occurs during fast idle
operation, go to Step 8
*lf symptom occurs at idle after
warm-up, go to Step 9
SYSTEM SELECTOR
displayed
check sequence)
49 H018 9A1
c r page F1-20
“ 88” flashes
SELECT SW: A Refer to ” No.38 SELF-DIAGNOSIS
No indication at all
CHECKER WILL NOT WORK"
Do Engine Signal Monitor lamps flash for Yes Go to next step
specified terminals while cranking engine?
c r pages F1-86
No Check as follows according to
F1-88 results:
Do not flash and OV indicated for in
Terminal: 2U, 2V, 2Y, 2Z dividual terminal(s)
• Continuity of injector(s)
• Continuity between PCME and
injector(s)
• Condition of injection connector and
PCME connector
Repair or replace parts and/or wiring
harness as necessary
Is strong blue spark visible at each disconnected Yes Go to next step

high-tension lead while cranking engine?
No Check as follows;
• High-tension lead(s) c r Section G

4 Connect jumper w ire between F/P and GND ter- Yes Check as follows:
minal of data link con nector; will engine run? • 1H terminal voltage, at PCME c r page F1-82
• Continuity between 1H terminal and
fuel pump relay connector terminal
\ • Condition of PCME and fuel pump re
lay connector female terminals
UNU h/K J ^
4 \\\ DATA LINK No Check if fuel pump operating sound
CONNECTOR
is heard?
-— iftr • If no, check fuel pump circuit
GND with a jumper wire; is fuel line pressure cor
rect with ignition switch ON? No Low pressure
c r page F1-49
Check fuel line pressure while pinch
ing fuel return hose
270—310 kPa (2.7—3.2 kgf/cm2, 39—46 psi) check pressure regulator c r page F1-55
6 Is air leakage felt or heard at intake air system com Yes Repair or replace
ponents while racing engine to higher speed?
No Go to next step
7 Is engine compression correct? Yes Go to Step 9

c r Section B1
No Check for cause c r Section B1
Engine compression (Minimum):
820 kPa (8.4 kgf/cm2, 120 psi)-300 rpm
8 Does engine start with throttle valve held quarter Yes Check as follows:
open? • Operation of air valve c r page F1-46
• Operation of EGR control valve c r pages F1-65
F1-67
• Operation of EGR function control
(Except California) c r page F1-65
No Go to next step
9 Does following terminal voltage at PCME increase Yes Go to next step

smoothly?
c r page F1-86
• Ground of engine coolant temperature
Terminal 2Q voltage: Approx. 0.5—2.5V sensor
• Continuity between engine coolant
temperature sensor and PCME con
nector
• Condition of engine coolant
temperature sensor and PCME
connector female terminals
F 1-1 14

10 Are spark plugs OK? Yes »lf symptom occurs at any engine
WEAR AND CARBON cr Section G temp., go to Step 14
BURNT • If symptom occurs fast idle opera
PLUG
GAP tion, go to Step 14
►If symptom occurs at idle after
warmup, go to next step
DAMAGE AND
DETERIORATION
No Clean or replace cr Section G
DAMAGE
11 Is resistance of idle air control valve correct? Yes Go to next step

cr page F1-46
Resistance: 7.7—9.30 (at 20°C (6 8 °F ))
No Replace BAC valve cr page F1-42
BAC VALVE
12 Try a known good BAC valve; does condition im Yes Replace BAC valve cr page F1-42
prove?
No Reinstall BAC valve and go to next

step
13 Is the heated oxygen sensor operation OK? Yes Go to next step

cr page F1-93
• Poor connection of engine coolant
temperature sensor connector
MEASURING
TERMINAL

•N o fuel leakage cr page F1-58
• Injectors not clogged cr page F1-57
No Replace injector(s) cr page F1-57
15 Try a known good PCME; does condition improve?

cr page F1-81
46U0F1-166
12 ENGINE STALLS •IDLE WITH A/C, P/S, and/or E/L ON

• Engine stops unexpectedly when A/C, P/S, and/or E/L turned ON at idle
DESCRIP • Idle condition is normal when A/C, P/S, and E/L are OFF
TION
• Air conditioning sensor (2) Idle air control valve
Are switches correct when checked by using SST Yes Go to next step
monitor lamp or indicator while ignition switch ON?
c r page F1-38 No Lamp not ON/OFF with specified switch
Check for cause (Refer to specified check
• Blower switch sequence) c r page F1-39
• Rear window defroster switch
• Air conditioning sensor
Is "0 0" displayed on SST with ignition switch Yes “ 00” displayed
ON?
SYSTEM SELECTOR

displayed
49 H 018 9A1
check sequence)
MONITOR'/
c r page F1-20
- j ^ L A M P HjL-
SELECT SW: A “ gg” flashes
CHECKER FLASHES "88”
Is terminal voltage at PCME correct at idle? Yes Check BAC valve and replace c r page F1-46
c r p a g e F 1 —8 8
2W terminal:
£ vs No Try a known good PCME and check if

condition improves c r page F1-81
46U0F1-167
F 1-1 16
13 ENGINE STALLS * DRIVEAWAY
• Engine stops unexpectedly upon driveaway
DESCRIP • Idle condition normal
TION
© Injector © Fuel filter © Engine coolant temperature sensor
• Fuel leakage from injector(s) • Fuel filter clogged • Poor connection of connector
• Injector(s) clogged @ Distributor
© Pressure regulator • Poor connection of connector
• diaphragm damaged • Cap and/or rotor damaged
Is “ 00" displayed on SST with ignition switch Yes “ 00” displayed
ON?
cr page F1-18 Go to next step
SYSTEM SELECTOR
displayed
49 H01 8 9A1
check sequence)
MOS | f y cr page F1-20
SELECT SW: A
“ 88” flashes
CHECKER FLASHES 88"
Using Engine Signal Monitor, do voltage reading Yes Go to next step
and lamp operation change as follows upon
driveaway? c r page F1-81
Terminal Condition
• Condition of female terminals in related
20 Voltage gradually increases connector
2Q Do not suddenly change • Continuity between injector connector
voltage and PCME connector
2U, 2V, Flashing of green and red
2Y, 2Z lamps becomes quicker
cr page F1-49 Check fuel line pressure while pinching
fuel return hose
Fuel line pressure: • If pressure quickly increases, check
260—-32QkPa (2.6—3 .3 kgf/cm2, 37—46 psi) pressure regulator cr page F1-55
• If pressure gradually increases, check
for clogging between fuel pump and
pressure regulator
maximum pressure cr page F1-53
INSTALL CLANMPS
Are injectors OK? Yes Try a known good PCME; does condi
• No fuel leakage cr page F1-58 tion improved? c r page F1-81
• Injectors not clogged cr page F1-57 No Replace injector cr page F1-57
46U0F1-168
F 1 TROUBLESHOOTING GUIDE
14, 15 ENGINE STALLS *ON ACCELERATION/WHILE CRUISING

• Engine stops unexpectedly at beginning of acceleration or during acceleration
DESCRIP • Engine stops unexpectedly while cruising
TION
© Fuel pump © Mass airflow sensor
© Pressure regulator © Main relay
• Diaphragm damaged • Poor connection of connector
© Distributor
• Cap and/or rotor damaged
1 Is "00" displayed on SST with ignition switch Yes “ 00" displayed
ON?
SYSTEM SELECTOR

displayed
1 Check for cause (Refer to specified
MONITOR check sequence)
LAMP c r page F1-20
SELECT SW: A <<gg” flashes
CHECKER FLASHES "88"
2 Is a strong blue spark visible at each disconnected Yes Check spark plugs c r Section G
high-tension lead while cranking engine? => If OK, go to next step
==> If not OK, clean or replace spark
plug
• Condition of distributor connector
y 1 female terminals
3 Are mass airflow sensor connector terminals and Yes Go to next step
connection good? c r page F1-90
No Repair connector terminal(s)
4 Ground terminal F/P of data link connector with ig Yes Go to next step
nition switch ON;
is operation sound of fuel pump heard? No Check as follows:
• Poor connection of fuel pump relay
\ \ \\ \ • Poor connection of fuel pump con-
GND
A k v |\\ \
F/P J ,[ W \DATA LINK
nector
• Melted EGI INJ fuse (30A) c r page F1-107
Refer to "No.1 - MELTS MAIN OR
OTHER FUSE"
• Poor connection of main relay
•Operation of main relay cr page F1-94
F 1-1 18
cr page F1-55
No Check pressure regulator cr page F1-55
Fuel line pressure:
210—250 kPa [2.1—2.6 kgf/cm2, 30—36 psi)
Fuel line pressure:

260—320 kPa (2.6—3.3 kgf/cm2, 37—46 psi)

cr page F1-81
46U0F1-169
16 ENGINE STALLS •ON DECELERATION

• Engine stops unexpectedly at beginning of deceleration or recovery from deceleration
DESCRIP • Exhaust afterburn
TION
© Fuel pump © Idle air control valve
• Poor connection of connector • Solenoid valve stuck
© Idle speed © EGR control valve
• Idle speed too low • Solenoid valve stuck
© Distributor • EGR control valve stuck
• Poor connection of connector © EGR function control (Except California)
@ Mass airflow sensor • EGR function control stuck
Connect System Selector to data link connector Yes Go to Step 3
and set test switch to SELF TEST;
is idle speed correct after warm-up? No Remove System Selector and Go to
cr page F1-16 next step
Idle speed: 650—750 rpm
DATA LINK
CONNECTOR
Does idle speed drop in following conditions? Yes Check as follows;

• Circuit from idle air control valve to
Condition PCME for open and short c r page F1-81
• Electrical load ON • Idle air control valve for sticking c r page F1-46
• Air conditioner ON
• P/S operating
No Adjust idle speed cr page F1-16

ON?
SYSTEM SELECTOR

displayed
49 H018 9A1
check sequence)
cr page F1-20
SELECT SW: A ‘88” flashes

F 1-120
Are switch operation correct when checked by Yes Go to next step
using SST monitor lamp or indicator while
ignition switch ON?
c r page F1-38
No Check for caused (Refer to specified

check sequence)
c r page F1-39
Are mass airflow sensor connector terminals and Yes Go to next step
connection good?
No Repair connector terminal
Are following terminals and connections good? Yes Go to next step

• Distributor connector
• Fuel pump connector
• Main relay
•PCME connector No Repair connector terminal
Disconnect vacuum hose from EGR control Yes Check as follows:

valve and plug it; does condition improve? • EGR solenoid valve
• Condition of solenoid valve connec
tors female terminals
(Except California)
No Go to next step
Try a known good PCME; does condition improve?

c r page F1-81
±
46U0F1-170
17, 18, 19 ENGINE ROUGH •IDLE AT ANY ENGINE TEMP/DURING FAST IDLE/IDLE AFTER WARM-UP
• Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at any
engine temp.
DESCRIP •Idle speed too slow and excessive engine shake at any engine temp.
TION • Fast idle speed too slow and excessive engine shake during fast idle, but returns to normal after warm-up
• Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle
after warm-up
© Injector • Poor connection of connector
• Fuel leakage from injector(s) © Mass airflow sensor
• Injector(s) clogged • Poor connection of connector
© Fuel pump © Engine coolant temperature sensor
• Maximum pressure low • Poor connection of connector
© Fuel pump relay © EGR control valve
• Poor connection of connector • EGR control valve stuck
@ Air leakage © EGR function control (Except California)
• Leakage in intake air system • EGR function control stuck
© Distributor © BAC valve
• Cap and/or rotor damaged • Air valve stuck
Is “ 00" displayed on SST with ignition switch Yes “ 00” displayed
ON? • If symptom occurs at idle at any
c r page F1-18 engine temp., go to next step
• If symptom occurs during fast idle
• If symptom occurs at idle after
warmup, go to Step 7
SYSTEM SELECTOR No Diagnostic Trouble Code No.

displayed
check sequence)
cr page F1-20
49 H 0 1 8 9A1
<<88” flashes
SELECT SW: A CHECKER FLASHES 88"
No indication at all
CHECKER WILL NOT WORK”
Do Engine Signal Monitor lamp flash for speci Yes Go to next step
fied terminals while cranking engine?
c r pages F1-86 No Check as follows according to results;
F1-88 Do not flash and OV indicated for
individual terminal(s)
Terminal: 2U, 2V, 2Y, 2Z • Continuity of injector(s) c r page F1-59
• Continuity between PCME and
injector(s)
PCME connector
F 1-122
3 Is a strong blue spark visible at each disconnected Yes Go to next step
No Check distributor cap and rotor

Check as follows;
c r page F1-49
Check fuel line pressure while
pinching fuel return hose
Fuel line pressure:
• If pressure quickly increases,
5 Is there air leakage at intake air system Yes Repair or replace

components while racing engine to higher
speed?
No Go to next step
6 Is engine compression correct? Yes Go to next step

c r Section B1
No Check for cause
Engine compression (minimum): c r Section B1
820 kPa (8.4 kgf/cm2, 120 psi)-300 rpm

Connect engine signal monitor to PCME and set the Yes Go to next step
position 2Q
Does following terminal voltage in PCME increase No Check as follows:
smoothly? • Ground of engine coolant temperature
c r page F1-86
sensor
• Continuity between engine coolant
Terminal 2Q voltage: Approx. 0.5—2.5V temperature sensor and PCME
connector
• Condition in engine coolant
temperature sensor and PCME
conncetor female terminals
Are spark plugs OK? Yes • If symptom occurs at any engine

c r Section G temp., go to Step 12
• If symptom occurs during fast idle
• If symptom occurs at idle after
warmup, go to next step
No Clean or replace
Is resistance of idle air control valve correct? Yes Go to next step
Resistance: 7.7—9.30 (at 20°C (6 8 °F |) No Replace BAC valve c r page F1-42
BAC VALVE
10 Try a known good BAC valve; does condition Yes Replace BAC valve c r page F1-42
improve?
No Reinstall BAC valve
Go to next step
F 1-124
11 Is heated oxygen sensor operation correct? Yes Go to next step
c r page F1-93
No Replace heated oxygen sensor

No Replace injector c r page F1-57

c r page F1-81
46U0F1-171
20 ENGINE ROUGH •IDLE WITH A/C, P/S AND/OR E/L ON

• Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle
DESCRIP when A/C, P/S and/or E/L ON
TION
© Idle speed • Blower switch
• Idle speed too low • Coolant fan relay
© Monitor switch function (SST) • Stoplight switch
• Air conditioning sensor © Idle air control valve
Correct System Selector to diagnosis connector and Yes Go to next step
set test switch to SELF TEST;
is idle speed correct after warm-up? No Adjust idle speed and go to next step c r page F1-16
c r page F1-16
Idle speed: 650—750 rpm

ON?
SYSTEM SELECTOR

displayed
49 H 018 9A1 Check for cause (Refer to specified
check sequence)
c r page F1-20
SELECT SW: A
**88” flashes
Are switches correct when checked by using Self- Yes Go to next step
Diagnosis Checker monitor lamp with ignition
switch ON? No Check for cause (Refer to specified
c r page F1-38 check sequence)
c r page F1-39
• Blower switch
• Coolant fan relay
• Stoplight switch
AO
BO BB
MONITOR SCLECTSV
COO [01*
F 1-1 26
4 Is following terminal voltage at PCME correct? Yes Go to next step
Terminal 1P:
B + (steering wheel turned fully)
• Wiring harness between steering
OV (steering wheel In straight-ahead
pressure sensor and PCME
position)
terminal 1P for open circuit
5 Warm-up engine Yes Go to next step

Does idle speed change when idle air control
valve connector disconnected?
No Check idle air control valve for sticking c r page F1-46
BAC ;
6 Does air conditioner operate continuously with Yes Check as follows:

ignition switch ON and A/C switch and blower • Malfunction of A/C relay c r 1994 626/MX-6 body
switch OFF? electrical troubleshoot
ing manual section G
• Wiring harness between A/C relay and
PCME terminal 1J for short circuit c r page F1-82
No Go to next step

c r page F1-81
46U0F1-172
F 1 TROUBLESHOOTING GUIDE
21 ENGINE ROUGH *ON DECELERATION

• Engine shakes at beginning of deceleration, during deceleration, or recovery from deceleration
TION
© Fuel pump @ Distributor
• Poor connection of connector • Poor connection of connector
© Injector © Mass airflow sensor
• Fuel leakage from injector(s) • Poor connection of connector
© Idle speed © Idle air contol valve
• Idle speed too low • Solenoid valve stuck
1 Connect System Selector to data link connector Yes Go to Step 3
and set test switch to SELF TEST; is idle speed
correct after warm-up?
c r page F1-16 No Remove System Selector and go to
next step
Idle speed: 650—750 rpnn
l
~ ~ Z //
f 1
1 ATA LINK
----------- / C ONNECTOR
2 Does idle speed drop in following conditions? Yes Adjust idle speed
Condition: c r page F1-16
• Electrical load ON No Check as follows:
• Air conditioner ON • Wiring harness from idle air control
• P/S operating valve to PCME for short and open
circuit
c r page F1-81
• Idle air control valve stuck c r page F1-46
3 Is "00” displayed on SST with ignition switch Yes “ 00” displayed
ON?
SYSTEM SELECTOR
S rS ) No Diagnostic Trouble Code No.

displayed
M O N IT O R ^ Check for cause (Refer to specified
ps:
L A M P -i check sequence)
SELECT SW: A c r page F1-20
“ 88” flashes
CHECKER FLASHES 88"
Diagnosis Checker monitor lamp with ignition switch
ON?
No Check for caused (Refer to specified
c r page F1-38
check sequence)
c r page F1-39
Is there fuel leakage from injector nozzles or Yes Reinstall or replace injector
injector holder? c r page F1-58 c r page F1-57
No Go to next step
Are mass airflow sensor connector terminal and Yes Go to next step
connection condition good?
Are following connections good? Yes Go to next step

•Distributor connector
• Fuel pump connector No Repair connector terminal
• Main relay
• PCME connector

c r page F1-81
46U0F1-173
22, 23 POOR ACCELERATION •DRIVEAWAY

•ON ACCELERATION
DESCRIP • Engine speed increases normally but vehicle speed slowly increases during driveaway or acceleration
TION
© Injector © Distributor
© Pressure regurator • Cap and/or rotor damage
• Pressure regulator malfunction © Mass airflow sensor
© Fuel filter • Poor connection of connector
• Clogged filter
Is "00” displayed no SST with ignition switch Yes “ 00” displayed
ON?
SYSTEM SELECTOR

49 H 018 9A1
displayed
MONITOR'/
check sequence)
LAMP
c r page F1-20
SELECT SW: A
*<gg” flashes
Is a strong blue spark visible at each disconnected Yes Check spark plugs
high-tension lead while cranking engine? ^ If OK, go to next step
=*> If not OK, clean or replace spark
plug
femals terminals
Is connection of mass airflow sensor connector Yes Go to next step

OK?
No Repair terminal
Is intake manifold vacuum correct at idle? Yes Go to next step
Vacuum: No Check as follows:

More than 60.0 kPa{450 mmHg, 17.7 inHgj
• Intake air system components and
installation
• Vacuum hoses for disconnection
and damage
F1—130
c r page F1-55
No Low pressure
Fuel line pressure:
Check as follows:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi) • Fuel filter for clogging
• Operation of pressure regulator c r page F1-55
• Fuel leakage from injector (s) c r page F1-58
6 Try a known good PCME; does condition improved?

c r page F1-81
46U0F1-174
24 HIGH IDLE SPEED AFTER WARM-UP

• Idle speed continues at fast idle after warm-up
DESCRIP • Engine returns slowly to idle after accelerator is released
TION
© Engine coolant temoerature sensor (3) BAC valve
• Poor connection of connector • Idle air control valve or air valve stuck
© Throttle position sensor
• Incorrect adjustment
Is ‘'00” displayed on SST with ignition switch Yes “ 00” displayed
ON?
SYSTEM SELECTOR

displayed
49 H01 8 9A1
check sequence)
c r page F1-20
SELECT SW: A
•<88” flashes
Connect System Selector to the data link Yes Check condition of engine coolant
connector and set system select to position 1 temperature sensor (CIS) and throttle
Does idle speed down with the test switch position sensor connector female
SELF-TEST? terminals
<=> If OK, go to next step
49 B0 1 9 9A0 <=> If not OK, repair the female
connector
No Check if idle air control valve or air
valve stuck
If OK, go to Step 4
=> If not OK, replace BAC valve
DATA LINK
CONNECTOR
Is following terminal voltage at PCME correct? Yes Go to next step
Terminal 2M: No Replace throttle body

0.1—1.1V (throttle valve closed throttle
c r page F1-42
position)
3.1—4.4V (throttle valve wide open throttle)

c r page F1-81
46U0F1-175
F1-132
25 IDLE FLUCTUATES
IDLE HUNTS
• Engine speed changes back and forth between specified idle speed and higher speed
DESCRIP
TION
© PCV valve (D Idle air control valve
• PCV valve stuck •Solenoid valve stuck
© Spark plug
• Spark plug(s) damaged
Is "00” displayed on SST with ignition switch Yes “ 00” displayed
ON?
SYSTEM SELECTOR

displayed
49 H 0 18 9A1 Check for cause (Refer to specified
MONITORS check sequence)
LAMP i . c r page F1-20
SELECT SW: A
“ 88” flashes
CHECKER FLASHES 88"
Terminal 1N: No Check as follows:

Below 1.0V (accelerator pedal released) • Wiring harness from idle switch to
B+ (accelerator pedal depressed) PCME for short and open circuit
Replace throttle body if necessary
c r page F1-42
Connect System Selector to data link connector Yes Check as follows:

and set system select to position 1 • Idle air control valve for sticking
Does idle hunting stop when test switch to • Poor sealing between throttle body
SELF-TEST? and BAC valve
49 B 0 19 9 A0 No Go to next step
DATA LINK
CONNECTOR
F 1-133

4 Is a strong blue spark visible at each disconnected Yes Check spark plug(s)
•=> If not OK, replace spark plug(s)
• Distributor cap and rotor for damage c r Section G
5 Is PCV valve stuck? Yes Replace PCV valve

c r page F1-69
No Go to next step

c r page F1-81
46U0F1-176
F 1-1 34
26 • HESITATES
• STUMBLES ON ACCELERATION
• Momentary pause at begining of acceleration or during acceleration
DESCRIP
TION
© Fuel pump • Cap and/or rotor damage
• Poor connection of connector © High-tension lead(s)
© Pressure regulator • Lead(s) damaged
• Pressure regulator stuck © Mass airflow sensor
© E G R control valve • Poor connection of connector
• EGR control valve stuck © Throttle position sensor
© EGR function control (Except California) • Poor connection of connector
• EGR modulator valve stuck
© EGR solenoid valve
• Solenoid valve stuck
ON?
SYSTEM SELECTOR

49 H 018 9A1 displayed
check sequence)
SELECT SW: A
cr page F1-20
“ 88” flashes
high-tension lead?
• Distributor cap and rotor for damage cr Section G
• High-tension lead(s) for damage cr Section G
•Condition of distributor and PCME
connectors female terminals
Is fuel line pressure correct at idle? Yes Go to next step

c r page F1-55
No Low pressure
Fuel line pressure: Check fuel line pressure while
2 1 0 — 21 kPa (2.1—2.7 kgf/cm2, 3 0 - 3 8 psi) pinching fuel return hose
• If pressure quickly increases,
check pressure regulator cr page F1-55
INSTALL CLANMPS
F 1-135

4 Does fuel pressure increase when throttle valve Yes Go to next step
opened?
No Check pressure regulator
C7- page F1-55
5 Disconnect vacuum hose from EGR valve and Yes Check as follows:
plug it; does condition improve? • EGR solenoid valve for sticking
• Condition of solenoid valve
(Except California)
No Go to next step
EGR C O N TR O L ---------
v a lv e y y
6 Is following terminal voltage at PCME correct? Yes Go to next step
2 0 terminal: No Check condition of mass airflow sensor

Approx. 1.0—1.5V (Ign switch ON)
and PCME connectors female terminals
Approx. 1.5—5V (engine running) • If OK, replace mass airflow sensor
c-c r page F1-86 • If not OK, repair female terminal
F 1-1 36
7 Is following terminal 2F voltage at PCME correct? Yes Go to next step
Terminal 2M:
No Check the female terminal condition
0.1— 1.1V (throttle valve closed throttle
in throttle postion sensor connector
position) and PCME connector
3.1—4.4V (throttle valve wide open throttle) • If OK, replace throttle position sensor cr page F1-42
•If not OK, repair female terminal
8 Is there fuel leakage from injector(s) Yes Check as follows:

• Poor installation of injector
cr page F1-57
No Go to next step

cr page F1-81
46U0F1-177
27 SURGES WHILE CRUISING

'Momentary minor irregularity in engine output at steady vehicle speed
DESCRIP
TION
© Injector
© Spark plug
© Mass airflow sensor
ON?
SYSTEM SELECTOR

displayed
49 H 0 1 8 9 A 1 Check for cause (Refer to specified
M O N IT O R check sequence)
_T” L A M P - c r page F1-20
S E L E C T SW : A
“ 88” flashes
Does the mass airflow sensor operate correctly? Yes Go to next step
c r page F1-90
• Condition of mass airflow sensor and
PCME connectors female terminals
Does idle become rough when shaking Yes Check as follows:

connector of injector? • Condition of injector and PCME
No Go to next step
F 1-1 38

4 Is a strong blue spark visible at each disconnected Yes Check spark plug(s) for damage
high-tension lead while cranking engine? ■=> If OK, go to next step
=> If not OK, replace spark plug(s)

c r page F1-81
46U0F1-178
28 LACK OF POWER
• Performance poor under load (i.e., power down when climbing hills)
DESCRIP
TION
© Mass airflow sensor
© Intake air temperature sensor
Poor connection of connector
© Distributor
• Damaged distributor cap or rotor cr Section G
© Injector
• Injector harness shorted to ground
© Fuel filter
• Clogged filter
© Air cleaner element
• Clogged element cr page F1-15
© Three-way catalyst
• Clogged three-way catalyst c r page F1-62
46U0F1-179
29 POOR FUEL ECONOMY

• Fuel economy unsatisfactory
DESCRIP
TION
© A ir leakage
• Poor installation of air intake hose, throttle body, intake manifold, EGR control valve and/or EGR function control
• Vacuum hose damaged or disconnected
© Heated oxygen sensor
• Open in harness (Code No. 15 output) cr page F1-93
• Hold fuel pressure high c r page F1-56
• Vacuum hose disconnected or damaged
46U0F1-18Q
30 A/C DOES NOT WORK

• A/C compressor magnetic clutch does not engage with air conditioning sensor ON
DESCRIP
TION
© A/C relay
• Relay malfunction cr 1994 626/MX-6 body electrical
trobleshootlng manual Section G
© Air conditioning sensor
• Does not send signal to PCME terminal 1Q cr page F1-84
©PCME
• Does not send signal to A/C relay with ignition switch ON cr 1994 626/MX-6 body electrical
trobleshootlng manual Section G
46U0F1-181
31 • KNOCKING
• PINGING
• Sound produced when air/fuel mixture is ignited by something other than spark plug (i.e., hot spot in
DESCRIP combustion chamber)
TION
© Ignition timing
• Incorrect ignition timing
© Carbon deposits in cylinder
• Carbon deposits in cylinder sensor cr Section B1
36U0F1-283
F 1-1 40
32 FUEL ODOR
• Gasoline fuel smell or visible leaks
DESCRIP
TION
© Purge control solenoid valve
• Open or short in harness (Code No.26 output) c r page F1-71
© Charcoal canister
• Canister full of fuel and leaking
46U0F1-182
33 EXHAUST SULFUR SMELL

• Rotten egg smell (sulfur) from exhaust
DESCRIP
TION
High sulfer content fuel used
36U0F1-285
34 HIGH OIL CONSUMPTION

• Oil consumption excessive
DESCRIP
TION
PCV valve
• PCV valve stuck open c r page F1-69
46U0F1-183
35 SELF-DIAGNOSIS CHECKER FLASHES “ 88”

• Checker flashes 88 with test terminal (TEN) grounded
DESCRIP
TION
© Short circuit in wiring between data link connector terminal FEN and PCME terminal 1F
© PCME
• PCME malfunction c r page F1-81
46U0F1-184
36 MIL NEVER ON
• Self-Diagnosis Checker indicates Service Code No. but MIL never ON
DESCRIP
TION
© W irin g harness between PCME 1E terminal and MIL
• Open in harness
© Light burnt
46U0F1-185
F1-141
F1 SERVICE POINTS
SERVICE POINTS
OUTLINE
[Power and ground]
Main Relay (Battery Power)
• If the circuit is open, the engine will not start.
• If the circuit is shorted, the EGI INJ fuse (30A) will burn out.
Room Fuse (PCME Memory Power)

• If the circuit is open, the PCME memory function will not operate, and diagnostic trouble codes for inter
mittent malfunctions will not be indicated. Also, the learning control will be canceled, but will not produce
any particular symptom.
• If the circuit is shorted, the ROOM fuse (15A) will burn out.
Ground (Output Devices, Injector, System)

• If an output device, an injector or system has an open ground circuit, no particular symptom will be produced.
If a related output device, injectors and system have open ground circuits, the engine stalls and will not start.
Ground (Analogue)
• If the circuit is open, Diagnostic trouble Code No.09, 11, 12, 14 output.
[Input Device]
Mass Airflow Sensor
• If the Vs terminal of the mass airflow sensor has a open or short circuit, Diagnostic Trouble Code No.08
will be output, and the PCME determines intake air amount by the throttle valve opening angle.
Intake Air Temperature Sensor

• If the intake air temperature sensor has an open or short circuit, Diagnostic Trouble Code No.11 will be
output, and the PCME uses a preprogrammed intake air temperature of 20°C |68°F}.
• If the intake air temperature sensor system fails, no particular symptom will be noticed.
Throttle Position Sensor

• If the Vref terminal has an open circuit or the TVO terminal has an open or short circuit, Diagnostic Trouble
Code No.12 is output.
• If the Vref terminal has an short circuit, the engine stalls and will not start.
• If the ground terminal has an open circuit, Diagnostic Trouble Code No. 12 is output.
• In the above conditions, the PCME uses a preprogrammed throttle valve fully-open’s value.
• If the throttle position sensor system fails, idle speed drops will result or engine stalls and will not restart
when A/C, P/S, E/L ON.
TEN Terminal (Data Link Connector)

• If the circuit is open, the Self-Diagnosis Checker cannot perform diagnostic trouble code checks and switch
monitoring checks.
• If the circuit is shorted, the opening amount of the idle air control valve will not change, causing hard
starting and rough idle. The ignition timing will be fixed, causing lack of power and poor acceleration.
The Self-Diagnosis Checker cannot perform sensor monitoring checks.
• If the circuit is shorted, the coolant fan operates whenever the throttle valve is opened.
Daytime Running Light Unit (Canada)

• If the circuit is open, idle speed may be slightly low.
• If the circuit is shorted, idle speed may be slightly high.
Idle Switch
• The switch monitor function can confirm the presence of an open or short circuit.
• If the circuit is open, fan operates continuously with TEN terminal grounded in data link connector or idle
speed is high after warm up.
• If the circuit is shorted, idle speed stays or hunts at approx. 2,000 rpm.
SERVICE POINTS F1
Heated Oxygen Sensor
• If sensor output voltage is not generated because of an open or short circuit, Diagnostic Trouble Code
No. 15 or 17 is output.
• If the heated oxygen sensor output voltage continues unchanged 40 sec. after the engine exceeds 1,500
rpm, Diagnostic Trouble Codes No. 17 is output.
• In the above conditions, no closed loop control will be present and no symptom will be noticed.
Crankshaft Position Sensor (NE, G Singnal)

• If the NE signal circuit has an open or short, Diagnostic Trouble Code No.02 is output.
• If the G signal circuit has an open or short, Diagnostic Trouble Code No.03 is output.
Input Diagnostic
Fail-safe function Symptom
NE signal G signal trouble code
X O 02 No injection/ignition Engine does not start
O X 03 Cancels sequencial injection —
X X 02 No injection/ignition Engine does not start
O: Normal x : Malfunction
Starter signal
• A lack of starter signal input will cause hard starting.
Steering Pressure Sensor

• If the circuit is open or shorted, no symptom will be noticed.
A/C Signal (Air Conditioning Sensor)

• If the circuit is open, the air conditioner will not operate.
• If the circuit is shorted, the air conditioner will constantly operate when the blower is ON.
Engine Coolant Temperature Sensor

• If the temperature sensor has an open or short circuit, Diagnostic Trouble Code No.09 is output, and the
PCME uses a preprogrammed temperature value of 34°C (93°F).
• A malfunction in the engine coolant temperature sensor system may cause hesitation, engine stalling, high
idle speed after warm up or hard starting.
Blower Signal
• The switch monitor funciton can confirm the presence of an open or short circuit.
• If the circuit has an open or short, no symptom will be noticed.
Stoplight Signal
• An open or short circuit will produce no symptom.
Vehicle Speed Sensor

Neutral and Clutch Switches

Rear Window Defroster Switch

• If the circuit is open, no symptom will be noticed.
• If the circuit is shorted, defroster operates continuously.
Headlight Switch
• If the circuit is open, or shorted, no symptom will be noticed.
F1-143
F1 SERVICE POINTS
EGR Function Sensor
• If the circuit is open or shorted, Diagnostic Trouble Code No. 16 is output.
[Output Device]
Injector
• If the circuit is open, the injector will not operate, causing rough idle, hard starting and poor acceleration.
• If the circuit is shorted, the injector will inject fuel constantly, causing hard starting, engine rough or stall,
and poor acceleration.
IGT Signal (Igniter)

• If no IGT signals are input to the igniter because of an open or short circuit, the engine stalls and will not
start and tachometer will not operate.
Idle Air Control Valve (IN BAC Valve)

• If the valve or circuit has an open or short, Diagnostic Trouble Code No.34 is output.
• If the circuit is open, the valve will be fully closed, causing hard starting, engine stalling, or engine rough
at driveaway when engine is cold.
• If the circuit is shorted, the valve will be fully opened and the idle speed stays or fluctuates at approx.
2,000 rpm.
Fuel Pump Relay

• If the circuit is open, the engine stalls and will not restart.
• If the circuit is shorted, the fuel pump will operate whenever the ignition switch is ON.
Purge Control Solenoid Valve

• If the solenoid valve has an open or short circuit, Diagnostic Trouble Code No.26 is output.
• A short circuit may cause an improper air/fuel ratio, causing engine stalling, poor acceleration idle and
hard starting.
A/C Signal (A/C Relay) and Condencer Fan Relay

EGR Solenoid Valve (Except California)

EGR Solenoid Valve (Vacuum-California)

EGR Solenoid Valve (Vent-California)

• If the solenoid valve has on open short circuit, Diagnostic Trouble Code No.29 is output.
PRC Solenoid Valve

• If the circuit is shorted, no symptom will be noticed.
• If the circuit is open, the engine will be hard to start after heat soaked.
Coolant Fan Relay No.1

• If the relay has an open or short circuit, Diagnostic Trouble Code No.67 is output.
• If the circuit is shorted, the coolant fan will always operate while the ignition switch is ON.
• If the circuit is open, the coolant fan will remain OFF when the water temperature exceeds 97°C {207°F}.
F 1-1 44
SERVICE POINTS F1
• If the relay has an open or short circuit, Diagnostic Trouble Code No.68 is output.
• If the circuit is shorted, the coolant fan will always operate with the ignition switch ON.
• If the circuit is open, the coolant fan will remain OFF when the engine temperature exceeds 108°C {226°F}.
MEN Terminal (Data Link Connector)

• If the circuit is open, the Self-Diagnosis Checker monitor lamp will not illuminate.
• If the circuit is shorted, the Self-Diagnosis Checker monitor lamp will stay on.
FEN Terminal (Data Link Connector)

• If the circuit is open, the Self-Diagnosis Checker buzzer will not sound during the diagnostic trouble code
check.
• If the circuit is shorted, code “ 88" will keep flashing and the buzzer will continue sounding, preventing
a diagnostic trouble code check.
46U0F1-186
F1 SERVICE POINTS
WIRING DIAGRAM
16U0F1-290
F 1-1 46
SERVICE POINTS F1
©0
F 1-147
F1 SERVICE POINTS
ELECTRICAL DIAGNOSIS SUPPORT
Condition
Circuit
Open circuit Short circuit Poor ground
PCME (1B)—Main relay Engine stalls and will not EGI INJ fuse (30A) burns
NA
restart out with ignition switch ON
46U0F1-187
Room Fuse (Memory Power)

Condition
Circuit
PCME (1 A)—Room fuse No symptom Room fuse (15A) burns out NA
36U0F1-171
Ground (Output Device, Injector, System, Analogue)

Condition
Circuit
PCME (2A)—Ground (Injector) Engine stall and will not Engine may not start
PCME (2B)—Ground (Power) restart
PCME (2C)—Ground (System) NA
PCME (2D)—Ground (Analogue) Diagnostic trouble code
No.9, 11,12 output
46U0F1-188
[input Device]
Mass Airflow Sensor
Condition
Circuit
PCME (20)—Mass airflow sensor Diagnostic trouble code Diagnostic trouble code
No.08 output No.08 output
Lack of power Lack of power
Poor acceleration Poor acceleration
Hesitate at driveaway Hesitate at driveaway
Vehile shake on de NA
Vehicle shake on de
celeration celeration
Main relay—Mass airflow sensor Engine stall and will not
restart
Melts EGI INJ 30A fuse
PCME (2C)—Mass airflow sensor NA —
46U0F1-189
Data Link Connector (TEN terminal)

Condition
Circuit
PCME (1K)— Data link connector Cannot perform diagnostic Hard starting
trouble code checks and Rough idle NA
switch monitor checks Poor acceleration
36U0F1-176
Throttle Sensor
Condition
Circuit
PCME (2K)—Throttle position Diagnostic trouble code Diagnostic trouble code
sensor (Vref) No. 12 output No. 12 output
Idle speed drops when Engine stalls and will not
A/C, P/S, or E/L ON restart
NA
PCME (2M)—Throttle position Diagnostic trouble code Diagnostic trouble code
sensor No. 12 output No. 12 output
Idle speed drops when Idle speed drops when
A/C, P/S, or E/L ON A/C, P/S, or E/L ON
PCME (2D)—Throttle position Diagnostic trouble code
sensor No. 12 output
NA —
Idle speed drops when
A/C, P/S, or E/L ON
N A : N o t a p p lic a b le 36U0F1-178
F1-148
SERVICE POINTS F1
Condition
Circuit
PCME (2L)—Intake air temperature Diagnostic trouble code Diagnostic trouble code
sensor No.11 output NA
No.11 output
PCME (2D)—Intake air temperature Diagnostic trouble code
sensor NA —
No.11 output
36U0F1-177
idle Switch
Condition
Circuit
PCME (1N)—Idle swicth Fan operates continuously Idle speed stays or hunts
with TEN terminal at spprox. 2,000 rpm
grounded NA
High idle speed after
warm up
Idle switch—Ground Fan operates continuously
with TEN terminal
grounded NA —
High idle speed after
warm up
36U0F1-179

Condition
Circuit
PCME (2N)—Heated oxygen Diagnostic trouble code Diagnostic trouble code
sensor No.15/17 output No. 15/17 output NA
Poor fuel economy Poor fuel economy
Heated oxygen sensor—Ground Diagnostic trouble code No symptom
No. 15/17 output NA
Poor fuel economy
Heated oxygen sensor (heater)— No symptom Melts WIPER 20A fuse
Ignition swicth —
36U0F1-180
Crankshaft Position Sensor (NE signal, G signal)

Condition
Circuit
PCME (2E)—Crankshaft position Diagnostic trouble code No.02 output
sensor Engine stalls and will not restart
NA
PCME (2G)—Crankshaft position Diagnostic trouble code No.03 output
sensor No symptom
PCME (2C)—Crankshaft position No symptom No symptom
NA
sensor
36U0F1-181
Starter Signal (Ignition Switch)

Condition
Circuit
PCME (1C)—Ignition switch Hard to start Melts IG KEY 40A fuse
when ignition switch turn
to STA position NA
Engine stalls and will not
restart
36U0F1-182

Condition
Circuit
PCME (1P)—Steering pressure No symptom
—
sensor
36U0F1-183
NA: Not applicable
F1 SERVICE POINTS
A/C Signal (Air Conditioning Sensor)
Condition
Circuit
PCME (1Q)—Air conditioning Air conditioner will not Air conditioner will con
sensor operate stantly operate with blower NA
ON
36U0F1-184

Condition
Circuit
PCME (2Q)—Engine coolant Diagnostic trouble code No.09 output
temperature sensor Hard to start after warm-up with TEN terminal grounded
High idle speed after warm-up (approx. 1,000 rpm) NA
Engine stalls at idle with TEN terminal grounded
Hesitate at driveaway and acceleration
PCME (2D)—Engine coolant tem Diagnostic trouble code No.09 output
perature sensor Hard to start after warm-up with TEN terminal grounded
High idle speed after warm-up (approx. 1,000 rpm) —
Engine stalls at idle with TEN terminal grounded
Hesitate at driveaway and acceleration
46U0F1-190
Blower Signal
Condition
Circuit
PCME (1R)—A/C amplifier No symptom —
36U0F1-188

Condition
Circuit
PCME (1M)—Vehicle speed sensor No symptom NA
46U0F1-191
Neutral and Clutch Switches

Condition
Circuit
PCME (1V)—Neutral switch No symptom No symptom
NA
PCME (1V)—Clutch switch
46U0F1-192
Stoplight Signal (Stoplight Switch)

Condition
Circuit
PCME (10)—Stoplight switch No symptom No symptom NA
36U0F1-189

Condition
Circuit
PCME (1L)— Rear window defroster No symptom Defroster operates con
NA
switch tinuously
36U0F1-192
Headlight Switch
Condition
Circuit
PCME (1U)—Headlight switch No symptom NA
NA: Not applicable
F 1-150
SERVICE POINTS F1
EGR Function Sensor (Except California)
Condition
Circuit
PCME (2J)—EGR function sensor Code No. 16 output
NA
PCME (2D)—EGR function sensor
46U0F1-203
EGR Function Sensor (California)

Condition
Circuit
PCME (2J)—EGR function sensor Code No. 16 output Code No. 16 output
No symptom NA
No symptom
46U0F1 -204

Condition
Circuit
PCME (11)—Daytime running light Idle speed may be slightly Idle speed may be slightly
unit NA
low high
36U0F1-261
[Output Device]
Injector
Condition
Circuit
PCME (2U, 2V, 2Y, 2Z)-lnjector Hard to start, Rough idle Will not start or hard to start
Poor acceleration at low Engine rough or stalls NA
speed Poor acceleration
36U0F1-194

Condition
Circuit
PCME (2F)—Igniter Engine stalls and will not restart
NA
Tachometer will not operate
Igniter—Ground No symptom NA Engine will not start
36U0F1-195
Idle Air Control Valve (IN BAC Valve)

Condition
Circuit
PCME (2W)—Idle air control valve Diagnostic trouble code Diagnostic trouble code
Rough idle Idle speed stays or fluc
Engine stalls after racing tuates at approx. 2,000
Hard to start after warm-up rpm
NA
Idle air control valve—Main relay Engine rough at driveaway EGI fuse (30A) burns out
when engine is cold with ignition switch ON
A/C, P/S, or electrical load
ON
36U0F1-196
Fuel Pump Relay

Condition
Circuit
PCME (1H)—Fuel pump relay Engine stalls and will not Fuel pump will continue
restart operating with ignition NA
switch ON
36U0F1-197
NA: Not applicable
F1-151
F1 SERVICE POINTS
Purge Control Solenoid Valve
Condition
Circuit
PCME (2X)—Solenoid valve No.26 output No.26 output
(purge control) No symptom Engine stalls, Hard starting
Poor acceleration at
driveaway NA
Solenoid valve (purge control) EGI INJ fuse (30A) burns
—Main relay out with ignition switch ON
36U0F1-198
A/C Signal (A/C Relay)

Condition
Circuit
PCME (1 J)—A/C relay Air conditioner will not Air conditioner will remain
NA
operate operating with blower ON
46U0F1-194
EGR Solenoid Valve (Except California)

Condition
Circuit
PCME (2S)—EGR solenoid valve Diagnostic trouble code Diagnostic trouble code
No symptom No symptom
EGR solenoid valve—Main relay EGI INJ fuse (30A) burns NA
out with ignition switch ON
start
46U0F1-195
EGR Solenoid Valve (Vacuum-California)

Condition
Circuit
PCME (2S)—Solenoid valve (EGR) Diagnostic trouble code Diagnostic trouble code
Solenoid valve (EGR)—Main relay EGI INJ fuse (30A) burns NA
start
46U0F1-196
EGR Solenoid Valve (Vent-Caiifornia)

Condition
Circuit
PCME (2R)—Solenoid valve (EGR) Diagnostic trouble code Diagnostic trouble code
Solenoid valve (EGR)—Main relay EGI INJ fuse (30A) burns NA
start
46U0F1-197
PRC Solenoid Valve

Condition
Circuit
PCME (2T)—Solenoid valve (PRC) Diagnostic trouble code Diagnostic trouble code
Hard to start after heat No symptom
Solenoid valve (PRC)—Main relay soaked EGI INJ fuse (30A) burns NA
start
46U0F1-198
NA: Not applicable
F1—152
SERVICE POINTS F1
Data Link Connector (MEN terminal)
Condition
Circuit
PCME (1D)—Data link connector Monitor lamp will not il Monitor lamp will stay ON
NA
luminate
36U0F1-174
Data Link Connector (FEN terminal)

Condition
Circuit
PCME (1F)—Data link connector Self-Diagnosis Checker Code "88” will keep
buzzer will not sound dur flashing and buzzer will
ing diagnostic trouble continue sounding during NA
code check diagnostic trouble code
check
36U0F1-175
Coolant Fan Relay

Condition
Circuit
PCME (1S)—Coolant fan relay No.1 Diagnostic trouble code Coolant fan operates con
No.67 output tinuously
Coolant fan relay No.1—Ignition Coolant fan will not op ENGINE fuse (15A) burns NA
switch erate above the water out with ignition switch ON
temperature 97°C
(207°F)
36U0F1-202
NA: Not applicable
F2
FUEL AND EMISSION

CONTROL SYSTEMS
(KL)
IN D E X .......................................................................................F 2 - 2 SYSTEM OPERATION.................................................... F 2 - 77
O U T L IN E ................................................................................. F 2 - 6 EGR SOLENOID VALVE (VACUUM ).......................... F 2 - 77
SYSTEM DIAGRAM..........................................................F 2 - 6 EGR SOLENOID VALVE (VENT).................................. F 2 - 77
VACUUM HOSE ROUTING DIAGRAM ...................... F 2 - 7 EGR FUNCTION SENSOR............................................F 2 - 78
WIRING DIAG RAM ..........................................................F 2 - 8 EGR CONTROL VALVE................................................. F 2 - 78
SPECIFICATIONS.............................................................F 2 - 10 POSITIVE CRANKCASE VENTILATION
COMPONENT DESCRIPTIONS....................................F 2 - 11 (PCV) S Y S T E M ...................................................................F 2 - 80
ENGINE TUNE-UP.................................................................F 2 - 14 DESCRIPTION................................................................. F 2 - 80
PREPARATION.................................................................F 2 - 14 PCV VALVE.......................................................................F 2 - 80
BASIC INSPECTION........................................................ F 2 - 14 FUEL EVAPORATIVE S Y S T E M ...................................... F 2 - 81
ADJUSTMENT............................................................... F 2 - 15 DESCRIPTION................................................................. F 2 - 81
ON-BOARD DIAGNOSIS S Y S T E M ................................. F 2 - 17 SYSTEM OPERATION....................................................F 2 - 82
DESCRIPTION..................................................................F 2 - 17 PURGE SOLENOID VALVE.......................................... F 2 - 82
PREPARATION.................................................................F 2 - 18 FUEL VAPOR VALVE..................................................... F 2 - 83
DIAGNOSTIC TROUBLE CODE N U M B ER ............... F 2 - 18 CHECK VALVE (TWO-WAY)......................................... F 2 - 83
SWITCH MONITOR F U N C TIO N ...................................F 2 - 43 CHARCOAL CANISTER................................................. F 2 - 83
HEATED OXYGEN SENSOR MONITOR FUEL-CUT CONTROL SY S TE M ...................................... F 2 - 84
FUN CTIO N...................................................................... F 2 - 43 DESCRIPTION................................................................. F 2 - 84
INTAKE AIR S Y S T E M ........................................................ F 2 - 48 PREPARATION................................................................ F 2 - 84
COMPONENT PARTS.................................................... F 2 - 48 SYSTEM OPERATION....................................................F 2 - 85
THROTTLE B O D Y ........................................................... F 2 - 49 A/C CUT OFF S Y S T E M ..................................................... F 2 - 86
ACCELERATOR P E D A L................................................ F 2 - 50 DESCRIPTION.................................................................F 2 - 86
ACCELERATOR C A B LE................................................ F 2 - 50 SYSTEM OPERATION....................................................F 2 - 86
AIR INTAKE PIPE/INTAKE MANIFOLD...................... F 2 - 51 DECHOKE CONTROL S Y S T E M ...................................... F 2 - 87
IDLE-SPEED CONTROL S Y S T E M .................................. F 2 - 52 DESCRIPTION................................................................. F 2 - 87
DESCRIPTION.................................................................. F 2 - 52 SYSTEM OPERATION.................................................... F 2 - 87
PREPARATION A .............................................................F 2 - 53 COOLANT FAN CONTROL SYSTEM .............................F 2 - 88
SYSTEM OPERATION.................................................... F 2 - 53 DESCRIPTION................................................................. F 2 - 88
BAC V A LVE...................................................................... F 2 - 53 PREPARATION................................................................ F 2 - 88
VARIABLE RESONANCE INDUCTION SYSTEM OPERATION....................................................F 2 - 89
SYSTEM (V R IS )..................................................................F 2 - 54 CONTROL S Y S T E M ............................................................F 2 - 90
DESCRIPTION..................................................................F 2 - 54 PREPARATION................................................................ F 2 - 90
SYSTEM OPERATION.................................................... F 2 - 55 STRUCTURAL VIEW .......................................................F 2 - 91
COMPONENT PARTS.................................................... F 2 - 56 POWERTRAIN CONTROL MODULE (PCME)........... F 2 - 92
VRIS SHUTTER VALVE ACTUATOR (No. 1, No. 2). F 2 - 57 MAIN RELAY........................................................ .......... . F 2 -1 0 4
CHECK VALVE.................................................................F 2 - 57 VOLUME AIRFLOW SENSOR...................................... F 2 -1 0 4
VRIS SOLENOID VALVE (No. 1, No. 2 ) .....................F 2 - 57 CRANKSHAFT POSITION SENSOR No.1
VACUUM CHAM BER......................................................F 2 - 57 (IN DISTRIBUTOR)..................................... .................. F 2 -1 0 5
FUEL S Y S T E M ...................................................................... F 2 - 58 CRANKSHAFT POSITION SENSOR No.2.................. F 2 -1 0 5
DESCRIPTION..................................................................F 2 - 58 ENGINE COOLANT TEMPERATURE SENSOR ...... F 2 -1 0 6
PREPARATION....................................................... .........F 2 - 59 THROTTLE POSITION SENSOR.................................. F 2 -1 0 7
SYSTEM OPERATION.................................................... F 2 - 59 HEATED OXYGEN SENSOR (RH, LH)........................F 2 -1 0 8
FUEL T A N K ...................................................................... F 2 - 61 KNOCK SENSOR............................................................ F 2 -1 1 0
FUEL PUM P...................................................................... F 2 - 63 CLUTCH SWITCH (MTX)................................................F 2-111
FULE FILTE R................................................................... F 2 - 65 NEUTRAL SWITCH (MTX)............................................. F 2-111
INJECTOR.........................................................................F 2 - 66 STEERING PRESSURE SENSOR................................. F 2-111
PRESSURE REGULATOR............................................. F 2 - 70 TROUBLESHOOTING G U ID E .......................................... F 2 -1 1 2
FUEL PUMP RELAY....................................................... F 2 - 70 QUICK DIAGNOSIS CHART......................................... F 2-1 1 2
PRESSURE REGULATOR CONTROL SYSTEM ..........F 2 - 71 RELATIONSHIP CHART.............................. ......... .........F 2 -1 1 6
DESCRIPTION.................................................................. F 2 - 71 USING THIS SECTION...................................... ............F 2 -1 1 8
PRC SOLENOID VALVE................................................ F 2 - 72 DIAGNOSTIC INDEX.......................................................F 2 -1 2 0
EXHAUST S Y S T E M .............................................................F 2 - 73 SYMPTOM TROUBLESHOOTING................................F 2 -1 2 4
COMPONENT PARTS.................................................... F 2 - 73 SERVICE P O IN T S ......................................................... F 2-161
OUTLINE OF EMISSION CONTROL SYSTEM .............F 2 - 75 OUTLINE........................................................................ . F 2-161
DESCRIPTION.................................................................. F 2 - 75 WIRING DIAGRAM ......................................................... F 2-1 6 6
EXHAUST GAS RECIRCULATION (EGR) ELECTRICAL DIAGNOSIS SUPPORT.........................F 2 -1 6 8
FUNCTION CONTROL SYSTEM ....................................F 2 - 76 46U0F2-001
DESCRIPTION.................................................................. F 2 - 76
— ...
F2 INDEX -v
INDEX
46U0F2-002
1. Fresh airduct 8. Vacuum chamber

Removal / Inspection / Removal / Installation........ ....page F2- 56
Installation............................ . page F2- 48 Inspection......................... ....page F2- 57
2. Air cleaner element 9. Check valve
Removal / Installation............. . page F2- 48 Removal / Installation........ ....page F2- 56
Inspection..............................., page F2- 15 Inspection......................... ....page F2- 57
3. Volume airflow sensor 10. Intake manifold
Removal / Installation............. page F2- 48 Removal / Installation........ ....page F2- 48
Inspection............................... page F2- 104 Inspection......................... ....page F2- 51
4. Throttle body 11. Air intake pipe
Removal / Installation............. page F2- 48 Removal / Installation........ ....page F2- 48
Inspection............................... page F2- 49 Inspection......................... ....page F2- 51
5. BAC valve 12. Accelerator pedal
Removal / Installation............. page F2- 48 Removal / Inspection /
Inspection............................... page F2- 53 Installation....................... ....page F2- 50
6. Air intake hose 13. Accelerator cable
Removal / Installation............. page F2- 48 Inspection / Adjustment..... ....page F2- 50
7. VRIS shutter valve actuator (No. 1, No. 2)
Inspection............................... page F2- 57
F 2 -2
INDEX *s
F2
46U0F2-185
1. Fuel pump relay 9. Volume airflow sensor (with 16. Heated oxygen sensor
Inspection.... page F2- 70 intake air temperature sensor) Inspection....page F2-108
2. Pressure regulator Inspection.... page F2-104 Replacement
Inspection....page F2- 70 Removal / Installation ................. page F2-109
Removal / Installation ................... page F 2 - 48 17. Knock sensor
................... page F2- 66 10. Throttle position sensor (with Removal I Installation
3. Fuel Injector idle switch) ................. page F2-110
Inspection (On-vehicle) Inspection.... page F2-107 18. Main relay
.................. page F2- 66 Replacement Inspection....page F2-104
Removal / Installation ................... page F2-108 19. Steering pressure sensor
................... page F2- 66 11. EGR control valve Inspection....page F2-11
Inspection.... page F2- 68 Inspection.... page F 2- 78 20. Clutch switch (MTX)
4. VRIS solenoid valve (No. 1, Replacement Inspection....page F2-11
No. 2) ................... page F 2- 79 Replacement
Removal / Installation 12. Fuel filter (High-pressure) ................. page F2-11
................... page F2- 56 Replacement 21. Neutral switch (MTX)
Inspection....page F2- 57 ................... page F 2- 65 Inspection....page F2-11
5. PCV valve 13. Engine coolant temperature Replacement
Inspection....page F2- 80 sensor ................. page F2-11
6. Purge solenoid valve Removal / Installation 22. EGR function sensor
Inspection.... page F2- 82 ................... page F2-106 Inspection....page F2- 78
7. Charcoal canister Inspection.... page F2-106 23. EGR solenoid valve (vacuunn
Inspection.... page F2- 83 14. Crankshaft position sensor Inspection....page F2- 77
8. Powertrain control module No. 2 (NE2 signal) 24. EGR solenoid valve (vent)
(PCME) Inspection.... page F2-105 Inspection....page F2- 77
Removal / Installation Removal / Installation 25. PRC solenoid valve
................... page F2- 92 ................... page F2-106 Inspection....page F2- 72
Inspection....page F2- 93 15. Crankshaft position sensor
No. 1 (G signal, NE1 signal)
Inspection.... page F2-105
F 2 -3
F2 INDEX
46U0F2-004

Removal / Inspection / - Inspection.......... ......................page F2-83
Installation...............................page F2-61 Removal / Installation............... page F2-61
2. Fuel filter (Low-pressure) 5. Fuel vapor valve
Removal / Installation............... page F2-65 Inspection.................................page F2-83
3. Fuel pump
Inspection.................................page F2-63
Removal / Installation............... page F2-64
INDEX v
F2
CALIFORNIA
46U0F2-005
1. Main silencer 5. Insulator

Removal / Inspection / Removal / Installation....... pages F2-73, 74
Installation.......................pages F2-73, 74 6. Exhaust manifold
2. Pre silencer Removal / Inspection /
Removal / Inspection / Installation...................... pages F2-73, 74
Installation.......................pages F2-73, 74 7. EGR pipe
3. Three way catalyst Removal / Inspection /
Removal / Installation....... pages F2-73, 74 Installation...................... pages F2-73, 74
4. Front pipe
Removal / Inspection /
Installation.......................pages F2-73, 74
F 2 -5
(O
■< ■n
THRO TTLE POSITION SENSOR IDLE AIR CONTROL VALVE
(0 to
PRC SOLENOID VALVE
H
SHUTTER VALVE ACTUATOR (VRIS 2)
m
VOLUME AIRFLOW SEN SO R
PURGE SOLENOID VALVE * VACUUM CHAMBER
i m
O
AIR CLEANER HOUSING 3D
>
ONE-WAY CHECK VALVE

INTAKE AIR *
SUTTER VALVE TEM PERATURE
BAC VALVE SENSOR FRESH AIR DUCT
ACTUATOR (VRIS 1)-
VRIS SOLENOID
PRESSURE REGULATOR VALVE (No.2)[ 1 EGR-VENT
SO LENO ID VALVE
CHARCOAL CANISTER
CHECK VAL
(TWO-WAY)
PCV VALVE
EGR-VACUUM
. „ r \ CRANKSHAFT
' ° 9 POSITION o
c
SOLENOID SENSOR No.1
FUEL FILTER
(LOW PRESSURE
VALVE (NE1, G) H
-E G R FUNCTION n
SIDE)
------INJECTOR
SENSOR z
-EG R CONTROL
m
KNOCK SENSOR
VALVE
FUEL VRIS SOLENOID VALVE (No.1)
VAPOR VALVE
WARM UP THREE-W AY CATALYST (CALIFORNIA)
FUEL
FUEL
\NKSH AFT POSITION SENSOR No.2 (NE2)
HEATED O XYGEN SENSOR
ENGINE COOLANT TEM PERATURE SENSOR THREE WAY CATALYST
WARM UP THREE-W AY CATALYST (CALIFORNIA) * TO PCM E

OUTLINE F2
VRIS SOLENOID VALVE No.1
VRIS SHUTTER VALVE ACTUATOR No.2 PURGE SOLENOID VALVE
VRIS SHUTTER VALVE ACTUATOR No.1
CHECK VALVE
I SOLENOID
VALVE (VENT)
VACUUM CHAMBERS
PRESSURE REGULATOR
EGR SOLENOID
VALVE (VACUUM)
TO POWER
BRAKE UNIT
CHARCOAL
CANISTER
EGR CONTROL VALVE
PRC SOLENOID VALVE

F2_________________ _________ OUTLINE
WIRING DIAGRAM
CLUTCH
HEATED
OXYGEN
SENSOR
(CALIFORNIA)
$ (LEFT BANK)
VEHICLE SPEED SENSOR
HEATED
OXYGEN
SENSOR
(CALIFORNIA)
(RIGHT BANK)
^ HEATED
$ OXYGEN
•S SENSOR
* (FEDERAL
« CANADA)
^ (RIGHT BANK)
BATTERY
16E0F2-Q09
F 2 -8
OUTLINE F2
PRC SOLENOID
VALVE
EGR SOLENOID
EGR VALVE (VENT)
VRIS \ SOLENOID
IDLE AIR SOLENOID \ VALVE
CONTROL VALVE VALVE No.2 (VACCUM)
1 VRIS / PURGE INJECTOR INJECTOR
STEERING SOLENOID / SOLENOID No.1 No.3 No.5 No.2 No.4 No.6
DATA LINK PRESSURE! VALVE No.1/ VALVE
CONNECTOR SENSOR \ ______ \ ' I _JL fflnltrn
O OIOIOIO
ra m fn i
OIOIOIOOIO
2 utu-
UJ
I A
B ii
o io m i ) -------------- (ao) (bi)------------- ( jj) (;o) — ■ (3 m) — (3 p )---------(3 Q > - — {a u )— (jw ) — ( jy ) -
CONNECTOR
I TACHOMETER
DISTRIBUTOR (IGNITER, IGNITION COIL,

AND CRANKSHAFT POSITION
SENSOR No.1)
. BLOWER
SWITCH
F 2 -9
F2________________ _________ OUTLINE
SPECIFICATIONS
Item Specification
Idle speed* rpm 6 00 -7 00 (650 ± 50)

Ignition timing* BTDC 9 °—11° (10° ± 1°)
Throttle body
Throat diameter mm {in) 60 {2.4)
Fuel pump
Type Impeller (in-tank)
Maximum output pressure kPa {kgf/cm2, psi) 640 {6.5, 92)
Fuel filter
Type
Pressure regulator
Regulating pressure kPa {kgf/cm2, psi) 280 {2.9, 41)
Injector
Type High-ohmic, side-feed
Resistance 1 2 -1 6 (at 20°C (68°F))
Solenoid resistance fl 10.7-12.3 (at 20°C {68°F))
Purge solenoid valve
Solenoid resistance 0 3 0 -3 4 (at 20°C {68°F))
Crankshaft position sensor No.1 (Ne1, G signal)
Type Hall effect pick-up
Volume Airflow sensor
Type Measuring core type
Closed throttle
2 0 -6 0 0
E2 <- VS position
Wide open throttle 2 0-1,000
Resistance 12 E2 «• VC 200 -4 00
E2 <*• THA -2 0 °C {-4 °F ) 10,000-20,000
(Intake air
20°C {68°F) 2,000-3,000
temperature
sensor) 60°C { 140°F) 4 00 -7 00
- 2 0 °C {-4 °F ) 13.5—16.5
20°C {68°F) 2.20-2.70
80°C { 176°F) 0.29-0.35
Resistance kfi 91°C { 196°F) 0.226-0.241
97°C {207°F) 0.193-0.205
108°C (226°F) 0.145—0.153
110°C {230°FJ 0.137-0.146
Fuel tank
Capacity L {US gal, Imp gal) 58.5 {15.5, 12.9)
Air cleaner housing
Fuel
Specification Unleaded— (R + M)/2 method 91 or higher
* TEN terminal of data link connector grounded.
F 2 -1 0
OUTLINE F2

A/C relay Controls A/C compressor magnetic clutch
Air cleaner housing Filters air entering throttle body
Air valve Supplies bypass air into intake manifold • Engine speed increased to shorten warm
(engine cold) up period
• Thermowax type
Barometric absolute Detects barometric absolute pressure; sends In PCME
pressure sensor signal to PCME
Bypass air control Supplies bypass air into intake manifold Consists of air valve and idle air control valve
(BAC) valve
Check valve (two-way) Controls pressure in fuel tank —
Crankshaft position Detects No.1 cylinder TDC; sends signal to Installed in distributor
sensor No.1 PCME (G signal)
IG signal \ Detects crank angle at 60° intervals;
\Ne1 signal/ Sends signal to PCME (Ne1 signal)
Crankshaft position Detects crank angle at 60° intervals; Installed at crankshaft pulley
sensor No.2 sends signal to PCME
(Ne2 signal)
Data link connector Concentrated sevice connector terminals: 25-pin (located near front left fuse box)
1. CIS on-board diagnosis 1. FEN terminal
2. EC-AT on-board diagnosis [ATX] 2. FAT terminal [ATX]
3. Initial set 3. TEN terminal
4. Fuel pump check 4. F/P terminal
5. Engine speed output 5. IG- terminal
6. Switch and heated oxygen sensor 6. MEN terminal
monitor
7. Supply battery positive voltage 7. + B terminal
8. Ground 8. GND terminal
9. ABS self-diagnosis 9. TBS and FBS terminals
10. A/C self-diagnosis 10 TAC and FAC terminals
11. Cruise control self-diagnosis 11. TSC and FSC terminals
EGR function sensor Detects EGR control valve position Installed on EGR control valve
EGR solenoid valve Controls vacuum to EGR control valve (vent • Controlled by duty signal from PCME
(vent) side)
EGR solenoid valve Controls vacuum to EGR control valve • Controlled by duty signal from PCME
(vacuum) (vacuum side)
Engine coolant Detect coolant temperature; send signals to • Installed in engine (for CIS and fan)
temperature sensors PCME
Fuel filter Filters particles from fuel —
Fuel pump Provides fuel to injectors • Operates while engine running
• Installed in fuel tank
Fuel pump relay Voltage for fuel pump while engine running —
Fuel vapor valve Prevents fuel from flowing into charcoal
—
canisters
Heated oxygen sensor Detects oxygen concentration; sends signal to • Zirconic and platinum coating
PCME • With heater
Idle air control valve Supplies bypass air into intake manifold • Controlled by duty signal from PCME
Igniter Receives spark signal from PCME and • Installed in distributor
generates high voltage in ignition coil
Ignition switch Sends engine cranking signal to PCME
—
(START position)
Injector Injects fuel into intake port • Controlled by signal from PCME
(side-feed type)
Intake air temperature Detects intake air temperature; sends signal • Installed in volume airflow sensor
sensor to PCME
Knock sensor Detects engine knocking; sends signal to
—
PCME
F2-11
F2 OUTLINE

Main relay Supplies current to output devices and PCME —
Neutral and clutch Detects in-gear condition; sends signal to • Switch ON in neutral
switch (MTX) PCME
One-way check valve Prevents malfunction of VRIS shutter valve • For VRIS and EGR
and EGR valve during heavy—load operation
Park/Neutral switch Detects load condition; sends signal to PCME • Switch ON in P, N range
(ATX)
PCV valve Controls blow-by gas introduced into engine —
module (PCME) 1. A/C operation 1. Air conditioning sensor
3. Barometric absolute pressure 3. Barometric absolute pressure sensor
4. Braking signal 4. Stoplight switch
6. E/L operation 6. Blower motor switch, coolant fan relay,
headlight switch, and rear window
defroster switch
7. Engine coolant temprerature 7. Engine coolant temperature sensor
8. E n g in e s p e e d 8. Crankshaft position sensor No.2 (Ne2
signal)
9. ignition ON signal 9. Ignition switch
10. In-gear condition 10. Neutral and clutch switches (MTX) or
Park/Neutral switch (ATX)
11. Intake air amount 11. Volume airflow sensor
(in volume airflow sensor)
13. EGR control valve position 13. EGR function sensor
14. No.1 piston TDC 14. Crankshaft position sensor No.1
(G signal)
16. Test mode signal (ignition timing, idle 16. Data link connector (TEN terminal)
speed, diagnostic trouble code No.)
18. Throttle valve closed throttle position 18. Idle switch (in throttle position sensor)
Controls operation of following:
1. A/C (Cut-off) 1. A/C relay
2. On-board diagnosis function 2. Self-Diagnosis Checker
3. Fuel injection system 3. Injector
5. Ignition system (electronic spark 5. Igniter
advance)
6. Monitor function 6. Monitor lamp (Self-Dagnosis Checker)
8. VRIS control system 8. VRIS Solenoid valve
9. EGR function control system 9. EGR solenoid valve
10. Pressure regulator control system 10. PRC solenoid valve
11. Coolant fan control system 11. Coolant fan relay
12. Condenser fan control 12. Condenser fan relay
13. Lockup control system 13. Powertrain control module (PCMT)
14. Slip control system 14. Powertrain control module (PCMT)
PRC solenoid valve Controls vacuum to pressure regulator —
Purge solenoid valve Controls evaporative fumes from charcoal • Controlled by duty signal from PCME
canister to intake manifold
Resonance chamber Reduces intake air noise —
Shutter valve actuator Opens/closes shutter valve to inprove torque • For variable resonance induction system
characteristics (VRIS)
F2—12
OUTLINE F2
Steering pressure Detects P/S operation • Steering pressure sensor ON when steering
sensor wheel turned
Stoplight switch Detects braking; sends signal to PCME —
Three way catalyst Reduces HC, CO, NOx by chemical reaction Monolith type
Throttle position Detects throttle valve opening angle • Installed on throttle body
sensor
Vehicle speed sensor Detects vehicle speed; sends signal to PCME • Installed in instrument cluster
Volume airflow sensor Detects intake air amount; sends signal to Intake air temperature sensor included
PCME
VRIS Solenoid valve Controls vacuum to shutter valve actuator
—
(No.1 and No.2)
Warm up three way Reduces HC, CO, NOx by chemical reaction Monolith type
catalyst
46U0F2-007
F2 ENGINE TUNE-UP
ENGINE TUNE-UP
PREPARATION
SST
49 B019 9A0 For

inspection of
System Selector )) ignition timing
and idle speed
^ 2 ?
16E0F2-012
BASIC INSPECTION
Engine Oil
1. Remove the dipstick and check the engine oil level and con
dition.
2. Add or change oil as necessary.
6
16E0F2-013
Coolant (engine cold)
Warning
46U0F2-008 clockwise to the first stop. Step back while the pres
sure escapes.
remove it.
1. Verify that the coolant level is near the radiator filler neck.
2. Verify that the coolant level on the coolant dipstick is be
tween the F and L marks.
Battery
Removing the label on the top of the battery or removing the
vent caps will void the battery’s warranty.
1. Clean any corrosion on the clamps or battery posts.
Note
F 2 -1 4
ENGINE TUNE-UP F2
Air Cleaner Element
Inspection
and damage.
Caution
duce the element’s ability to filter the air. Don’t use
ADJUSTMENT
Preparation
2. Turn all electric loads OFF.
• Blower switch
• A/C sensor
IG - as shown.
Ignition Timing
1. Perform Preparation. (Refer to above.)
2. Verify that the idle speed is within the specification; if not,
adjust it. (Refer to page F2-16.)

nector.
6. Vefiry that the idle speed is within the specification.
Idle speed (Ground the terminal TEN): 550—750 rpm
7. Verify that the timing mark (yellow) on the crankshaft pulley

and the mark on the timing belt cover are aligned.
Ignition timing: BTDC 9 °—11° (10° ± 1 ° )
8. If the marks are not aligned, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
Tightening torque:
19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf}
46U0F2-013
F 2-1 5
F2 ENGINE TUNE-UP
10. Verify that the ignition tinning is within the specification.
Idle Speed
4. With the coolant fan off, verify that the idle speed is within
specification.
5. If not within the specification, adjust the idle by turning the

air adjusting screw.
46U0F2-014 6. Disconnect the SST.
F 2 -1 6
DESCRIPTION
When trouble occurs in the main input or output devices, check for the cause by using the SST. Failure
of input and output devices is indicated and retrieved from the powertrain control module (PCME) as diag
nostic trouble codes.
For input devices, the PCME continuously checks for malfunction. For output devices, it checks for mal
functions only in a three-second period after the ignition switch is turned to ON, or the TEN terminal of
the data link connector is grounded.
PCME
46U0F2-015
F2—17
PREPARATION
SST

Self-diagnosis checker
1. Connect the SST (Self-Diagnosis Checker) to the data link
connector.
2. Set switch select to position 1.
36U0F2-017
4. Connect the SST to the System Selector and a ground.
5. Set the select switch to position A.
7. Verify that "88” flashes on the digital display and the buzz
er sounds for 3 sec. after turning the ignition switch ON.
8. If “ 88” does not flash, check the main relay (refer to page
F2-104), power supply circuit, and data link connector
wiring.
than 20 sec., check for a short circuit between the PCME
terminal 1F and the data link connector. Replace the
PCME if necessary and perform Steps 3 and 7 again.
NEGATIVE BATTERY CABLE 10. Note any code numbers and check for the causes by refer
ring to the check sequences shown on pages F2-22
through F 2-41. Repair as necessary.
11. After repairs, cancel the code numbers by performing the
“ After-repair procedure” . (Refer to page F2-42.)
36U0F2-022
1. Code cycle break

The time between diagnostic trouble code cycles is 4.0 seconds (the time the buzzer is off).

1 CYCLE
CYCLE BREAK
ON
OFF
IT
4.0 SEC.
36U0F2-023

The digit in the ones position of the diagnostic trouble code represents the number of times the buzzer
sounds 0.4 second during one cycle.
DIAGNOSTIC TROUBLE CODE DIAGNOSTIC TROUBLE

1 CYCLE
CODE: 03
ON
1 2 3 CYCLE BREAK
n
OFF i
0.4 0.4 4.0 SEC.
SEC. SEC.
36U0F2-024

The digit in the tens position of the diagnostic trouble code represents the number of times the buzzer
is on 1.2 seconds during one cycle.
The buzzer is off for 1.6 seconds between the long and short pulses.
1 CYCLE DIAGNOSTIC TROUBLE CODE DIAGNOSTIC TROUBLE

CODE: 22
nr
1 2 CYCLE
BREAK
- 0.4 fir
1.2 SEC. SEC. 1.6 4.0 SEC.
h SEC,
FIRST DIGIT SECOND
DIGIT
36U0F2-025
F 2-1 9
Diagnostic Trouble Code Numbers
Diagnosed Memo
No. Indicator flashing pattern Condition Point
circuit rized
• Crankshaft position
sensor No. 2 connector
NE 2 signal,
ON • Wiring from crankshaft
crankshaft
02 N o NE 2 signal position sensor No. 2 to Yes F 2 -2 2
position
OFF PCME
sensor No. 2
• C rankshaft position
sensor No. 2
• D istributor con necto r
G signal,
ON • W iring from m ain
crankshaft
03 N o G signal relay to distributor Yes F 2 -2 3
position
OFF >W iring from distribu
sensor No. 1
tor to PCME
> C rankshaft position
NE 1 signal, sensor No. 1
ON
crankshaft
04 N o NE 1 signal Yes F 2 -2 4
position
OFF sensor No. 1
• K nock sensor co n
ON nector
05 K nock sensor O pen o r short circuit • W iring from knock Yes F 2 -2 5
OFF sensor to PCME
• K nock sensor
• V olum e airflow
ON sensor con necto r
V olum e airflow
08 O pen o r short circuit • Wiring from volume air Yes F 2 -2 6
sensor
OFF flow sensor to PCME
• Volume airflow sensor
• Engine coolant temper
ature sensor connector
ON E ngine coolant >Wiring from engine
09 tem perature coolant temperature Yes F 2 -2 7
OFF sensor sensor to PCME
>Engine coolant temper
ature sensor resistance
>V olum e airflow
sensor con necto r
Intake air tem prer-
ON »Wiring from volume air
ature sensor (in
10 flow sensor to PCME Yes F 2 -2 8
volum e airflow
O FF > Intake air tem p e ra
sensor)
O pen o r short ture sensor re
circuit sistance
* T hrottle position sen
sor con necto r
ON »W iring from throttle
Throttle position
12 sensor
position sensor to Yes F 2 -2 9
OFF PCME
«Throttle position
sensor
Barom etric
ON
absolute
14 -P C M E Yes F 2 -3 0
pressure sensor
OFF (in PCME)
S ensor ou tput c o n • H eated oxyg en sen

tinues less than 0.55V sor con necto r
ON H eated oxygen
100 sec. after engine >Wiring from heated oxy
15 sensor Yes F 2 -3 0
exce eds 1,500 rpm gen sensor to PCME
OFF (Inactivation)
• H eated oxygen
sensor
> EGR fun ction sensor
ON con necto r
EGR function O pen or
16 • Wiring from EGR func Yes F 2 -3 1
sensor short circuit
OFF tion sensor to PCME
> EGR fun ction sensor
S ensor o u tp u t not »Fuel pressure
ON H eated oxygen ch a n g e d 50 sec. after > Injection fuel leakage
17 sensor engine exce eds 1,500 • Ignition system Yes F 2 -3 2
OFF (Inversion) rpm >A ir leakage
>PCME
F 2-2 0
Indicator flashing pattern Diagnosed Memo
No. Condition Point Page
circuit rized
S ensor ou tput co n » H eated oxygen sen
ON H eated oxygen
tinues less than 0.55V sor con necto r
23 sensor Yes F 2 -3 0
100 sec. after engine • Wiring from heated oxy
OFF (RH)
exce eds 1,500 rpm gen sensor to PCME
• Heated oxygen sensor
S ensor ou tput not > Fuel pressure

ON C losed loop ch a n g e d 50 sec. after • Injection fuel leakage
24 system en gine exceeds 1,500 > Ignition system Yes F 2 -3 2
O FF (RH) rpm • A ir leakage
•P C M E
> PRC solenoid valve
ON • connection
PRC solenoid >Wiring from PRC sole
25 No F 2 -3 4
valve noid valve to PCME
O FF
> PRC solenoid valve
continuity
> P urge solenoid valve
connection
ON
Purge solenoid »Wiring from purge sole
26 No F 2 -3 5
valve noid valve to PCME
OFF • P urge solenoid valve
con tinuity
■ EGR solenoid (vacu
um ) valve connection
ON
EGR solenoid * Wiring from EGR solenoid
28 No F 2 -3 6
valve (vacuum ) valve (vacuum) to PCME
OFF
• EGR solenoid valve
(vacuum ) continuity
» EGR solenoid valve
(vent) connection
ON
EGR solenoid * Wiring from EGR solenoid
29 No F 2 -3 7
valve (vent) valve (vent) to PCME
OFF
» EGR solenoid valve
O pen o r short circuit (vent) continuity
» Idle air control valve
con necto r
ON
Idle air »Wiring from idle air
34 No F 2 -3 8
control valve control valve to PCME
OFF
» Idle air control valve
continuity
• VRIS solenoid valve
1 connection
ON VRIS Solenoid >Wiring from VRIS sole
41 No F 2 -3 9
valve 1 noid valve 1 to PCME
OFF >VRIS solenoid valve
1 continuity
2 connection
ON
VRIS solenoid • W iring from VRIS sole
46 No F 2 -4 0
valve 2 noid valve 2 to PCME
OFF
2 continuity
• C oolant fan relay
ON con necto r
C oolant fan
67 ' W iring from relay to No F 2 -4 1
relay (No.1)
O FF PCME
1C oolant fan relay
46U0F2-018
The buzzer sounds only for the ones position when using the Digital Code Checker. To judge the correct
diagnostic trouble code number, refer to the digital display.
Refer to Section F1 when using the Digital Code Checker.
Note
• If more than one failure is present, the code numbers will be indicated in numerical order.
After repairs, cancel the code numbers by performing the “ After-repair procedure” .
F2-21
Troubleshooting
If a diagnostic trouble code numbers is shown on the SST, check for the cause by referring to the related
chart.
CODE NO. 02 (CRANKSHAFT POSITION SENSOR No.2 NE 2 SIGNAL)

1 Does crankshaft position sensor circuit have Yes Repair connector and/or wiring
poor connection?
No Go to next step
2 Is resistance of crankshaft position sensor OK? Yes Go to next step
Resistance: 520—5800 No Replace crankshaft position sensor

No.2 c r page F2-105
3 Is there continuity between ground and 3F or Yes Check for short circuit in wiring
ground and terminal 3H? (at harness side) (Crankshaft position sensor-
terminal 3F or 3H)
No Go to next step
4 Disconnect connector from PCME; is resistance Yes Replace PCME

between terminals 3F and 3H OK?
Resistance: 520—580(2 (Crankshaft position sensor-
terminal 3F or 3H)
46U0F2-019
Circuit Diagram
16E0F2-035
F 2 -2 2
CODE No. 03 (CRANKSHAFT POSITION SENSOR No.1 G SIGNAL)
1 Is Code No.04 also present? Yes Go to next step
No Go to Step 4
2 Does distributor circuit have poor connection? Yes Repair connector and/or wiring harness
No Go to next step
3 Is connector terminal 1B voltage OK with d is tri Yes Repair or replace distributor c r Section G
utor connector disconne cted?
Condition Voltage
No Repair distributor terminal 1B wire
Ign switch ON Battery positive
voltage
4 Is connector terminal (1D) voltage OK with dis Yes Repair or replace distributor o - Section G
tributor connector disconnected?
No Check for short circuit in wiring harness
Condition Voltage
(Distributor terminal [1D]—Ground)
If OK, replace PCME
46U0F2-020
Circuit Diagram
TO IGNITION DISTRIBUTOR
FROM
SWITCH
IGNITION FROM
IGNITION
SW ITCH BATTERY
COIL
TO TACHO
METER
MAIN
RELAY
TO DATA LINK
CO NNECTOR ^
PCME CRANK
SHAFT
POSITION
SENSOR
G SIGNAL
J - G SIGNAL
+B
NE1 SIGNAL i NE1 SIGNAL
DISTRIBUTOR
1F|i E11D11C11B11A | l2C|2B|2A
16E0F2-037
F 2-2 3
CODE No. 04 (CRANKSHAFT POSITION SENSOR No.1 NE1 SIGNAL)

1 Is Code No.03 also present? Yes Go to next step
No Go to Step 4
2 Does distributor circuit have poor connection? Yes Repair connector and/or wiring harness
No Go to next step
3 Is connector terminal 1B voltage OK with d is tri Yes Repair or replace distributor c r Section G
utor connector disconne cted?
Condition Voltage
No Repair distributor terminal 1B wire
Ign switch ON Battery positive
voltage
4 Is connector terminal 1C voltage OK with distrib Yes Repair or replace distributor c r Section G
utor connector disconnected?
No Check for short circuit in wiring har
Condition Voltage
ness (Distributor terminal 1C Ground)
=0 If OK, replace PCME
46U0F2-021
Circuit Diagram
DISTRIBUTOR
--- ------ ^ ^
|lF |lE |lD |lC |lB |lA i |2C |2B |2A |
S—--------------------' ' -V
16E0F2-039
F 2 -2 4
CODE No. 05 (KNOCK SENSOR)
STEP INSPCTION ACTION
1 Does knock sensor circuit have a poor con Yes Repair connector and/or wiring harness
nection?
No Go to next step
2 Is there continuity between knock sensor and Yes Check continuity between PCME ter
PCME terminal 2M? minal 2M and ground
■=!> If continuity, repair or replace

wiring
■=> If no continuity, go to next step
3 Try known good knock sensor; is same code Yes Replace PCME c r page F2-92
No. present?
No Replace knock sensor c r page F2-110
46U0F2-022
Circuit Diagram
KNOCK SENSOR
16E0F2-041
F 2-2 5
CODE No. 08 (VOLUME AIRFLOW SENSOR)

Is there continuity between volume airflow sensor Yes Repair wiring harness
terminal A and a ground?
No Go to next step
Is volume airflow sensor terminal B voltage OK Yes Go to next step

with volume airflow sensor connector discon
nected? No Check for short or open circuit in wiring
harness (volume airflow sensor terminal
Condition Voltage B PCME terminal 21)
o If OK, replace PCME
Is resistance of volume airflow sensor OK? Yes Replace PCME cr page F2-92
Volume airflow Closed throttle Wide open

No Replace volume airflow sensor cr page F2-48
sensor position (fi) throttle (Q)
A—B 20—600 2 0-1,000
B -D 2 0 0 -4 0 0
46U0F2-023
Circuit Diagram
VOLUME AIRFLOW SENSOR
(j j f l D l C l B l A l ) )
16E0F2-043
F 2 -2 6
1 Does the engine coolant temperature sensor cir Yes Repair connector and/or wiring harness
cuit have a poor connection?
No Go to next step
2 Is engine coolant temperature sensor terminal A Yes Go to next step

voltage OK with engine coolant temperature sen
sor connector disconnected?
No Check for short or open circuit in wir
ing harness (engine coolant tempera
Condition Voltage
ture sensor terminal A—PCME
Ign switch ON Approx. 5.0V terminal 2E)
=> If OK, replace PCME

<=> If not OK, repair wiring harness
3 Is there continuity between engine coolant tem Yes Go to next step
perature sensor terminal A and a ground
4 Is resistance of engine coolant temperature sensor Yes Replace PCME c r page F2-92
OK?
Coolant temp. Resistance (kfi)

-2 0 °C (—4°F) 13.5-16.5 No Replace engine coolant temperature c r page F2-106
20°C (68°F) 2.20-2.70 sensor
80°C { 176°F) 0.29-0.35
46U0F2-024
Circuit Diagram
ENGINE COOLANT TEMPERATURE SENSOR
( n n ;n
. 1 Bl A I,
---n---'
16E0F2-045
F 2 -2 7
CODE No. 10 (INTAKE AIR TEMPERATURE SENSO R-IN VOLUME AIRFLOW SENSOR)
1 Does the volume airflow sensor circuit have a Yes Check volume airflow sensor connec
poor connection? tor for poor connection and repair as
necessary
No Go to next step
2 Is volume airflow sensor terminal E voltage OK with Yes Go to next step

volume airflow sensor connector disconnected?
Condition Voltage No Check for short or open circuit in wiring

harness (Volume airflow sensor terminal
Ign switch ON Approx. 5.0V E—PCME terminal 2K)
3 Is resistance of intake air temperature sensor OK? Yes Replace PCME c r page F2-92
Intake air temp. Resistance (kQ)

-2 0 °C (—4°F) 1 0 -2 0 No Replace volume airflow sensor c r page F2-48
20°C |68°F) 2 -3
60°C { 140°F) 0.4—0.7
46U0F2-025
Circuit Diagram
16E0F2-Q47
F 2 -2 8
CODE No. 12 (THROTTLE POSITION SENSOR)
1 D o e s th ro ttle p o sitio n s e n so r c irc u it h a ve a p o o r Y es R e p a ir c o n n e c to r a n d /o r w irin g
c o n n e c tio n ? h a rn e ss
No G o to n e xt ste p
2 Is th ro ttle p o s itio n s e n so r te rm in a l A v o lta g e O K Yes G o to n e xt ste p

w ith th ro ttle p o s itio n s e n s o r d is c o n n e c te d ?
No C h e c k fo r o p e n o r sh o rt c irc u it in w irin g
Condition Voltage
harness (Throttle position sensor term inal
Ig n s w itch O N A p p ro x . 5 .0 V A — P C M E te rm in a l 21)
o If O K, re p la c e PC M E
=> If n o t O K , re p a ir w irin g ha rn e ss
3 Is th e re c o n tin u ity b e tw e e n th ro ttle p o sitio n se n Y es C h e c k fo r s h o rt c irc u it in w irin g h a rn e s
sor and PCM E? (T hrottle p o sitio n se n so r te rm in a l B —
P C M E te rm in a l 2F)
Throttle position sensor PCME
=> If O K , g o to n e xt ste p
B 2F
=> If n o t O K, re p a ir w irin g h a rn e ss
D G ro u n d
No R e p a ir w irin g h a rn e ss
4 Is th e re c o n tin u ity b e tw e e n te rm in a ls A a n d B Yes R e p la ce P C M E cr page F2-92

w ith th ro ttle v a lv e c lo s e d th ro ttle p o sitio n to w id e
o p e n th ro ttle ?
No R e p la ce th ro ttle p o sitio n se n so r cr page F2-108
46U0F2-026
Circuit Diagram

/----- n n —-
i l D 1 C I B I A ll
16E0F2-O49
F 2-2 9
CODE No. 14 (BAROMETRIC ABSOLUTE PRESSURE SENSOR—IN PCME)

STEP ACTION
1 R e p la c e P C M E c r page F2-92
46U0F2-199
CODE No. 15 and/or 23 (HEATED OXYGEN SENSOR—INACTIVATION)

Note
• If Code No.15 and 17 are both present, first perform the checking procedure for Code No.17.
1 D o e s h e a te d o x y g e n s e n s o r c irc u it h a ve a p o o r Yes R e p a ir c o n n e c to r a n d /o r w irin g
c o n n e c tio n ? ha rn e ss
2 Is h e a te d o x y g e n s e n so r o u tp u t v o lta g e O K? Yes G o to n e xt step
No R e p la ce h e a te d o x y g e n se n so r a- page F2-109
3 Is th e re c o n tin u ity b e tw e e n h e a te d o x y g e n sen Y es C h e c k fo r s h o rt c irc u it in w irin g

s o r a n d P C M E te rm in a l 2 D (R H : 2C)?
If O K, re p la ce PC M E
=> If n o t O K, re p a ir w irin g ha rn e ss
36U0F2-036
Circuit Diagram
HEATED OXYGEN HEATD OXYGEN

r.— — SENSOR r ---- SENSOR C A L IF O R N IA : B O D Y G R O U N D
cA LH c A RH
D B D B
— —
16E0F2-052
F 2 -3 0
CODE No. 16 (EGR FUNCTION SENSOR)
D o e s EG R fu n c tio n s e n so r c irc u it h a ve a p o o r Y es R e p a ir c o n n e c to r a n d /o r w irin g
c o n n e c tio n ? h a rn e ss
Is EG R fu n c tio n s e n s o r te rm in a l C v o lta g e O K Yes G o to n e xt ste p

w ith EG R fu n c tio n s e n so r c o n n e c to r d is c o n
n e c te d ?
No C h e c k fo r sh o rt o r o p e n c irc u it in w ir
in g h a rn e ss (EGR fu n c tio n s e n so r te r
Condition Voltage
m inal C — P C M E te rm in a l 21)
Ig n sw itch O N A p p ro x . 5 .0 V
=> If O K, re p la c e PC M E
<
=>If n o tO K , re p a ir w irin g h a rn e ss
Is th e re c o n tin u ity b e tw e e n EG R fu n c tio n s e n so r Yes C h e c k fo r sh o rt c irc u it in w irin g h a r
and PCME? ness (EGR fu n c tio n s e n so r te rm in a l
A — P C M E te rm in a l 2J)
EG R fu n c tio n s e n so r PCM E
■=£> If O K , g o to n e xt ste p
A 2j m ^ If n o t O K, re p a ir w irin g h a rn e ss
B G ro u n d
R e m o v e EG R fu n c tio n se n so r; is s e n so r rod Yes R e p la ce EG R fu n c tio n s e n so r

dam aged?
cr page F2-78
Is th e re u n b ro k e n c o n tin u ity b e tw e e n te rm in a ls A Yes R e p la ce P C M E cr page F2-92

a n d C w h ile EG R fu n c tio n s e n so r ro d is m o v e d
fro m fu lly e x te n d e d to fu lly d e p re s s e d ?
No R e p la ce EG R fu n c tio n se n so r
46U0F2-027
Circuit Diagram
SENSOR
16E0F2-054
F2-31
CODE No. 17 and/or 24 (HEATED OXYGEN SENSOR-INVERSION)

1 Is th e s a m e C o d e N o. p re s e n t fo llo w in g a fte r Yes G o to n e xt ste p
re p a ir p ro c e d u re ? c r page F2-42
No C h e c k h e a te d o x y g e n s e n so r c irc u it
fo r a p o o r co n n e c tio n
^ If O K, p e rfo rm d ia g n o s tic tro u b le

C o d e N o. 15
2 D o e s m o n ito r la m p o f S e lf-D ia g n o sis C h e c k e r il Yes G o to n e xt ste p

lu m in a te a t id le a fte r th e e n g in e has b e e n w a rm e d
u p a n d run a t 2500—3000 rpm fo r 3 min? Note
• A /F m ixtu re rich
No G o to S te p 5
Note
• A /F m ixtu re is lean o r m isfire is o c
c u rrin g
3 Is fu e l lin e p re s s u re c o rre c t a t idle? Yes G o to n e xt ste p

c r page F2-70
Fuel line pressure: No High pressure
210—250 kPa {2.1—2.6 kgf/cm2, 30—36 psi)
C h e c k if fuel re tu rn hose is c lo g g e d o r
(vacuum hose to pressure regulator re stricte d
disconnected)
■=> If O K , re p la ce p re ssu re re g u la to r c r page F2-66
4 Is th e re fu e l le a k a g e at in je cto r? Yes R e p la ce in je cto r c r page F2-66

c r page F2-68
No C h e c k e n g in e c o o la n t te m p e ra tu re
se n so r? c r page F2-106
•=> If it is O K, re p la c e h e a te d o x y g e n
se n so r
o If it is n o t O K , re p la c e it c r page F2-106
5 D is c o n n e c t e a ch h ig h -te n s io n le a d at idle; d o e s Yes G o to n e xt ste p
e n g in e s p e e d d e c re a s e e q u a lly at e a ch c y lin d e r?
No G o to S te p 8
46U0F2-028
Circuit Diagram
F 2 -3 2
6 Is fu e l line p re s s u re c o rre c t at idle? Yes G o to n e xt ste p
cr page F2-70
No Low pressure
Fuel line pressure:
C h e c k fuel line p re s s u re w h ile p in c h
210—250 kPa (2.1—2.6 kgf/cm2, 30—36 psi) in g fuel re tu rn hose
(vacuum hose to pressure regulator
disconnected)
^ If it quickly in crea se s, c h e c k p re s
s u re re g u la to r cr page F2-70
^ If it gradually in crea se s, c h e c k fo r
c lo g g in g b e tw e e n fu e l p u m p a n d
p re s s u re re g u la to r
If h o se is n o t c lo g g e d , c h e c k fuel
p u m p m a xim u m p re s s u re cr page F2-63
7 Is th e re a ir le a ka g e in intake air system co m p o n e n ts? Yes G o to n e xt ste p
No R e p la ce h e a te d o x y g e n s e n so r cr page F2-109
8 Is th e re a m isfire o f a d e a d c y lin d e r fro m S te p 5 in Y es R e p a ir o r re p la c e ig n itio n syste m c o m

s p e c tio n ? p o n e n ts )
9 Is th e re an in je c to r o p e ra tin g s o u n d at id le o f d e a d Yes G o to n e xt ste p

c y lin d e r fro m S te p 5 in sp e ctio n ?
No C h e c k fo r a p p ro x . B + at in je c to r te r
m inal A
■=> If th e re is, re p la ce in je c to r cr page F2-66

=> If th e re is not, c h e c k fo r a sh o rt o r
o p e n c irc u it in w ire h a rn e ss
10 R e p la c e in je c to r a t d e a d c y lin d e r fro m S te p 5 in Y es T ry k n o w n g o o d PC M E
s p e c tio n
cr page F2-32
No S ystem O K
Is th e s a m e C o d e N o. p re s e n t fo llo w in g a fte r re p a ir
p ro c e d u re ?
cr page F2-42
46U0F2-029
Circuit Diagram
F 2-3 3
CODE No. 25 (PRESSURE REGULATOR CONTROL SOLENOID VALVE)

1 Does PRC solenoid valve circuit have a poor Yes Repair connector and/or wiring harness
connection?
No Go to next step
2 s connector terminal A /oltage OK with PRC Yes Go to next step

solenoid valve connecto disconnected?
Condition Voltage
Ign switch ON Battery positive harness (PRC solenoid valve terminal
voltage A—Main relay terminal D)
3 Is continuity between PRC solenoid valve termi Yes Check for short circuit in wiring harness
nal B and PCME terminal 3M? (PRC Solenoid valve terminal B—
PCME terminal 3M)
■=> If OK, go to next step

^ If not OK, repair wiring harness
4 Is PRC solenoid valve OK? c r page F2—72 Yes Replace PCME c r page F2-92
No Replace PRC solenoid valve
46U0F2-030
Circuit Diagram
FROM IGNITION SWITCH FROM BATTERY
PRC SOLENOID VALVE
16E0F2-059
F 2 -3 4
CODE No. 26 (PURGE SOLENOID VALVE)
1 Does purge solenoid valve circuit have a poor Yes Repair connector and/or wiring
connection? harness
No Go to next step
•
2 Is connector terminal A /oltage OK with purge Yes Go to next step
solenoid valve connecto disconnected?
Condition Voltage
No Check for open or short circuit in wir
Ign switch ON Battery positive ing harness (Purge solenoid valve ter
voltage minal A—Main relay terminal D)
3 Is there continuity between purge solenoid valve Yes Check for short circuit in wiring har
terminal B and PCME terminal 20? ness (Purge solenoid valve terminal
B—PCME terminal 20)
If OK, go to next step

4 Is purge solenoid valve OK? c r page F2-82 Yes Replace PCME c r page F2-92
46U0F2-031
Circuit Diagram
MAIN RELAY
PURGE SOLENOID VALVE

?
b F a!
16E0F2-061
F 2-3 5
CODE No. 28 (EGR SOLENOID VALVE-VACUUM)

1 Does EGR solenoid valve circuit have a poor Yes Repair connector and/or wiring harness
connection?
No Go to next step
2 Is connector terminal A voltages OK with EGR Yes Go to next step

solenoid valve (vacuum) connector discon
nected?
Voltage No Check for open or short circuit in wiring

Condition
harness (EGR Solenoid valve (vacuum)
Ign switch ON Battery positive terminal A—Main relay terminal D)
voltage
3 Is there continuity between EGR solenoid valve Yes Check for short circuit in wiring from
(vacuum) terminal B and PCME terminal 3P? EGR solenoid valve (vacuum) terminal
B to PCME terminal 3P

4 Is EGR solenoid valve (vacuum) OK? Yes Replace PCME o- page F2-92
a - page F2-77
No Replace EGR solenoid valve (vacuum)
46U0F2-032
Circuit Diagram
EGR SOLENOID VALVE

(VACUUM)
n n
JibJu a-IS _______________

16E0F2-063
F2—36
CODE No. 29 (EGR SOLENOID VALVE VENT)
1 Does EGR solenoid valve (vent) circuit have a Yes Repair connector and/or wiring harness
poor connection?
No Go to next stop
2 Is connector terminal A voltage OK with EGR Yes Go to next step

solenoid valve (vent) corinector disconnected?
Condition Voltage
Ign switch ON Battery positive harness (EGR solenoid valve (vent)
voltage terminal A—Main relay terminal D)
3 Is there continuity between EGR solenoid valve Yes Check for short circuit in wiring harness
(vent) terminal B and PCME terminal 30? (EGR solenoid valve (vent) terminal B—
PCME terminal 30)
■=£> If OK, go to next step

^ If not OK, repair wiring harness
4 Is EGR solenoid valve (vent) OK? Yes Replace PCME cr page F2-92
cr page F2-77
No Replace EGR solenoid valve (vent)
46U0F2-033
Circuit Diagram
16E0F2-065
CODE No. 34 (IDLE AIR CONTROL VALVE)

1 Does idle air control valve circuit have a poor Yes Repair connector and/or wiring harness
connection?
No Go to next step
2 Is connector terminal A /oltage OK with idle air Yes Go to next step

control valve connector disconnected?
Condition Voltage
Ign switch ON Battery positive harness (Idle air control valve terminal
voltage A—Main relay terminal D)
3 Is there continuity between idle air control valve Yes Check for short circuit in wiring harness
terminal B and PCME terminal OK? (Idle air control valve terminal B—PCME
terminal 30)

4 Is idle air control valve OK? c r page F2-53 Yes Replace PCME c r page F2-92
No Replace idle air control valve c r page F2-48
46U0F2-034
Circuit Diagram
O bT a D
16E0F2-067
F 2 -3 8
CODE No. 41 (VRIS SOLENOID VALVE No.1)
1 Does VRIS solenoid valve No.1 circuit have a Yes Repair connector and/or wiring harness
poor connection?
No Go to next step
2 s connector terminal A voltage OK with VRIS Yes Go to next step

solenoid valve No.1 con nector disconnected?
Condition Voltage
Ign switch ON Battery positive harness (VRIS solenoid valve No. 1 termi
voltage nal A—Main relay terminal D)
3 Is there continuity between VRIS solenoid valve No.1 Yes Check for short circuit in wiring harness
terminal B and PCME terminal 31? (Solenoid valve No.1 terminal B—PCME
terminal 31)

4 Is VRIS solenoid valve No.1 OK? Yes Replace PCME cr page F2-92
c r page F2-57
No Replace VRIS solenoid valve No.1 cr page F2-56
46U0F2-035
Circuit Diagram
MAIN RELAY
'A
VRIS SOLENOID VALVE

No.1
i I
| GY | R / B |
16E0F2-069
F 2 -3 9
CODE No. 46 (VRIS SOLENOID VALVE No.2)

1 Does VRIS solenoid valve No.2 circuit have a Yes Repair connector and/or wiring harness
poor connection?
No Go to next step
2 Is connector terminal A voltage OK with Yes Go to next step

VRIS solenoid valve No.2 connector discon
nected?
Condition Voltage No Check for open or short circuit in wiring

harness (VRIS solenoid valve No.2 termi
Ign switch ON Battery positive nal A—Main relay terminal D)
voltage
3 Is continuity between VRIS solenoid valve No.2 Yes Check for short circuit in wiring harness
terminal B and PCME terminal 3J? (VRIS solenoid valve No.2 terminal B—
PCME terminal 3J)
■=> If OK, go to next step

4 Is VRIS solenoid valve No.2 OK? Yes Replace PCME c r page F2-92
c r page F2-57
No Replace VRIS solenoid valve No.2 c r page F2-56
46U0F2-036
Circuit Diagram
1 °6/
MAIN RELAY
f
t
— r» 0/
16E0F2-071
F 2 -4 0
CODE No. 67 (COOLANT FAN RELAY No.1)
1 Does relay circuit have a poor connection? Yes Repair connector and/or wiring harness
No Go to next step
2 Is connector terminal A voltage OK with relay con- Yes Go to next step

nector disconnected?
Condition Voltage
Ign switch ON Battery positive harness (Relay terminal A—Ignition
voltage switch terminal IG1)
3 Is there continuity between relay terminals A Yes Go to next step
and B?
No Replace relay
4 Is there continuity between relay terminal B and Yes Check for short circuit in wiring harness
PCME terminal 3L? (Relay terminal B to PCME terminal
3L)
■=> If OK, replace PCME c r page F2-92

46U0F2-037
Circuit Diagram
COOLANT FAN RELAY No.1
COOLANT FAN RELAY No.1
c A
D B
16E0F2-Q73
After-repair Procedure
Cancel the memory of diagnostic trouble code by discon
necting the negative battery cable and depressing the brake
pedal for at least 20 sec.. Reconnect the negative battery
cable.
46U0F2-038
Self-Diagnosis Checker
nector.
2. Set system select to position 1.
36U0F2-049
5. Set the select of the Self-Diagnosis Checker to position A.
7. Verify that no diagnostic trouble codes are displayed.
46U0F2-039
F 2 -4 2
SWITCH MONITOR FUNCTION
Individual switches can be inspected by the SST (Self-Diagnosis Checker).
Preparation
The TEN terminal of the data link connector must be grounded and the ignition switch turned to ON (en
gine off). If either switch remains activated, the monitor light will be illuminated.
Self-Diagnosis Checker (Monitor lamp)

Switch Remarks
Light ON Light OFF
Clutch switch (MTX) Pedal released Pedal depressed In gear
Neutral switch (MTX) In gear Neutral Clurch pedal released
Park/Neutral switch (ATX) L, S, D, or R range N or P range —
Idle switch
Pedal depressed half Pedal released fully —
(in throttle position sensor)
Stoplight switch Pedal depressed Pedal released —
Headlight switch ON OFF Positionlight ON
Blower switch ON OFF A t 3 rd o f 4th p o sitio n
Rear window defroster switch ON OFF —
ON Blower switch at 1st or 2nd

Air Conditioning sensor OFF
position
Daytime running light
ON OFF ON; Parking lever relased
(CANADA)
46U0F2-040
HEATED OXYGEN SENSOR MONITOR FUNCTION

With the System Selector test switch set to 02 Monitor, the heated oxygen sensor is monitored as described.
Condition
Item monitored Function
Engine System Selector Switch
Heated oxygen sensor out
put more than 0.45V
Heated oxygen sensor Monitor lamp ON
Running O2 monitor
output signal Heated oxygen sensor out
put less than 0.45V
Monitor lamp OFF
36U0F2-054
nector.
4. Set TEST SW to SELF-TEST.
46U0F2-041
tion A.
7.Turn the ignition switch to ON (engine off).
46U0F2-042
Procedure
46U0F2-Q43
Neutral and Clutch switches (MTX)
Idle switch
Stoplight switch
46U0F2-046
F2—45
Headlight switch
46U0F2-047
DRL
Blower switch
46U0F2-049
46U0F2-050
Rear window defroster switch
46U0F2-051
F 2-4 6
Park/Neutral switch (ATX)
46U0F2-052
INTAKE AIR SYSTEM

COMPONENT PARTS
1. Remove in the order shown in the figure, referring to Removal Note. (Refer to page F2-49.)
3. Install in the reverse order of removal, referring to Installation Note. (Refer to page F2-49.)
7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 inlbf)
O-RINQ, REPLACE O-RING, REPLACE
19—25 (1.9—2.6, 14— 18)
GASKET, REPLACE
GASKET, REPLACE
O-RING, REPLACE
19—25 |1 .9 —2.6, 14— 18)
WASHER, REPLACE
7 .9 -1 0 .7 N m
180— 110 kgfcm,
70—95.4 Inlbf)
19—25 (1.9—2.6, 14— 18)
7.9—10.7 N-m (80— 110 kgf-cm, 70—95.4 In-lbf)
7.9— 10.7 N-m [80— 110 kgf-cm, 70—95.4 ln-lbf)
N-m |kgf-m, ft-lbf)

46UOF2-053
1. Fresh air duct 6. Fuel pipe
Inspect for damage and cracks 7. Intake manifold
2. Air cleaner housing Inspection................................ page F2-51
Inspect for damage and cracks 8. Throttle body
3. Volume airflow sensor Inspection................................ page F2-49
Inspection...............................page F2-104 9. BAC valve
4. Air intake hose Inspection................................ page F2-53
Inspect for damage 10. Air intake pipe
5. Accelerator cable Inspection................................ page F2-51
Inspection / Adjustment.......... page F2- 50 11. Fuel distributor
F 2 -4 8
Removal Note
Fuel hose
Warning
dures’’ on page F2-59.
46U0F2-054
Water hose
1. Loosen the drain plug and drain the coolant from the radi
ator. (Refer to Section E2.)
2. Remove the water hose from the BAC valve.
3. After installation of the throttle body, refill the radiator.
(Refer to Section E2.)
46U0F2-186
Installation Note
O-RINGS, REPLACE Air intake pipe
1. Apply a small amount of clean engine oil to new O-rings
before installing them.
2. Install the air intake pipe.
Tightning torque:
7.9—10.7 N m {80—110 kgf cm, 70—95.4 inlbf)
46U0F2-187
THROTTLE BODY
Inspection
1. Check the throttle body for wear, coolant leakage, and
deposits.
2. Verify that the throttle valve moves smoothly from closed
throttle position to wide open throttle.
3. Replace the throttle body, if necessary.
F 2-49
ACCELERATOR PEDAL
1. Accelerator cable 5. Accelerator pedal

Inspection / Adjustment below Inspect for damage
2. Actuator cable 6. Return spring
3. Retainer 7. Bracket
4. Clip
ACCELERATOR CABLE
Installation / Adjustment
Free play: 1.5—4.5mm {0.06—0.17 in)
3. If not as specified, turn stopper B while pressing lock but

ton A to release the lock.
4. Push the spring in direction C and adjust the cable free play.
5. Lock stopper A after locking stopper B.
36U0F2-074
F 2 -5 0
AIR INTAKE PIPE/INTAKE MANIFOLD
Inspection
1. Check for damage and cracks.
2. Verify flatness of the air intake pipe and intake manifold con
tact surface as shown.
3. Replace the air intake pipe and/or intake manifold, if
necessary.
F2-51

DESCRIPTION
improve idle stability, warm-up, and driveability. This system consists of the idle air control valve, air valve,
powertrain control module, and input devices.
ENGINE COOLANT
TEM PERATURE SENSOR
CLUTCH SW ITCH (MTX)
POWERTRAIN CONTROL
I MODULE
CRANKSHAFT POSITION SENSOR No.2

(NE2 SIGNAL) \ NEUTRAL SWITCH (MTX)
PARK/NEUTRAL SWITCH (ATX)
36U0F2-076
F 2-52
PREPARATION
SST
49 B019 9A0 For

inspection of
System Selector f/T idle air control
valve and air
valve
36U0F2-259
SYSTEM OPERATION
TACHOMETER
2. Turn all electric loads OFF.
IG - as shown.
4. With the cooling fan off, verify that the idle speed is within
specification.
DATA LINK CONNECTOR 5. Verify that the idle speed is within the specification under
46U0F2-056 the conditions below.
Condition Idle speed (rpm)
No load 6 00 -7 00 (650 ± 50)
Electrical load ON 6 00 -7 00 (650 ± 50)
(headlights, rear window defroster, etc)
Air Conditioner ON 7 75 -8 75 (825 ± 50)
P/S operating 6 00 -7 00 (650 ± 50)
BAC VALVE
Inspection
Air valve
{68°F}.
3. Set the system select to position 1 and test switch to SELF
TEST.
5. Verify that the idle speed decreases gradually as the en
gine warms up.

1. Remove the throttle body. (Refer to page F2-48.)
2. Measure the resistance of the idle air control valve.
BODY
Resistance: 10.7—12.3 O [at 20°C (68°F)]
46U0F2-058
F2—53
F2 VARIABLE RESONANCE INDUCTION SYSTEM (VRIS)
VARIABLE RESONANCE INDUCTION SYSTEM (VRIS)

DESCRIPTION
The inside of the dynamic chamber is divided into two sections, interconnected by two shutter valves and
connecting pipes for variable resonance induction operation.
This system opens and closes the shutter valves according to the engine speed to improve the charging
efficiency by utilizing the pressure waves of the intake air.
There are two vacuum chambers under the left bank of the intake manifold that are used to supply con
stant vacuum to the VRIS shutter valve actuators during wide-open throttle operation and other low-vacuum,
low-speed situations.
VRIS
VRIS SHUTTER
VALVE No.
VALVE
VALVE No.2
VACUUM CHAMBERS
SHUTTER VALVE
ACTUATOR No.1
SHUTTER VALVE ACTUATOR No.2
TORQUE CHARACTERISTICS
Nos.1 AND 2 CLOSED

No.1 OPEN, No.2 CLOSED
Nos.1 AND 2 OPEN
3,250 4,250 6,250 (RPM)

ENGINE SPEED
36U0F2-101
Operation
Engine speed (rpm) 0 -3 ,2 5 0 3,250-4,250 4,250-6,250 6,250-7,500

Shutter valve No.1 Closed Open Open Closed
Shutter valve No.2 Closed Closed Open Closed
F 2 -5 4
VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) F2
SYSTEM OPERATION
2. Open the throttle valve quickly.
46U0F2-188
3. Verify that the rod of shutter valve actuator No.1 and No.2
operates.
SHUTTER VALVE ACTUATOR No.1
46U0F2-059
F2 VARIABLE RESONANCE INDUCTION SYSTEM (VRIS)
COMPONENT PARTS
46U0F2-060
1. VRIS solenoid valve No.1 4. Intake manifold (Refer to page F2-51)

Inspection.................................page F2-57 5. Vacuum chamber
2. VRIS solenoid valve No.2 Inspection.................................page F2-57
Inspection.................................page F2-57 6. Check valve
3. Shutter valve actuator Inspection.................................page F2-57
Inspection.................................page F2-57
F2—56
VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) F2
VRIS SHUTTER VALVE ACTUATOR (No.1, No.2)
Inspection
1. Disconnect the vacuum hose from the shutter valve actuator.
2. Connect a vacuum pump to the actuator.
3. Apply vacuum and verify that the rod is pulled into the ac
tuator.
46U0F2-061
CHECK VALVE
Inspection
W HITE ____ GREEN
_
1. Remove the check valve.
2. Blow through A and verify that air flows from B.
X /ff 3. Blow through B and verify that air does not flow from A.
I'v-.V
((
y ; .‘V)- s y /
16E0F2-109
VRIS SOLENOID VALVE (No.1, No.2)
Inspection
1. Disconnect the solenoid valve.
2. Verify air flow between each-port as shown below.
Port Airflow
A -B No
A -C No
B -C Yes
46U0F2-062
3. Apply battery positive voltage and a ground to the termi
nals of the solenoid valve.
4. Verify air flow between each port as shown below.
Port Airflow
A -B Yes
A -C No
B -C No
46U0F2-189
VACUUM CHAMBER
Inspection
1. Visually check the vacuum chambers for clogging, dam
age, and cracks.
2. Replace if necessary.
16E0F2-110
F 2 -5 7
F2 FUEL SYSTEM
FUEL SYSTEM
DESCRIPTION
This system supplies fuel to the fuel injectors at a constant pressure. Fuel is metered and injected into
the intake manifold ports according to injection control signals from the PCME. The system consists of
the fuel tank, fuel pump, fuel filters, fuel distributor, pressure regulator, fuel injectors, and fuel pump relay.
FUEL INJECTOR ASSEMBLIES
PRC SOLENOID VALVE
TO FUEL TANK
FROM FUEL PUMP

PUMP
FUEL FILTER
VALVE (TWO-WAY)
FUEL TANK
36UOF2-080
F 2 -5 8
FUEL SYSTEM F2
PREPARATION
SST
16E0F2-117
Warning
• Fuel vapor is hazardous. It can very easly ignite,
Warning
46U0F2-063 • Fuel line spills and leaks are dangerous. Fuel can
ty Procedures” .
Fuel Line Sately Procedures

A .Release the fuel pressure before disconnecting a fuel line.
B. Avoid leakage
C. Install hose clamps to secure the fuel pressure gauge to
fuel filter and the main hose.
SYSTEM OPERATION
Warning
dures” above.

46U0F2-065
F 2-5 9
F2 FUEL SYSTEM
2. Install a fuel pressure gauge.
16E0F2-121
a jumper wire.
pump.
Fuel pressure:
More than 150 kPa {1.5 kgf/cm2, 21 psi]
36U0F2-082
• Fuel pump (Refer to page F2-63.)
• Pressure regulator (Refer to page F2-70.)
• Injector fuel leakage (Refer to page F2-68.)
46U0F2-185
Warning

2. Install a fuel pressure gauge. (Install clamps as shown.)
a jumper wire.
JUMPER
Fuel line pressure:

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi)
Pressure low — Measure fuel pump maximum pressure.

(Refer to Page F2-63.) If as specified,
fuel line or fuel filter might be clogged or
DATA LINK restricted.
CONNECTOR Pressure high — Replace pressure regulator.
46U0F2-067
F 2 -6 0
FUEL SYSTEM F2
FUEL TANK
Warning
Warning
• Fuel line spilis and leaks are dangerous. Fuel can ignite and cause serious injuries or death
Warning
• Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion
or fire may cause death or serious injury. Always properly steam clean a fuel tank before repair
ing it.

1. Pre silencer 6. Fuel tank straps

2. Insulator 7. Fuel tank
3. Connector Inspect for cracks and corrosion
4. Fuel hoses 8. Check valve (Two-way)
Installation Note. page F2-62 Inspection................................ page F2-83
5. Evaporative hoses
Installation Note. page F2-62
F2-61
F2 FUEL SYSTEM
Removal Note
FUEL PUMP RELAY Before removing the fuel tank, drain the fuel from the tank.
3. After the engine stalls, turn off the ignition switch.
36U0F2-087
HOSE 5. Remove the filler cap and insert a hose into the fuel tank
deg. ^
through the filler pipe.
---------2160mm 85.0 in)-------- 6. Start the pump and suck up the fuel into a container.
Note
Outer diameter: 13mm (0.51 in)

Length: 2,160mm (85.0 in)
46U0F2-205
Installation Note
1. Push the ends of the main fuel hose, fuel return hose, and
evaporative hoses onto the fuel tank fittings at least 25mm
[1.0 In).
2. Push the fuel filler hose onto the fuel tank pipe and filler pipe
25mm (1
at least 35mm (1.4 In).
16E0F2-131
F 2 -6 2
FUEL SYSTEM F2
FUEL PUMP
Inspection
Warning

JUM PER WIRE
2. Connect a fuel pressure gauge to the main fuel pipe and
plug the outlet of the gauge as shown. (Install clamps as
shown.)
4. Connect data link conector terminals F/P and GND by us
ing a jumper wire.
DATA LINK
CONNECTOR Fuel pump maximum pressure:
36U0F2-091 500—630 kPa {5.0—6.5 kgf/cm2, 72—92 psi)
Continuity Inspection
1. Disconnect the fuel tank unit connector.
2. Check for continuity between the fuel tank unit connector
® and (6).
3. If there is none, replace the fuel pump.
36U0F2-092
F2 FUEL SYSTEM
1. Remove the fuel tank. (Refer to page F2-61.)
3. Install in the reverse order of disassembly, referring to Installation Note.
46U0F2-070

Removal / Installation Note................ Below
Removal Note
Rotate the fuel pump ring counterclockwise, and remove it.
Installation Note
Rotate the fuel pump ring clockwise until the flange touches
the stopper.
F 2 -6 4
FUEL SYSTEM F2
FUEL FILTER
Replacement
High-pressure side
The fuel filter must be replaced at the intervals outlined in the maintenance schedule.
1. Disconnect the fuel hoses from the fuel filter.
4. Verify that the fuel hoses are pushed fully onto the fuel filter nozzles.
N m (kgf m, ft-lbf)
46U0F2-071
1. Negative battery cable 3. Harness

2. Air cleaner housing 4. Fuel filter (High-pressure side)

FUEL
46U0F2-072
F2 FUEL SYSTEM
INJECTOR
Inspection (On-vehicle)
1. Warm up the engine and let it idle.
2. Listen for operational sound of each injector with a screw
driver or a sound scope.
Note
• The best way to judge the performance of an injector is
to compere its sound with the sound of other injectors.
Warning

46U0F2-O74
1. Negative battery cable 7. Insulator

2. Air cleaner housing 8. Accumulated connector
3. Injector connector 9. Spacer
4. Fuel hose and fuel pipe 10. Injector
5. Fuel distributor (RH) 11. Pressure regulator
6. Fuel distributor (LH) Inspection.................................page F2-70
FUEL SYSTEM F2
Installation Note
Injector installation
1. Install new O-rings.
2. Apply a small amount of clean engine oil to the O-rings be
fore installing them.
3. Verify that the injector holder is clean.
4. Clean the holder with gasoline, if necessary.
5. Install the injector squarely into the distribution pipe while
turning it back and forth.
6. Fit the injector tab into the notch in the distribution pipe.
7. Install the harness.
Tightening torque:
2.5—3.5 N m (25—36 kgf cm, 22—31 in lbf)
16E0F2-147
Fuel leakage test
1. With the injector assembly removed, install the fuel hoses
16E0F2-148
a jumper wire.
3. Turn the ignition switch ON and check for fuel leaks from
the fuel distributor.
4. If fuel leaks, check the injector O-rings and fuel distributor
for damage.
46U0F2-075
Fuel distributor installation
2. Install the insulators, making sure that each is pressed in
fully, and that it is not twisted or bent. Incorrectly installed
insulators can cause rough idle.
46U0F2-076
F 2 -6 7
F2 FUEL SYSTEM
Inspection
Note
• It is not necessary to remove the injectors to perform the
following procedures.
Injector resistance
1. Disconnect injector connectors.
2. Measure resistance of the injectors.
Harness Terminal Injector No.
a—b 1
Right Bank a—c 5
RIGHT a—d 3
BANK
d—c 2
Left Bank d—b 4
d—a 6
Resistance: Approx. 13.8Q (20°C {68°F})
LEFT 3. If not as specified, check continuity of the harness and check

No.2 No.4 No.6
BANK for poor connection.
4. If the harness is OK, replace injector.
Fuel leakage test

1. Remove the fuel distributor assembly from the intake mani
fold. (Refer to page F2-66.)
2. Connect the fuel hoses.
46U0F2-078
3. Connect the data link connector terminals F/P and GND by
JUMPER WIRE
using a jumper wire.
the injectors.
Fuel leakage: Less than 1 drop/2 min.
DATA LINK
CONNECTOR
36U0F2-104
5. If not as specified, remove the leaking injector and check
the O-rings and fuel distributor for damage. Replace as
necessary.
6. Install the injector.
injector.
46U0F2-079
F 2 -6 8
FUEL SYSTEM F2
Volume Test
1. Remove the injectors and fuel distributor assembly.
2. Connect the SST as shown in the figure.
Warning
3. Measure the injection volume of each injector by using a

graduated container.
Injection volume:
48—56 cm3 {48—56 cc, 2.9—3.4 cu in)/15 sec.
16E0F2-157
F2—69
F2 FUEL SYSTEM
PRESSURE REGULATOR
Inspection
Fuel line pressure
Warning

Fuel line pressure:

210—250 kPa {2.1—2.6 kgf/cm2, 30—36 psi}
6. Disconnect the vacuum hose from the pressure regulator

and plug it.
7. Measure the fuel line pressure again.
Fuel line pressure:

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi)
FUEL PUMP RELAY

FUEL PUMP RELAY Inspection
Operation check
Listen for clicking of the fuel pump relay while cranking the
engine.
36U0F2-095
1. Apply battery positive voltage (B + ) and check continuity
between terminals of the relay.
B + applied Yes
B + not applied No
2. If not as specified, replace fuel pump relay.
46UQF2-200
F 2 -7 0
DESCRIPTION
To prevent percolation of the fuel during hot restart idle, vacuum to the pressure regulator is momentarily
cut and the fuel injection pressure is increased to slightly more than 280 kPa {2.9 kgf/cm2, 41 psi).
Pressure in the fuel line at idle is approx. 230 kPa {2.3 kgf/cm2, 33 psi).
F2-71
F2 PRESSURE REGULATOR CONTROL SYSTEM
PRC SOLENOID VALVE
Inspection
On-vehicle
2. Disconnect the vacuum hose from the pressure regulator.
Verify that vacuum is felt.
46U0F2-082
3. Ground the solenoid valve terminal wire (GYIG) by using
a jumper wire. Verify that no vacuum is felt.
16E0F2-160
Solenoid valve
16E0F2-161
4. Apply battery voltage to solenoid valve terminal.
16E0F2-162
F 2 -7 2
EXHAUST SYSTEM F2
EXHAUST SYSTEM
COMPONENTS PARTS
Start the engine and verify that there is no exhaust gas leakage from the exhaust system components.

2. Check all parts and repair or replace as necessary.
Federal and Canada
46U0F2-Q83
1. Main silencer 5. Front pipe

2. Pre silencer 6. Insulator
Inspect for deterioration and restriction 7. EGR pipe
3. Three way catalyst Inspect for deterioration and cracks
Inspect for deterioration and restriction 8. Exhaust manifold
4. Transverse member Inspect for deterioration and cracks
F2—73
F2_____________ _______ EXHAUST SYSTEM
California
7.9—10.7 N m (80—110 kgf cm, 70—95.4 In-lbf)
59—74 ( 6.0—7.6, 44—54)
7.9—10.7 N-m
(80—110 kgf-cm, 70—95.4 In-lbf)
GASKET. REPLACE
20—28
1 5 -2 0 )
16—22
38—51 13.8—5.3, 28—38)
GASKET, REPLACE
38—51 (3.8—5.3,
SELF LOCK NUT, REPLACE
38—51 (3.8—5.3, 28—38
SELF LOCK NUT, GASKET, REPLACE
REPLACE
7.9—10.7 N-m (80—110 kgf cm,

(6.5—9.1, 4 8 -6 5 )
70—95.4 ln-lbf)
(9.5—13.4, 69—96.9)
N m (kgf m, ft-lbf)
46U0F2-084
1. Main silencer 5. Front pipe

2. Pre silencer 6. Insulator
Inspect for deterioration and restriction 7. EGR pipe
3. Three way catalyst Inspect for deterioration and cracks
Inspect for deterioration and restriction 8. Exhaust manifold
4. Transverse member (with warm-up three way catalist)
Inspect for deterioration and cracks
F 2 -7 4
DESCRIPTION
To reduce exhaust gas emissions, the positive crankcase ventilation (PCV) system and fuel evaporative
system are employed.
This system consists of the deceleration control system, fuel evaporative system, EGR function control
system, and PCV system.
The purpose of these systems is to reduce CO, HC and NOx emissions.
FUEL PUMP
FUEL FILTER
VALVE (TWO-WAY)
FUEL TANK
RGE SOLENOID VALVE
PCV VALVE
EGR CONTROL VALVE
CHARCOAL CANISTER
THREE WAY
CATALYST
I
EGR SOLENOID VALVE
36UOF2-108
F2—75
F2 EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM
EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM
DESCRIPTION
This system recirculates a small amount of exhaust gas into the intake manifold to reduce the combustion
temperature, and reduce the NOx emissions.
This system consists of the EGR valve, EGR function sensor, two solenoid valves, powertrain control mod
ule (PCME) and input devices.

TO AIR CLEANER HOUSING
TO VACUUM CHAMBER
PCME THROTTLE VALVE

EGR
FUNCTION
SENSOR
EGR
CONTROL VALVE
THROTTLE VOLUME
(ENGINE COOLANT
POSITION AIRFLOW
TEMPERATURE
SENSOR SENSOR
SENSOR
CRANK ANGLE
SENSOR No.2 (1)
(NE2 [NE1] SIGNAL)
1: DETECTION OF ENGINE RUNNING CONDITION

2: DETERMINATION OF EGR GAS AMOUNT
36U0F2-110
Operation
Cold Engine (Coolant temperature less than 55°C {131 ° F })
EGR operation is stopped to improve driveability when the engine temperature is cold.
Warm Engine
The powertrain control module controls the solenoid valves (vacuum side and vent side) to supply EGR
gases as described below.
Operating condition EGR operation Remark

Idle
Idle switch: ON
Deceleration
Stopped
High speed Above 5,500 rpm
Heavy load —
Acceleration —
Warming up Reduced EGR gas amount Coolant temperature: Between
55°C {131°F) and 60°C [140°F)
Other Control supply of EGR gas amount by using signal
from EGR function sensor —
F 2-7 6
F2 EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM
EGR FUNCTION SENSOR
Output voltage inspection
49 92 00 162 1. Disconnect the PCME connector.
2. Connect the SST to the PCME as shown and connect a
vacuum pump.
3. Turn the ignition switch to ON (engine OFF).
49 G 0 18 903
Vacuum
Terminal PCME 0 kPa 20.0 kPa
{0 mmHg, 0 inHgj {150 mmHg, 5.90 inHg)
C 21 4.5—5.5V
46U0F2-089
B 3D ov
A 2J Approx. 0.8V Approx. 4V
5. If not correct at 2J terminals, check the wiring harness and

21 terminals of the PCME.
Resistance
1. Disconnect the EGR function sensor connector, and con
nect an ohmmeter.
2. Disconnect the vacuum hose from the EGR control valve,
and connect a vacuum pump.
3. Measure the resistance between the terminals as shown
while vacuum is applied.
Terminal Resistance
A -B 0 .7 -5 kfi
A -C 0 .7 -5 kfi
B -C Approx. 5 kfi
EGR CONTROL VALVE

Inspection
3. Verify that the engine runs roughly or stalls at more than
the specified vacuum.
Specification:
5.4—7.9 kPa {40—60 mmHg, 1.6—2.3 inHgj
F 2 -7 8
EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM F2
Replacement
Plug the water hoses after disconnecting them.
below.
(1) EGR hoses
(2) Vacuum hose
2. Install a new gasket, and then install the EGR in the reverse
order of removal.
46U0F2-092
F 2-7 9
F2 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
DESCRIPTION
The PCV valve is operated by the intake manifold vacuum.
When the engine is running at idle, the PCV valve is slightly open and a small amount of blowby gas is
drawn into the dynamic chamber to be burned.
As the engine speed rises, the PCV valve is opened further, allowing a larger amount of blowby gas to
be drawn into the dynamic chamber.
36U0F2-109
PCV VALVE
Inspection
(68°F).
3. Disconnect the PCV valve along with the ventilation hose
from the cylinder head cover.
46U0F2-093
out of port B.
46U0F2-094
F 2-8 0
____________________ FUEL EVAPORATIVE SYSTEM_________________ F2
DESCRIPTION
The fuel evaporative system consists of the fuel vapor valve, check valve (two-way), charcoal canister,
purge solenoid valve, PCME, and input devices. The amount of evaporative fumes introduced into the
engine and burned is controlled by the solenoid valve to correspond to the engine’s operating conditions.
To provide the best engine performance, the solenoid valve is controlled by the PCME.
Operation
The purge solenoid valve is controlled by duty signals from the PCME to perform purging of the charcoal
canister. Purging is done when these conditions are met:
(1) After warm up
(2) Driving in gear
(3) Accelerator pedal depressed (idle switch OFF)
SYSTEM OPERATION
2. Run the engine at idle.
3. Disconnect the vacuum hose from the solenoid valve.
4. Check that no vacuum is felt.
5. Input a load signal to the PCME.
MTX model
Disconnect the neutral switch connector.
ATX model
Position the vehicle on a chassis roller and shift the selec
tor lever to D range.
6. Connect a tachometer and increase the engine speed to

1,000 rpm.
7. Verify that vacuum is felt after approx. 2 sec.
16E0F2-179
Inspection
1. Remove the purge solenoid valve.
2. Blow through the purge solenoid valve from hose A and
verify that no air flows.
46U0F2-097
3. Apply battery positive voltage to the purge solenoid valve
and verify that air flows through the valve from A to B.
4. If not as specified, replace the purge solenoid valve.
46U0F2-098
F 2 -8 2
FUEL EVAPORATIVE SYSTEM F2
FUEL VAPOR VALVE
Inspection
1. Verify that air flows through the valve from port A when the
valve is held as shown in the figure.
2. Verify that no air flows through the valve from port A when
the valve is held as shown.
3. If not as specified, replace the fuel vapor valve.

Inspection
2. Check the operation of the valve by using a vacuum pump.
Apply approx. 4.9 kPa
(37 mmHg, 1.5 inHg) Airflow
vacuum at port A
Apply approx. 5.9 kPa
(44 mmHg, 1.7 inHg) Airflow
vacuum at port B
CHARCOAL CANISTER
Inspection
1. Remove the charcoal canister.
2. Visually check the charcoal canister for damage and
leakage.
3. Blow through each port and verify that air flows.
F 2-8 3
DESCRIPTION
This system is used to improve fuel economy, to prevent engine bucking during deceleration, and to pro
tect the engine from overreving.
NEUTRAL AND CLUTCH DETECTION DETERMINATION

SWITCHES
OF OF
DECELERATION FUEL CUT
FUEL CUT
PARK/NEUTRAL SIGNAL ■
(PCMT)
(CRANKSHAFT CRANKSHAFT POSITION
POSITION SENSOR No.2 (NE 2 SIGNAL)
STOPLIGHT SENSOR No.1
SW ITCH [NE 1 SIGNAL])
ENGINE COOLANT
TEM PERATURE SENSOR
46U0F2-099
PREPARATION
SST
46U0F2-100
F 2-8 4
FUEL-CUT CONTROL SYSYTEM F2
SYSTEM OPERATION
TACHOMETER
IG-.
DATA LINK CONNECTOR

m
36U0F2-118
2. Connect the SST to the PCME.
let it idle.
49 G 018 903
46U0F2-101
4. Set the SST to positions 3U through 3Z and make sure the

green and red lamps flash alternately at each position.
5. Increase the engine speed to 4,000 rpm; then suddenly

release the throttle.
6. Verify that the red indicator lamp illuminates while the en
gine speed is above approximately 1,200 rpm (MTX)/1,500
rpm (ATX) on deceleration.
7. Increase the engine speed and verify that the maximum rpm
does not exceed the specification.
Caution
• Holding the maximum rpm for more than 3 seconds
can damage the engine.
Specification: Approx. 7,500 rpm
F2—85
F2 A/C CUT OFF SYSTEM
A/C CUT OFF SYSTEM

DESCRIPTION
An A/C cut off system is used to improve idle smoothness immediately after starting the engine and to
improve acceleration performance.
36U0F2-126
Operation
Engine condition Purpose Cut off period

After engine started Improved idle Approx. 3 sec.
Throttle valve fully open Improved driveability Approx. 5 sec.
Water temperature over 113°C |236°FJ Prevent engine from over heating Water temperature under 107°C (225°F)
SYSTEM OPERATION
1. Turn the ignition switch to ON.
2. Turn the blower switch and air conditioning sensor ON.
3. Turn the ignition switch to START and verify that the con
denser fan stops for approx. 3 sec..
Note
• The magnetic clutch and the additional fan operate to
gether.
46U0F2-103
F 2 -8 6
DECHOKE CONTROL SYSTEM F2
DESCRIPTION
To facilitate starting the engine when the spark plugs become fouled, such as when the engine is flooded,
fuel injection is cut if the throttle valve is held wide open during cranking.
This allows the spark plugs to dry and purges excess fuel from the cylinders.
PCME
IGNITION SW ITCH (START)
ENGINE SPEED BELOW 500 RPM _
THROTTLE VALVE WIDE OPEN THROTTLE .
FUEL CUT
16E0F2-195
SYSTEM OPERATION
1. Turn the ignition switch to START and verify that injector
operating sound is heard while the engine is cranking.
switch to START. Verify that no injector operating sound is
heard while cranking.
3. If operating sound is heard, check the PCME terminal 1C
voltage. (Refer to page F2-94.)
46U0F2-104
F 2 -8 7
DESCRIPTION
To improve idle smoothness and engine reliability, the PCME and the coolant tan control system control
the electric fan operation. This system consists of the coolant fan, condensor fan, fan relays, PCME, and
input devices.
PREPARATION
SST
36U0F2-264
COOLANT FAN CONTROL SYSTEM F2
SYSTEM OPERATION
2. Set system select to position 1 and the test switch to SELF
TEST.
36U0F2-128
3. Rotate the throttle link by hand and verify that the coolant
fan operates.
36U0F2-129
F2 CONTROL SYSTEM
CONTROL SYSTEM
PREPARATION
SST
49 9200 162 For 49 G018 For

Engine Signal PCME Adapter PCME
Monitor harness
49 H018 9A1 For 49 B019 9A0 For

Self-Diagnosis heated oxygen System heated oxygen
Checker sensor Selector sensor
49 H018 001 For 49 G018 904 For

replacement of inspection of
Wrench, knock sensor Sheet PCME
knock sensor
46U0F2-105
CONTROL SYSTEM F2
STRUCTURAL VIEW
1. Powertrain control module (PCME) 7. Heated oxygen sensor

Removal / Installation.... ........ page F2- 92 Inspection........................ ..... page F2-108
Inspection..................... ........ page F2- 93 Replacement.................... ..... page F2-109
2. Volume airflow sensor 8. Knock sensor
Inspection...................... ........ page F2-104 Removal / Installation....... ..... page F2-110
3. Throttle position sensor 9. Main relay
Inspection..................... ........ page F2-107 Inspection........................ .....page F2-104
Replacement................. ........ page F2-108 10. Steering pressure sensor
4. Engine coolant temperature sensor Inspection........................ ..... page F2-111
Removal / Installation.... ........ page F2-106 11. Cultch switch
Inspection...................... ........ page F2-106 Inspection......................... ..... page F2-111
5. Crankshaft position sensor No. 2 Replacement..................... ..... page F2-111
Inspection..................... ........ page F2-105 12. Neutral switch
Removal / Installation.... ........ page F2-106 Inspection......................... .....page F2-111
6. Crankshaft position sensor No. 1 Replacement..................... ..... page F2-111
Inspection.....................
F2-91
F2 CONTROL SYSTEM
POWERTRAIN CONTROL MODULE (PCME)
36U0F2-133
1. Negative battery cable 4. PCME

2. Cover
3. Front console
(Refer to Section S)
F 2-92
CONTROL SYSTEM F2
Inspection
1. Disconnect the PCME connector.
49 92 00 162
2. Connect the SSTs to the PCME as shown.
Use connector A of the Adapter to check the voltages at
terminals 1A through 1V and at terminals 3A through 3Z.
Use connector B to check the voltages at terminals 2A
through 2P.
49 G 01 8 903
46U0F2-107
3. Place the SST on the Engine Signal Monitor.
4. Measure the voltage at each terminal.
(Refer to pages F2-94 through F2-103.)
5. If any PCME terminal voltage is incorrect, check the relat
ed input or output devices and wiring. If no problem is found,
replace the PCME. (Refer to page F2-92.)
Caution
• Applying voltage to SST terminals A and B will dam
age the SST.
46U0F2-108
F2 CONTROL SYSTEM
Terminal voltage
Terminal Input Output Connected to Test condition Correct voltage Remark

1A — — Battery Constant B+ For backup
1B O Main relay Ignition switch OFF ov —

ON B+
1C O Ignition While cranking Approx. 10V
switch Ignition switch ON Below 1.0V
(START)
1D o Data link Test switch at SELF TEST 4.5—5.5V With Self-
connector Light illuminated for 3 sec. after ignition Diagnosis Check
(MEN switch OFF-»ON er and System
terminal) Light not illuminated after 3 sec. B+ Selector
Test switch at O2 MONITOR, idle light il 4.5—5.5V

luminated
Test switch at O2 MONITOR, idle light B+
not illuminated
1E o Malfunction Light illuminated for 3 sec. after ignition Below 2.5V With System
indicator switch OFF-* ON selector test
light (MIL) B+ switch at
Light not illuminated after 3 sec.
"SELF-TEST”
Light illuminated Below 2.5V
Light not illuminated B+
1F o Data link Buzzer sounded for 3 sec. after ignition Below 2.5V • With Self-
connector switch OFF->ON Diagnosis
(FEN B+ Checker and
Buzzer not sounded after 3 sec.
terminal) System Selector
Buzzer sounded Below 2.5V • With System
Buzzer not sounded B+ Selector test
switch at SELF
TEST
1G o Igniter Ignition switch ON Below 1.0V
Idle Voltmeter Approx. 0.6
Oscilloscope (V)
4
2I/ A
0 !
10 msec.
1H o Headlight Headlights ON B+
switch Headlights OFF Below 1,0V
11 o Data link System Selector test switch at O2 B+ • With Self-
connector MONITOR Diagnosis
(TEN 0V Checker and
System Selector test switch at SELF
terminal) System Selector
TEST
• Ignition switch
ON
1J o Rear window Rear window defroster switch OFF B+ Ignition switch
defroster Rear window defroster switch ON Below 1.0V ON
relay
1K o PCMT Water temperature: B+
(Torque re Above 60°C (140°F)
duce sig Water temperature: Below 1.0V
nal/water Below 60°C (140°F)
thermo
signal) Torque control during shifting Below 1,0V
46U0F2-109
F 2 -9 4
CONTROL SYSTEM F2
Always OV • ROOM (15A) fuse burnt
•Open circuit in wiring from ROOM (15A) fuse to PCME terminal 1A
Always OV • Main relay malfunction (Refer to page F2-104)
• Open or short circuit in wiring from main relay to PCME terminal 1B
Always OV (starter turns) •Open or short circuit in wiring from ignition switch to PCME terminal 1C
Always OV • Main relay malfunction (Refer to page F2-104)

• Open circuit in wiring from ignition switch to data link connector terminal B +
• Open or short circuit in wiring from data link connector terminal MEN to
PCME terminal 1D
Always approx. B + • Poor connection at PCME connector
•PCME malfunction
Always approx. 5V • PCME malfunction
Always below MIL always ON • Short circuit in wiring from combination meter to PCME terminal 1E
2.5V • PCME malfunction
MIL never ON • Open circuit wiring from combination meter to PCME terminal 1E
•PCME malfunction
Always below No display on Self- • Main relay malfunction (Refer to page F2-104)
2.5V Diagnosis Checker • Open circuit in wiring from ignition switch to data link connector terminal B +
“ 88” displayed and • Open or short circuit in wiring from data link connector terminal FEN to
buzzer sounds PCME terminal 1F
continuously
Always OV •Short circuit in wiring from igniter to PCME terminal 1G
Always below 1.0 (headlights OK) • Open or short circuit in wiring from headlight relay to PCME terminal 1H
Always below 1,0V •Short circuit in wiring from data link connector terminal TEN to PCME termi
nal 11
Always approx. B + • Open circuit in wiring from data link connector terminal TEN to PCME termi
nal 11
Always OV • Short circuit in wiring from rear window defroster switch to PCME terminal 1J
Always B + • Open circuit in wiring from rear window defroster switch to PCME terminal 1J
Always B + or OV • Open or short circuit in wiring from PCMT terminal 1K to PCME terminal 1K
46U0F2-110
F2 CONTROL SYSTEM
1L o A/C relay, Air conditioning sensor ON Below 2.5V Ignition switch ON

Condenser Air conditioning sensor OFF B+
fan low
relay
1M O Vehicle Ignition switch ON OV or approx.

speed 5.0V
sensor Driving Approx. 2.5V
1N O Steering Ignition switch ON B+
pressure Steering pressure sensor ON at idle Below 1,0V
sensor
Steering pressure sensor OFF at idle B+
10 o Air condition Air conditioning sensor ON Below 1.0V Ignition switch

ing sensor Air conditioning sensor OFF B+ ON and blower
motor ON
1P o Blower Fan speed control 3rd or 4th position Below 1.0V Ignition switch ON
switch Fan speed control OFF, 1st, or 2nd po B+
sition
1Q o Stoplight Brake pedal released Below 1.0V --

switch Brake pedal depressed B+
1R o Neutral and No load Below 1.0V Ignition switch ON
clutch Load B+
switches
(MTX)
PCMT (ATX)
1S PCMT*1 At shifting Below 1.0V --

Other B+
1T o Throttle posi Accelerator pedal released OV Ignition switch ON
tion sensor Accelerator pedal depressed 10—12V
(Idle switch)
1U o Ground (MTX) Ignition switch ON Below 1.0V --

Open (ATX) Ignition switch ON B+
1V 0 PCMT*2 At shifting Below 1.0V --
Other B+
2A o PCMT Ignition switch ON Approx. 3.9V
(Barometric 100 kPa (760 mmHg, 30 inHg)
absolute
pressure sen
sor signal)
2B o Volume air Ignition switch ON Approx. 4V
flow sensor Idle Approx. 2.8V
(VS)
Reduce torque signal 1 46U0F2-111

2 Reduce torque signal 2
F 2 -9 6
CONTROL SYSYTEM F2

Always below A/C does not operate • A/C relay malfunction
2.5V •Open circuit in wiring from ignition switch to A/C relay
•Open circuit in wiring from A/C relay to PCME terminal 1L
Air conditioning sensor •Short circuit in wiring from A/C relay to PCME terminal 1L
OFF but A/C operates •PCME malfunction
•PCME malfunction
Always OV •Open or short circuit in wiring from vehicle speed sensor to PCME terminal 1M
Always below 1.OV •Steering pressure sensor malfunction (Refer to page F2-111)
•Short circuit in wiring from steering pressure sensor to PCME terminal 1N
• PCME malfuction
Always B + •Steering pressure sensor malfunction (Refer to page F2-111)
• Open circuit in wiring from steering pressure sensor to PCME terminal 1N
• Open circuit in wiring from steering pressure sensor to ground
Always below 1.5V • Short circuit in wiring from A/C amplifier to PCME terminal 10
• Air conditioning sensor malfunction
•PCME malfunction
Always 4 .5 -5 .5 V •Open circuit in wiring from A/C amplifier to PCME terminal 10
• Air conditioning sensor malfunction
Always below 1,0V •Short circuit in wiring from A/C amplifier to PCME terminal 1P
•A ir conditioning sensor malfunction
•PCME malfunction
Always B + • Open circuit in wiring from A/C amplifier to PCME terminal 1P
•A ir conditioning sensor malfunction
Always below 1,0V (stoplights OK) •Open circuit in wiring from stoplight switch to PCME terminal 10
Always below 1.0V • Short circuit in wiring from neutral and clutch switch to PCME terminal 1R
(neutral and clutch switch (MTX) OK (MTX)
Park/Neutral switch (ATX) OK) •Short circuit in wiring from PCMT terminal 1D to PCME terminal 1R (ATX)
Always B + •Open circuit in wiring from neutral and clutch switch to PCME terminal 1R
•Open circuit in wiring from PCMT terminal 1D to PCME terminal 1R (ATX)
Always OV •Open or short circuit in wiring from PCMT terminal 1J to PCME terminal 1S
Always below 1,0V • Short circuit in wiring from throttle position sensor to PCME terminal 1T
•Throttle position sensor misadjustment
Always B + •Open circuit in wiring from throttle sensor to PCME terminal 1T
•PCME malfunction
Always B + (MTX) •Poor contact at ground terminal
• Open circuit in wiring from PCME
Always OV •Open or short circuit in wiring from PCMT terminal 1L to PCME terminal 1V
Always B + •PCME malfunction
Always below 2.0V or Approx. 4V •Refer to Code No.08 Troubleshooting (Refer to page F2-26)
46U0F2-112
F2—97
F2 CONTROL SYSYTEM

2C O Heated ox Ignition switch ON Below 1,0V
ygen sensor Idle Cold engine Approx. OV
(RH)
After warm up (V)
2D O Heated ox
ygen sensor
5
(LH)
0.5 sec.
Increasing engine speed
Approx. 0.8V
(after warm up)
Deceleration Approx. OV
2E O Engine coolant Engine coolant temperature 20°C (68°F) Approx. 2.5V Ignition switch ON
temperature After warm up Below 0.5V
sensor
2F O Throttle po Accelerator pedal released Approx. 0.5V Ignition switch ON

sition sensor Accelerator pedal fully depressed Approx. 3.7V
(TVO)
2H O A/C pressure A/C pressure sensor ON Below 1.0V

sensor A/C pressure sensor OFF B+
21 O Throttle position Ignition switch ON 5.0V
sensor/volume air
flowsensor/EGR
function sensor
2J O EGR func Ignition switch ON Approx. 0.8V
2K O
tion sensor
Intake air
Engine running
Ambient air temperature 20°C (68°F)
* Approx. 0.8—4.5V
Approx. 2.5V Ignition switch ON
temperature
sensor
2L O DRL relay Parking brake pulled with ignition switch B+
(CANADA) ON
Parking brake downed with ignition Below 2.5V
switch ON
2M’ O Knock Ignition switch ON Approx. 2.4V Measure the termi
sensor Idle Approx. 2.4V nal voltage by us
ing a digital type
voltmeter.
2N
20 O Purge sole Ignition switch ON B+
noid valve Idle
• Engine warm up (V)
• Idle switch OFF after approx. 3 sec.
• Load condition
M T X m odel
Disconnect neutral switch connector
ATX model Vb
shift selector lever to D range with
vehicle on chassis roller The pulse width varies
according to the
engine load.
46U0F2-113
*: Diagnostic Trouble Code No.05 may be memorized by the PCME when the Engine Signal Monitor is set to position 2M.
CONTROL SYSYTEM F2

OV after warm up • Refer to Code No.23 Troubleshooting (Refer to page F2-30)
Always approx. 1V after warm up • Refer to Code No.24 Troubleshooting (Refer to page F2-32)
OV after warm up •Refer to Code No. 15 Troubleshooting (Refer to page F2-30)
Always approx. 1V after warm up •Refer to Code No.17 Troubleshooting (Refer to page F2-32)
Always approx. OV or approx. 5V • Refer to Code No.09 Troubleshooting (Refer to page F2-27)
Always constant •Open circuit in wiring from PCME terminal 2F to throttle position sensor
Always above 1V •Throttle position sensor misadjustment
Always OV • Short circuit in wiring from A/C pressure sensor to PCME terminal 2H
Always B + • Open circuit in wiring from A/C pressure sensor to PCME terminal 2H
Always OV • Short circuit in wiring from PCME terminal 21 to throttle position sensor,
PCME, or volume air flow sensor
Always approx. OV or approx. 5V • Refer to Code No.16 Troubleshooting (Refer to page F2-31)
Always OV •Refer to Code No.10 Troubleshooting (Refer to page F2-28)
Always OV (DRL system OK) • Open or short circuit in wiring from DRL relay to PCME terminal 2L
Always OV or B + •Refer to Code No.05 Troubleshooting (Refer to page F2-25)
— —
Always OV or approx. 5V • Refer to Code No.26 Troubleshooting (Refer to page F2-35)
46U0F2-114
F 2-9 9
F2 CONTROL SYSYTEM
2P O Coolant fan Ignition switch ON B+
relay Idle Engine coolant temp. Above Below 1.0V
No.2 and
108°C (226°F)
No.3
Other B+
• Ignition switch ON Approx. 1.3V

• Ground data link connector terminal TEN
• Idle switch OFF
3A Ground (Output) Constant OV
3B Ground (Output) Constant OV
3C Ground (CPU) Constant OV
3D Ground (Input) Constant OV
3E O Crankshaft Ignition switch ON Approx. OV
position or 5V
sensor No.
Idle Oscilloscope
1 (in distrib
utor) [NE 1 I I I I I I
NE10
signal]
" 20 m sec.
Voltmeter Approx. 3.5V

3F O Crankshaft Constant OV
position
sensor No.
2 (Crank
shaft pully)
[Ground]
3G O Crankshaft Ignition switch ON Approx. OV
position or 5V
sensor No. Idle Oscilloscope
1 (in distrib (V), I i I
utor) [G
signal]
20 m se c.
Voltmeter Approx. 2.5V

3H O Crankshaft Ignition switch ON OV
position Idle Oscilloscope
sensor No.
2 (Crank %
shaft pully) -t- \H r
[NE 2 ' V 1/ 1/
signal]
" 1 0 m sec.
31 O VRIS solenoid Shutter valve closed B+

valve (No.1) Shutter valve open Approx. 1V
3J O VRIS solenoid S h u tte r v a lv e o p e n Approx. 1V
valve (No.2) Shutter valve closed B +
3K
46U0F2-115
CONTROL SYSYTEM F2

Always OV or B + •Open circuit in wiring from PCME

•Open circuit in wiring from PCME
Always approx. OV or approx. 2V •Refer to Code No.04 Troubleshooting (Refer to page F2-24)
Above OV • Poor connection at ground terminal

•Open circuit in wiring from PCME
Always approx. OV or approx. 5V •Refer to Code No.03 Troubleshooting (Refer to page F2-23)
Always approx. OV or difference in output • Refer to Code No.02 Troubleshooting (Refer to page F2-22)
wave • Damaged crankshaft pully
Always approx. OV or B + • Refer to Code No.41 Troubleshooting (Refer to page F2-39)
Always approx. OV or B + •Refer to Code No.46 Troubleshooting (Refer to page F2-40)
— —
46U0F2-116
F2-101
F2 CONTROL SYSYTEM
3L O Coolant fan Ignition switch ON B+
relay Idle Engine coolant temp. Above Below 1.0V
No.1 100°C (212 °F )
Other B+
• Ignition switch ON Approx. 0.6V
• Ground data link connector terminal TEN
• Idle switch OFF
3M O PRC Hot condition: Engine coolant temp, Approx. OV
Solenoid above 70°C (158°F) and intake air
valve temp, above 75°C (167°F) for 120 sec.
after engine starting
Other B+
3N O Condensor Ignition switch ON B+
fan high Idle Engine coolant temp. 108°C Below 1.0V
relay No.1 (226°F)
and No.2
Other B+
30 O EGR solenoid Idle B+ Engine Signal
valve (vent) Driving* Monitor: Green
B+
and red lamps
3P O EGR solenoid Idle B+ flash after warm
valve (vacuum) Driving* up
B+
30 O Idle air Ignition switch ON Approx. 6V
valve
(Ground data link connector
terminal TEN)
H
2 msec.
3R
3S
3T O Fuel pump Ignition switch ON B+
relay Idle Approx. OV
Injector Ignition switch ON B+ Engine Signal
3U O No.1 Monitor: Green
Idle* Oscilloscope
lamp flash
Injector
3V O No.2
Injector
3W O No.3
Injector
3X O No.4
—
Injector
3Y O No.5 ^ 5 msec.
Injector
3Z O No.6
46U0F2-117
Control Module Connector (Control Module Side)

B 3 -0 1 POWERTRAIN CONTROL MODULE
B/n * * *
06 W/G G /B G /R (YAJ R/W Y /B L B /L L /R L/W W GY/B G /L P /L R /G Y (e/o) W L /R R/W * GY/R P /B GY/G * GY P LG B /R B
*
CL) BR G /Y L /B L / Y G/W Y W R /Y W R /B W/B * G R /B W/R P /G G R W/G R /Y L/W BR/B * W/L R L / 0 L /R G L B /L B
2P 2N 2L 2J SH SF so SB 3Z 3X 3V
F 2-1 02
CONTROL SYSTEM F2

Always OV or B + • Open or short circuit in wiring from coolant fan relay to PCME terminal 3L
Always below 1.0V or B + • Refer to Code No.26 Troubleshooting (Refer to page F2-35)
Always below 2.0V • Open or short circuit in wiring from condenser fan relay to PCME terminal 3N
Always OV • Refer to Code No.28 Troubleshooting (Refer to page F2-36)
Always OV • Refer to Code No.29 Troubleshooting (Refer to page F2-37)
Always OV or B + • Refer to Code No.34 Troubleshooting (Refer to page F2-38)
— —
— —
Always below 1.OV • Open or short circuit in wiring from fuel pump relay to PCME terminal 3T
Always OV •Open or short circuit in wiring from injector to PCME terminal 3U, 3V, 3W,
3X, 3Y or 3Z
• Main relay malfunction (Refer to page F2-104)
46U0F2-118
F 2-103
F2 CONTROL SYSTEM
MAIN RELAY
Inspection
Operation check
Listen for operational sound of the main relay while crank
ing the engine.
36U0F2-174
RJ!jL 1. Remove the main relay.
2. Apply battery positive voltage (B + ) and check continuity
(c)— ( d)
between terminals of the relay.
0 B + applied Yes
B + not applied No

_________________________________________ 36U0F2-175
MEASURING CORE
Inspection
1. Check the volume airflow sensor body for cracks and dam
age. Replace as necessary.
2. Verify that the measuring core opens smoothly.
3. Measure resistance of the volume air flow sensor.
Terminal Resistance (0)

E2«V s 2 0 -6 0 0 (Closed: 20°C (68°F))
2 0-1,0 0 0 (Open: 20°C (68°F))
LU
>
2 00 -4 00 (Closed♦+Open: 20°C (68°F))

o
CM
t
46U0F2-119 E2«-*THA
(intake air -20 °C |-4 ° F ) 10,000—20,000
temperature 20°C (68°F) 2 ,0 0 0 - 3,000
sensor) 60°C (140°F) 400- 700
4. If not as specified, replace the volume airflow sensor.
46U0F2-12Q
CONTROL SYSTEM F2
CRANKSHAFT POSITION SENSOR No. 1
(IN DISTRIBUTOR)
Inspection
1. Remove the distributor. (Refer to Section G.)
3. Verify that the distributor connector (3 pin) is disconnected.
46U0F2-121
4. Connect the distributor connector (6-pin) as shown in the
figure.
46U0F2-122
1 CYCLE
ness) to the PCME.
NE 1 7. Set the SST (Engine Signal Monitor).
SIGNAL 8. Rotate the distributor drive by hand and measure the out
5V
OV “L_n_nnrLrui put voltage.
Specification
5V
Position Voltage
OV —
3E (NE 1 signal) Approx. 5V (6 pulses/rev)
G SIGNAL
3G (G signal) Approx. 5V (1 pulse/rev)
46U0F2-123

(Refer to Section G.)
10. Start the engine and adjust the ignition timing.
Ignition timing: BTDC 9 °—11° (10° ± 1°)
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf}
CRANKSHAFT POSITION SENSOR No.2
^CONNECTOR CRANKSHAFT POSITION SENSOR No. 2
Inspection
1. Disconnect the crankshaft position sensor 2 connector.
2. Measure the resistance between terminals A and B.
Resistance: 520—580Q (20°C {68°F})
3. Replace crankshaft position sensor No. 2 if not as specified.
46U0F2-193
F 2-105
F2 CONTROL SYSTEM
2. Remove the idler pulley bracket.
3. Remove the dipstick pipe.
4. Remove crankshaft position sensor No. 2.
6. Adjust the drive belt deflection. (Refer to Section B2.)
N-m (kgf-m, ft-lbf)

46U0F2-194
.E N G IN E COOLANT TEM PERATURE ENGINE COOLANT TEMPERATURE SENSOR
SENSOR Removal / Installation
WASHER, REPLACE
Warning
46U0F2-124 a thick cloth around it and slowly turn it counter
sure escapes.
remove it.
1. Remove the radiator cap.

nector.
4. Install a new gasket and the engine coolant temperature
sensor.
Tighting torque:
16—23 N m (1.6—2.4 kgf m, 12—17 ft Ibf)
Inspection
1. Place the sensor in water with a thermometer and heat the
water gradually.
Coolant Resistance (kQ)
20°C (68°F) 2 2 -2 .1
80°C { 176°F) 0.29-0.35
91°G { 196°F) 0.226-0.241
97°C (207°F) 0.193-0.205
108°C |226°F) 0.145-0.153
110°C (230°F) 0.137-0.146
3. If not as specified, replace the engine coolant temperature

sensor.
46U0F2-125
F 2-1 06
CONTROL SYSTEM F2
Inspection
49 92 00 162
ness) to the PCME.
2. Set the SST (Engine Signal Monitor) to position 2F.
49 G 0 18 903
46U0F2-126
4. Rotate the throttle link by hand and verify that the voltage
is within the specification, and make sure that the voltage
change is linear.
Specification
Throttle valve position

PCME terminal
Closed throttle position Wide open throttle
2F 0.1—1.1V 3.1-4 .4 V
5. If not as specified, adjust the throttle position sensor.
Idle switch
The throttle adjust screw is set at factory and must not be ad
V . justed. Any adjustment will negatively effect the engine per
formance.
2. Connect an ohmmeter to terminals IDL and GND.
IDL GND
46U0F2-201
3. Insert a feeler gauge between the throttle adjust screw and
the stopper lever. Check continuity of the switch.
Specification
Clearance Continuity
0.15mm {0.006 in) Yes
0.50mm {0.020 in) No
4. If not as specified, loosen the throttle position sensor screws.

5. Insert a 0.15mm {0.006 in} feeler gauge between the throt
tle stop screw and stopper lever.
6. Rotate the throttle position sensor clockwise approximate

ly 30 degrees, then rotate it back counterclockwise until
there is continuity.
7. Replace the feeler gauge with a 0.50mm {0.020 in} feel
er gauge and verify that there is no continuity.
8. Tighten the attaching screws.
Tightening torque:
1.6—2.3 N m (16—24 kgf cm, 14—20 inlbf)
36U0F2-155
F2-107
F2 CONTROL SYSTEM
TAB B TANG A
Replacement
2. Remove the attaching screws.
3. Replace the throttle position sensor.
5. Open the throttle valve slightly and catch the tang of the
TAB A
throttle body on the throttle position sensor plastic tabs. Align
tang A on throttle body with tab A on throttle position sen
sor. Note tangs on the throttle body mate with the tab on
THROTTLE POSITION the throttle position sensor on the side of the tab without
SENSOR
a slot.
46U0F2-195 6. Position the throttle position sensor on the throttle body so
that the mounting holes align.
7. Release the throttle.
8. Adjust the throttle position sensor output voltage and idle
switch. (Refer to page F2-107.)
HEATED OXYGEN SENSOR (RH, LH)

Terminal voltage inspection
1. Connect the Engine Signal Monitor to the PCME.
2. Connect a voltmeter (set to 1V range) to the special output
connectors of the Engine Signal Monitor as shown.
3. Set the Engine Signal Monitor to position 2C (RH) or 2D (LH).
46U0F2-128
4. Run the engine at 4,500 rpm until the voltmeter indicates
approx. 0.7V.
5. Measure.the voltage while increasing and decreasing the
engine speed suddenly several times.
Note
• With the brake pedal depressed, the monitor light shows
operation of the right heated oxygen sensor.
• With the brake pedal released, the monitor light shows
operation of the left heated oxygen sensor.
Specification
46U0F2-129
Engine condition Voltage (V)
While deceleration Appox. 0
While acceleration Above 0.8
Sensitivity self-diagnosis checker

1. Connect the SSTs to the data link connector as shown.
3. Set test switch to O2 MONITOR.
4. Increase the engine speed from 2,000 to 3,000 rpm, and
verify that the monitor lamp flashes for 10 sec.. If not as
specified, replace the heated oxygen sensor.
Monitor Lamp: Flashes more than 8 times/10 sec.
5. Replace the heated oxygen sensor if not as specified.
Heater
1. Measure resistance between terminals C and D.
Resistance: 6fl (20°C {68°F})
2. Replace the heated oxygen sensor if not as specified.
46U0F2-131
F 2-1 08
CONTROL SYSTEM F2
Replacement
Federal and Canada
Note
• Secure the harness of the heated oxygen sensor (RH)
with the power steering hose.
Tightening torque: y
30—49 N m {3.0—5.0 kgf m, 22—36 ft-lbf}
California
2. Remove the exhaust manifold. (Refer to page F2-74.)
3. Remove the heated oxygen sensor. /
Tightening torque:
30—49 N m {3.0—5.0 kgf m, 22—36 ft Ibf}
F2—109
F2 CONTROL SYSTEM
KNOCK SENSOR
Warning
and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete the “ Fuel

19—25 (1.9—2.6, 14—18)

N m | kgf m, ft-lbf)
46U0F2-135
1. Air hose 4. Water pipe

2. Intake manifold 5. Knock sensor
Removal Note Below Removal / Installation Note................ Below
3. Bypass pipe
Removal / Installation Note

Intake manifold
Drain the coolant into a container before removing the in
take manifold. (Refer to Section E2.)
Knock sensor
Use the SST to remove and install the knock sensor.
(
V
46U0F2-196
F 2-1 10
CONTROL SYSTEM F2
CLUTCH SWITCH (MTX)
Inspection
Pedal Continuity
Depressed Yes
Released No
3. If not as specified, replace the clutch switch.
Replacement
1. Loosen the nuts and remove the clutch switch.
2. Install the clutch switch.
3. Adjust the clutch pedal height referring to the above and
the height specifications. (Refer to Section H.)
4. Tighten the nuts to the specified torque.
Tightening torque:
14—17 N m [1.4—1.8 kgf m, 11—13 ft-lbf)
16E0F2-248
NEUTRAL SWITCH (MTX)
Inspection
Transaxle Continuity
Neutral Yes
Other ranges No
3. If not as specified, replace the neutral switch.
Replacement
2. Remove the neutral switch.
Tightening torque:
20—29 N-m {2.0—3.0 kgf-m, 15—21 ft Ibf)
46U0F2-137
Inspection
2. Start the engine, and check continuity of the switch.

Turned Yes
Straight ahead No
F2-111
F2__________________TROUBLESHOOTING GUIDE
This Quick Diagnosis Chart shows the relationship between troubleshooting items and inspection points,
Possible parts and reference page Fuel system Emissioncontrol system Control system
Melts main or other fuse

Will not crank or cranks slowly
Cranks nor No combustion
mally but will Partial combustion-
not start when engine cold
Partial combustion-
after warm-up
Cranks nor Any engine temp.
mally but When engine cold
hard to start After warm-up
Idle at any engine temp.
Idle after warm-up

Idle with A/C, P/S,
and/or E/L ON
Idle when shifted from N
or P to other ranges
Driveaway
On acceleration
While cruising
On deceleration
Engine runs Idle at any engine temp,
rough
Idle after warm-up
Idle with A/C, P/S,
and/or E/L ON
Idle when shifted from
N or P to other ranges
On deceleration
Poor ac Driveaway
celeration On acceleration
High idle speed after warm-up
F 2-112
Control system Automatic transaxle system Possible parts and reference page /
Section U I
Section T j
Section G
Section U
Section U
Section K
Section U
Section E
Section T
Section T
F2-104
F2-110
F 2 -1 11
F2-72
F2-57
F2-53
F2-93
i
CM
LL
!
i
Condenser fan high relay (Nos.1, 2)
A/C relay, Condenser fan low relay
Coolant fan relay (Nos.1, 2 and 3)
Vehicle speed pulse generator

VRIS solenoid valve (Nos.1, 2)
Lock up control solenoid

Steering pressure sensor
Reduce torque signal 1

Rear window defroster

Park/Neutral switch
Control valve body

PRC solenoid valve
ATF thermosensor
Lock up solenoid
Torque converter
Headlight switch
Stoplight switch
Reverse clutch
Blower switch
Knock sensor
Hold switch
Main relay
Oil pump
PCMT
PCME
CD
tr
03
CO
/ Item
I
I
I
I
I
I
I
I
I
o O Melts main or other fuse 1

O Will not crank or cranks slowly 2
O O No combustion Cranks normally but 3
Partial combustion — will not start
O 4
when engine cold
Partial combustion —
O 5
after warm-up
O Any engine temp. Cranks normally but 7
O When engine cold hard to start 8
o After warm-up 9
O Idle at any engine temp. Engine stalls 10
During fast idle 11
o O Idle after warm-up 12
Idle with A/C, P/S,
O o O O o o O O O 13
and/or E/L ON
o O O 0 0 O 14
O Driveaway 15
O O While cruising 17
O o O O 0 On deceleration 18
O Idle at any engine temp. Engine runs rough 19
o During fast idle 20
o O Idle after warm-up 21
Idle with A/C, P/S,
O o O o o o O 22
and/or E/L ON
23
On deceleration 24
o O o Driveaway Poor acceleration 25
O O o O o On acceleration 26
o O High idle speed after warm-up 27
F 2-113
\
F2-114
CO CO CO CO CO CO CO CO w CO INJ IV)
o
Item
CD 00 - n| CD CJl CO rv> CD oo
I High oil consumption

VO
A/C does not work
Surges while cruising
Idle fluctuates/idle hunts

Hesitates/Stumbles on acceleration
Self-Diagnosis Checker flashes ''88”
Knocking/Pinging
Poor fuel economy

Lack of power
Exhaust sulfur smell
MIL never ON
T l
c
Possible parts and reference page

CD_
O
Q-
o
\
OOO Injector
Fuel systemIntake air system Emission control system Ignition system Control system
F2-68
O Fuel pump F2-63
Fuel pump relay F2-70
O O Pressure regulator F2-70
O Fuel filter F2-65
O Air leakage F2-48
Idle speed F2-16
Throttle body F2-49
O Air cleaner body F2-15
Vacuum chamber F2-57
Check valve F2-57
O EGR solenoid valve (vacuum) F2-77
EGR solenoid valve (vent) F2-77
O Purge solenoid valve F2-82
EGR function sensor F2-78
O EGR control valve F2-78
Fuel vapor valve F2-83
Check valve (two-way) F2-83
o Charcoal canister F2-83
o o PCV valve F2-80
O O Distributor
O Igniter (in distributor)
Section G
O High-tension lead
O o Spark plug
Ignition timing
OOO Volume airflow sensor F2-104
Engine coolant temperature sensor F2-106
Oo Throttle position sensor F2-107
O Heated oxygen sensor (RH or LH) F2-108
Crankshaft position sensor No. 2 F2-105
Vehicle speed sensor Section T
Clutch and neutral switches F 2 -1 11
Steering pressure sensor F 2 -1 11
Stoplight switch Section T
o Idle air control valve F2-53
O OOo PCME F2-93
Control system
O A/C relay, Condenser fan low relay Section U
PRC solenoid valve F2-72
VRIS solenoid valve (Nos.1, 2) F2-57
Blower switch Section U
Condenser fan high relay (Nos.1, 2) Section U
Coolant fan relay (Nos.1, 2 and 3) Section E
O Knock sensor F2-110
o Air conditioning sensor Section U
Headlight switch Section T
Rear window defroster Section T
Main relay F2-104
Starter Section G
TROUBLESHOOTING
O Vehicle speed pulse generator
Automatic transaxle system

Park/Neutral switch
Hold switch
o O Lock up solenoid
O Lock up control solenoid
O PCMT
O Oil pump Section K
O Control valve body
O ATF thermosensor
o Torque converter
o Reverse clutch
GUIDE
Self-Diagnosis Checker flashes “ 88”
A/C does not work
Surges while cruising

MIL never ON
High oil consumption

Exhaust sulfur smell
Fuel odor
Knocking/Pinging
Poor fuel economy

Lack of power
Hesitates/Stumbles on acceleration
Idle fluctuates/idle hunts

F 2 -1 1 5
46U0F2-138
Item
CO CO CO CO CO CO 0 0 CO CO CO
o
(Y> t\o ro
/
CD 0 0 'N l 05 cn CO rv> CD CD
F2 TROBLESHOOTING GUIDE
RELATIONSHIP CHART
\ OUTPUT DEVICE
cc
BAC VALVE (IDLE AIR CONTROL VALVE)

RELAY
UJ
CONDENSER FAN HIGH RELAY No.1, No.2
(DIAGNOSTIC TROUBLE CODE) (FEN TERMINAL)
(MONITOR LAMP) (MEN TERMINAL)

No.2, No.3
<
INJECTOR
SOLENOID
£
_i
VALVE
<
No.1
z
AND CONDENSER FAN LOW

A/C RELAY (A/C CUT-OFF)
o
tn
FAN RELAY
FAN RELAY
PCMT (TORQUE REDUCI
RELAY
PRESSURE REGU
CONTROL
LATOR CONTROL
FUEL INJECTION
FUEL INJECTION
No.2) CONTROL
VRIS (No.1 AND
THERMOSIGNAL)
EGR CONTROL
FUEL PUMP
AMOUNT
COOLANT
COOLANT
IGNITER
TIMING
PURGE
INPUT DEVICE \
CRANKSHAFT G SIGNAL 0 O O O O
POSITION
SENSOR 1 NE1 SIGNAL o 0
CRANKSHAFT POSITION SENSOR 2 (NE2

o o O O O O O O 0
SIGNAL)
THROTTLE IDLE SWITCH o o o o O O o o O

POSITION
SENSOR THROTTLE POSITION SENSOR o o 0 O 0 0 o 0 0
VOLUME AIRFLOW SENSOR 0 o o o o
ENGINE COOLANT TEMPERATURE SENSOR o o o O o o O o o o O o
INTAKE AIR TEMPERATURE SENSOR o o o o o
HEATED OXYGEN SENSOR 0 o 0 O
KNOCK SENSOR o o
AIR CONDITIONING SENSOR o O o o o
STEERING PRESSURE SENSOR o 0
IGNITION SWITCH (START SIGNAL) o o o o o o o o o 0 o
STOPLIGHT SWITCH o o
PARK/NEUTRAL SWITCH (ATX) o o o o o o o

E/L SIGNAL* o 0
NEUTRAL AND CLUTCH SWITCHES (MTX) o o 0 0 o o o

DATA LINK CONNECTOR (TEN TERMINAL) 0 0 o o o 0
EGR FUNCTION SENSOR o o o
BAROMETRIC ABSOLUTE PRESSURE
SENSOR
o o o o
VEHICLE SPEED SENSOR o o
46U0F2-139
* E/L SIGNAL: Blower fan control switch third position or higher, headlights ON, or rear window defroster ON.
F 2-116
Output devices and Engine condition
36U0F2-265
USING THIS SECTION
Introduction
Most of the fuel and emission control systems are electronically controlled, often making it difficult to diag
nose problems, especially intermittent problems. Before undertaking actual checks, take a few minutes
to talk with a customer who approaches with a driveabilitiy complaint. The customer is often a good source
of information on such problems, especially the intermittent ones. Through a talk with the customer, you
will usually find out what the symptoms are and under what conditions they occur.
Work flow
CHECK IN
REFER TO TROUBLESHOOTING PAGE THAT........................................................ DIAGNOSTIC INDEX

CHECK FOR WHAT IS BAD IN SYSTEM..............................................................INSPECTION
CHECK FOR WHAT PART IS BAD..................................................................ACTION
REPAIR/REPLACE
-------------- DETERMINE IF TROUBLE HAS BEEN ELIMINATED.................................

No Yes
CHECK OUT
36U0F2-183
tom.
F 2-1 18
13, 14 ENGINE STALLS •IDLE WITH A/C, P/S, and/or E/L ON
•IDLE WHEN SHIFTED FROM N OR P TO OTHER
RANGES
DESCRIP • Engine stops unexpectedly v/hen shifted from N or P to other ranges at idle
TION • Idle condition is normal when A/C. PIS, and E/L are OFF and in N and P
• Air conditioning sensor (2) Idle air control valve
• Headlight switch • Idle air control valve stuck
INSPECTION
Diagnosis Checker monitor lamp while ignition
switch ON?
ZT page F2-44
• Blower switch
check sequence) czr page F2-45
•Selector lever
SYSTEM SELECTOR
~ SELEC T SW: A
Is "00" displayed on Self-Diagnosis Checker with Yes "OO” displayed 46U0F2-140

ignition switch ON?
r r page F2-18 Go to next step
Service Code No. displayed

check sequence)
c r page F 2 -2 0 ,
SELF-DIAGNOSIS
DESCRIPTION:
Further describes the system. Confirm that the chart addresses the actual symptom before beginning
troubleshooting.
STEP:
INSPECTION:
This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is necessary
to perform the INSPECTION, refer to the page specified by the " c r ” mark.
ACTION:
This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to perform
the action is described on the reference page specified by the " c r ” mark.
36U0F2-256
F 2-119
DIAGNOSTIC INDEX
□ c & C m r T IU N PAGE
No. TROUBLE
1 Melts main or other fuse F2-124
Will not crank or cranks slowly Starter does not work
2 Section G
Starter cranks engine at slow speed
Cranks normal No combustion Starter cranks engine at normal speed but engine
3 F2-125
ly but will not shows no indication of firing
start Partial combustion Starter cranks engine at normal speed and engine
— when engine coldz shows indication of firing but will not run when en
4 gine is cold or at initial starting F2-125
Engine will not continue running when cold when ig
nition switch is returned from STA to IG position
Partial combustion Starter cranks engine at normal speed and engine
— when engine warm shows indication of firing but will not run when en
5 gine is warm F2-127
Engine will not continue running when warm when
IGN switch is returned from STA to IG position
6 Will start in other than P and N ranges Engine starts in P, N and other ranges Section K
Cranks nor Any engine temp. Starter cranks engine at normal speed but engine re
mally but hard quires excessive cranking time before starting at any
7 to s tart engine temperature
Engine starts after stalling a few times at any engine
temperature
When engine cold Starter cranks engine at normal speed but engine re
quires excessive cranking time before starting when F2-128
8 engine is cold
Engine starts after stalling a few times when engine
is cold
After warm-up Starter cranks engine at normal speed but engine re
9 quires excessive cranking time before starting after
warm-up
Engine stalls Idle at any engine Engine stops unexpectedly at any engine temp.
10
temp.
F2-130
11 During fast idle Engine stops unexpectedly during fast-idle operation
12 Idle after warm-up Engine stops unexpectedly at idle after warm-up
Idle with A/C, P/S, Engine stops unexpectedly when A/C, P/S, and/or
13
and/or E/L ON E/L turned ON at idle F2-133
Idle when shifted from Engine stops unexpectedly when shifted from N or P Section K
*14
N or P to other ranges to other ranges at idle
15 Driveaway Engine stops unexpectedly upon driveaway F2-134
On acceleration Engine stops unexpectedly at begining of accelera
16
tion or during acceleration F2-136
17 While cruising Engine stops unexpectedly while cruising
On deceleration Engine stops unexpectedly at begining of decelera F2-138
*18
tion or recovery from deceleration exhaust afterburn Section K
Engine runs Engine speed fluctuates between specified idle
rough Idle at any engine speed and lower speed and excessive engine shake
19 temp. at any engine temp.
Idle speed too slow and excessive engine shake at
any engine temp.
F2-140
During fast idle Fast idle speed too slow and excessive engine shake
20
during fast idle, but returns to normal after warm-up
Idle after warm-up Engine speed fluctuates between specified idle
21 speed and lower speed and excessive engine shake
at idle after warm-up
* Refer to Section F2 before referring to K Sections.
F2—120
UCOV/nlr 1lUN PAGE
No. TROUBLE
Engine runs Idle with A/C, P/S, Engine speed fluctuates between specified idle
22 rough and/or E/L ON speed and lower speed and excessive engine shake
at idle when A/C, P/S, and/or E/L ON
F2-144
Idle when shifted from Engine speed fluctuates between specified idle
23 N or P to other range speed and lower speed and excessive engine shake
at idle when shifted from P or N to other range
On deceleration Engine shakes at begining of deceleration, during
*24 F2-146
deceleration, or recovery from deceleration
Exhaust afterburn Section K
Poor ac Driveaway Engine speed increases normally but vehicle speed
*25
celeration slowly increases during driveaway F2-148
On acceleration Engine speed increases normally but vehicle speed Section K
*26
slowly increases during acceleration
High idle speed after warm-up Idle speed continues at fast idle after warm-up Engine
27 F2-150
returns slowly to idle after acceleration is released
Idle fluctuates/idle hunts Engine speed changes back and forth between
28 F2-151
specified idle speed and higher speed
Hesitates/Stumbles on acceleration Momentary pause at begining of acceleration or dur
29 F2-153
ing acceleration
Surges while cruising Momentary minor irregularity in engine output at F2-156
*30
steady vehicle speed Section K
Lack of power Performance poor under load (i.e., power down F2-157
*31
when climbing hills) Section K
Poor fuel economy Fuel economy unsatisfactory F2-158
*32
Section K
A/C does not work A/C compressor magnetic clutch does not engage
33 F2-158
when Air conditioning sensor ON
Knocking/Pinging Sound produced when air/fuel mixture is ignited by
34 something other than spark plug (i.e., hot spot in F2-158
combustion chamber)
35 Fuel odor Gasoline fuel smell or visible leaks F2-159
36 Exhaust sulfur smell Rotten egg smell from exhaust F2-159
37 High oil consumption Oil consumption excessive F2-159
38 Self-Diagnosis Checker flashes 88 Checker flashes 88 with test connector ground F2-159
39 MIL never ON Self-Diagnosis Checker indicates
Diagnostic Trouble Code No. of input device but MIL F2-160
never ON
Vehicle does not move in D, S, L No creep at all
40 and/or R ranges Vehicle does not move when accelerator pedal Section K
depressed after shifted to D, S, L and/or R range
Vehicle moves in N range Vehicle creeps in N range
41 Section K
Vehicle moves when accelerator pedal not depressed
42 Vehicle moves in P range Vehicle rolls in P range, and drivetrain not locked up Section K
Excessive creep Vehicle moves quickly in D, S, L and R range (ac
celerator pedal not depressed)
43 Section K
Note
• Excessive N to R range and N to D range shift
shock felt
* Refer to Section F2 before referring to K Sections.
F2—121
U t d u n lr 1IUN PAGE
No. TROUBLE
No shift Single range shift (1st-»2nd, 2nd->3rd or 3rd->0/D)
only.
44 Sometimes shifts correctly
Section K
Note
• Gear position held in hold mode.
Abnormal shift Shifts incorrectly (incorrect shift pattern)
(ex) Vehicle shifts 1st->0/D
45 Section K
directly when accelerating with accelerator pedal
depressed slightly
Frequent shifting Downshift occurs when accelerator depressed slightly
46 Section K
in D, S and L ranges (except hold mode)
Shift point high or low Shift points do not match shift diagram
Shifts delayed when accelerating
47 Section K
Shifts occur too fast when accelerating and engine
speed does not increase
48 No lockup No lockup when vehicle speed reaches lockup range Section K
No kickdown Does not downshift when accelerator pedal
49 Section K
depressed more than 7/8 within kickdown range
50 Engine speed When accelerating Engine speed flares up on acceleration Section K
flares up When upshifting Engine flares up when accelerator pedal depressed
and/or downshifting for upshifting
51 Section K
Engine flares up suddenly when accelerator pedal
depressed for downshifting
Excessive shift P, N to R and/or N Strong shift shock felt at idle when shifting from N to
52 Section K
shock to D D or R range
When upshifting Excessive shift shock felt when accelerating at up-
and/or downshifting shifting
53 Section K
During cruising, excessive shift shock felt when ac
celerator pedal depressed at downshifting
No engine braking Engine speed drops to idle but vehicle does not slow
when accelerator pedal released during cruising at
medium to high speed
54 Section K
Engine speed drops to idle but vehicle does not slow
when accelerator pedal released when in L range at
low vehicle speed
No mode change Mode does not change to/from normal mode in D
55 Section K
range Hold mode not selected or not cancelled
56 Transaxle All ranges Transaxle noisy in all ranges when vehicle is idling Section K
57 noise D, S, L, R ranges Abnormal noise from transaxle in D, S, L, R Section K
58 Transaxle overheats ATF smells burnt and/or is discolored Section K
46U0F2-141
F 2-1 22
Description of Driveability Problems
ENGINE SPEED
46U0F2-197
Warning
ty Procedures” .

B. Avoid leakge.
C. Install hose to secure the fuel pressure gauge to the fuel
filter and the main hose.
Pinching Hose
When pinching an air hose or a fuel hose with pliers, wrap
the hose with a rag to prevent damage.
16E0F2-261
F2—123
1 MELTS MAIN OR OTHER FUSE


MAIN (100A)
BTN (60A) R T M fl I'-'n
ROOM (15A)
EGI INJ (30A)

Fuel pump relay ....... "■ Fuel pump
----------------- PCME terminal 1B

----------------- Distributor
----------------- Heated oxygen sensor
------------------- Solenoid valve (PRC)
------------------- Solenoid valve (VRIS1)
------------------- Solenoid valve (VRIS2)
------------------- Solenoid valve (EGR. Vacuum)
-------------------Solenoid valve (EGR. Vent)
-------------------Idle air control valve
-------------------Solenoid valve (purge control)
ENGINE (15A) F M r ilM P fiioo
METER (15A)
46U0F2-144
F 2-124
3 CRANKS NORMALLY BUT WILL NOT START •NO COMBUSTION
• Starter cranks engine at normal speed but engine shows no indication of firing
DESCRIP
TION
© Distributor
• Poor conection of connector
• Open in ignition coil c r Section G
© Main relay
• Malfunction of relay c r page F2-104
® PCME
• No IGT signal output from PCME terminal 1G to igniter (in distributor) c r page F2-94
46U0F2-145
4 CRANKS NORMALLY BUT WILL NOT START • PARTIAL COMBUSTION — WHEN ENGINE COLD
• Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine
is cold at initial starting
DESCRIP • Engine will not continue running when cold when ignition switch is returned from STA to IG position
TION • Refer to “ ENGINE STALLS” if this symptom appears after engine stall
• Fuel in tank
• Battery in terminal condition
© BAC valve (D Distributor
• Malfunction of air valve »Cap and/or rotor damaged
• Idle air control valve stuck • Poor connection of connector
© Injector © Volume airflow sensor
• Poor connection • Measuring core stuck
® Fuel pump relay
• Poor connection
@ Fuel pump
1 Is “ 00” displayed on SST with ignition switch Yes “ 00” displayed
ON?
SELF-DIAGNOSIS
CHECKER

displayed
check sequence)
c r page F2-20
M O N I T O R l
-^ L A M P “ 88” flashes
SELECT SW: A CHECKER FLASHES 88 c r page F2-159
2 Does engine start when throttle valve held quar Yes Check air valve operation
ter open? c r page F2-53
No Go to next step
F2-125

Do Engine Signal Monitor lamps flash for speci Yes Go to next step
fied terminals while cranking engine?
c r page F2-102
Terminal: 3U, 3V, 3W, 3X, 3Y, 3Z Does not flash and OV indicated for in
dividual terminals
• Continuity of injector
49 92 00 162 • Continuity between PCME and in
jectors)
c r page F2-68
•Condition of injector connector and
Repair or replace parts and/or wir
ing harness as necessary
49 G 018 903
Connect jumper wire between F/P and GND ter Yes Check as follows:
minals of data link connector; will engine start? •3T terminal voltage at PCME c r page F2-102
JUMPER •Continuity between 3T terminal and
WIRE fuel pump relay connector terminal
•Condition of PCME and fuel pump
relay connector female terminals
Y l I I GT No Check if fuel pump operating sound
is heard
• If no, check fuel pump and wiring
harness c r page F2-63
GND
DATA LINK
CONNECTOR
c r page F2-96
2B terminal: Approx. 4.0V (ign. ON) • Movement of measuring core in
volume air flow sensor
49 9200 162
• Ground of volume airflow sensor
• Continuity between volume airflow
sensor and PCME connector
• Condition of volume airflow sensor
and PCME connector female ter
minals
49 G 0 18 903
c r page F2-60
270-310 kPa (2.7—3.2 kgf/cm), 39-45 psi) check pressure regulator c r page F2-70
DATA LINK
CONNECTOR
F 2-126
Is a strong blue spark visible at each disconnected Yes Go to next step
No Check as follows c r Section G

•Distributor cap and rotor c r Section G
Are injectors OK? Yes Go to next step

No Replace injector(s)
c r page F2-66
Try known good PCME; does condition improve?

c r page F2-92
46U0F2-146
5 CRANKS NORMALLY BUT WILL NOT START •PARTIAL COMBUSTION — AFTER WARM UP
• Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine is warm
DESCRIP • Engine will not continue running when ignition switch is returned from STA to IG position
TION
• Hold fuel pressure low c r page F2-59
© Throttle body
•Carbon on throttle valve c r page F2-49
46U0F2-147
F 2-1 27
7, 8 ,9 CRANKS NORMALLY BUT HARD TO START •ANY ENGINE TEMP

•WHEN ENGINE COLD
• AFTER WARM-UP
• Starter cranks engine at normal speed but engine requires excessive cranking time before starting
DESCRIP • Engine starts after stalling a few times
•Engine runs normally at idle (if idle condition not OK, refer to “ Engine runs rough” [Nos. 19, 20, 21, 22 or 23])
© Injector © Solenoid valve (PRC)
• Fuel leakage from injector(s) • Solenoid valve stuck
© Fuel pump © Throttle body
• Malfunction of pump • Carbon on throttle plate
© Pressure regulator © Solenoid valve (EGR, vacuum or vent)
• Pressure regulator stuck • Solenoid valve stuck
© Spark plug © EGR control valve
• Dirty or worn spark plug(s) •EGR control valve stuck
ON?
SELF-DIAGNOSIS
CHECKER
SYSTEM SELECTOR
displayed
check sequence)
49 H 018 9A1
c r page F2-20
“ 88” Flashes
SELECT SW: A
CHECKER FLASHES 88 c r page F2-159
c r page F2-60 Check fuel line pressure while pinch
270—310 kPa [2.7—3.2 kgf/cm2, 39—45 psi) pressure regulator c r page F2-70
JUMPER check for clogging between fuel
WIRE
F/P If hose not clogged, check fuel
DATA LINK
CONNECTOR GND
Is fuel line pressure held after ignition switch turn- Yes • If symptom occurs at any engine temp.,
ed OFF? go to Step 6
c r page F2-59 • If symptom occurs when engine cold,
go to next step
Fuel line pressure: • If symptom occurs after warm-up, go to
More than 150 kPa (1.5kgf/cm2, 21 psi) for 5 Step 6
min. No Plug outlet of pressure regulator,
Is fuel line pressure held after ignition
switch turned OFF? c r page F2-59
• If yes, replace pressure regulator c r page F2-66
• If no, check fuel pump hold pressure c r page F2-70
If fuel pump OK, check injectors for fuel
leakage c r page F2-67
Is throttle body clean internally? Yes Clean throttle body
No Go to next step
Disconnect vacuum hose from EGR valve and Yes Check as follows:
plug it; does condition improve? • Solenoid valve (EGR, vacuum) for
N sticking
• Solenoid valve (EGR, vent) for sticking
• Condition of solenoid valve connector
female terminal(s)
No Check if EGR control valve moves

smoothly c r page F2-78
• If no, replace EGR valve c r page F2-79
c r page F2-92
46U0F2-148
F 2-129
10, 1 1 ,1 2 ENGINE STALLS •IDLE AT ANY ENGINE TEMP

•DURING FAST IDLE
•IDLE AFTER WARM-UP
• Engine stops unexpectedly at idle and/or during fast idle operation
DESCRIP
TION
© Injector © Air leakage in intake air system ©Engine coolant temperature sensor
• Fuel leakage from injector(s) © Distributor • Poor connection of connector
• Injector(s) clogged • Cap and/or rotor damaged © EGR control valve
© Fuel pump • Poor connection of connector EGR control valve stuck
• Maximum pressure low © Volume airflow sensor © BAC valve
© Fuel pump relay • Measuring core stuck • Air valve stuck
ON? • If symptom occurs at idle at any engine
cr page F2-18 temp., go to next step
SELF-DIAGNOSIS • If symptom occurs during fast idle op
CHECKER eration, go to Step 8
• If symptom occurs at idle after warm
SYSTEM SELECTOR up, go to Step 9
displayed
49 H 018 9A1 check sequence)
MONITOR cr page F2-20
LAMP '-Sr *<g3 ’’ ^lashes
Do Engine Signal Monitor lamps flash for specified Yes Go to next step
terminals while cranking engine?
Terminal: 3U, 3V, 3W, 3X, 3Y, 3Z Does not flash and OV indicated for in
dividual terminal(s)
•Continuity of injector(s)
• Continuity between PCME and injec
49 92 00 162 tors) cr page F2-68
• Condition of injection connector and
PCME connector
49 G 0 18 903

No Check as follows; cr Section G

• Distributor cap and rotor
• High-tension lead(s)
F2-130
Connect jumper wire between F/P and GND ter Yes Check as follows:
minal of data link connector; will engine run? •3T terminal voltage at PCME c r page F2-102
• Continuity between 3T terminal and fuel
pump relay connector terminal
• Condition of PCME and fuel pump relay
connector female terminals
I I
No Check if fuel pump operating sound is
heard?
• If no, check fuel pump circuit
GND F/P
DATA LINK
CONNECTOR
c r page F2-60
Check fuel line pressure while pinching
fuel return hose
check for clogging between fuel pump
and pressure regulator
maximum pressure c r page F2-63
DATA LINK
CONNECTOR
Is air leakage felt or heard at intake air system com Yes Repair or replace
ponents while racing engine to higher speed?
No Go to next step
Is engine compression correct? Yes Go to Step 9

c r Section B2
No Check for cause c r Section B2
Engine compression (Minimum):
981 kPa (10.0 kgf/cm2, 143 psi)/250 rpm
Does engine start with throttle valve held quarter Yes Check as follows:
open? • Operation of air valve c r page F2-53
• Operation of EGR control valve c r page F2-78
No Go to next step
Does following terminal voltage at PCME increase

smoothly? Yes Go to next step
c r p a g e F 2 —9 8
(2E terminal: Engine coolant temperature • Movement of measuring core in volume
sensor) airflow sensor
(V) 5 • Ground of volume airflow sensor
• Continuity between volume airflow sen
sor and PCME connector
• Condition of volume airflow sensor and
0 40 80 ( °C \ WATER
(32) (104)(176) U ° F )) t e m p .
F2-131

10 Are spark plugs OK? Yes • If symptom occurs at any engine temp.,
WEAR AND CARBON cr Section G go to Step 14
BURNT • If symptom occurs fast idle operation, go
PLUG
GAP to Step 14
• If symptom occurs at idle after warm-up,
go to next step
DAMAGE AND
DETERIORATION
No Clean or replace cr Section G
DAMAGE
cr page F2-53
Resistance: 10.7—12.3(2 (at 2 0°C (68eF))
THROTTLE BODY No Replace BAC valve c r page F2-48
12 Try known good BAC valve; does condition im Yes Replace BAC valve cr page F2-48
prove?
No Reinstall BAC valve and go to next step
13 Is the heated oxygen sensor operation OK? Yes Go to next step

c r page F2-108
SELF-DIAGNOSIS • Poor connection of engine coolant
CHECKER temperature sensor connector
• Incorrect installation of throttle position
SYSTEM SELECTOR sensor
49 H 018 9A1
SELECT SW: A

•N o fuel leakage cr page F2-68
No Replace injector(s) cr page F2-66
15 Try known good PCME; does condition improve?

c r page F2-92
46U0F2-149
F 2-132
13, 14 ENGINE STALLS •IDLE WITH A/C, P/S, and/or E/L ON
•IDLE WHEN SHIFTED FROM N OR P TO OTHER
RANGES
DESCRIP • Engine stops unexpectedly when shifted from N or P to other ranges at idle
TION Idle condition is normal when A/C, P/S, and E/L are OFF and in N and P
• Air conditioning sensor © idle air control valve
• Headlight switch • Idle air control valve stuck
Are switches correct when checked by using Yes Go to next step
SST monitor lamp or indicator while ignition
switch ON?
c r page F2-43
No Lamp or indicator not ON/OFF with
specified switch
• B lo w e r sw itch
• Headlight switch check sequence) c r page F2-45
• Selector lever
SELF-DIAGNOSIS
CHECKER
SYSTEM SELECTOR
49 H 018 9A1
SELECT SW: A
Is “ 00" displayed on SST with ignition switch Yes “ 00" displayed

ON?
SELF-DIAGNOSIS
CHECKER
SYSTEM SELECTOR
displayed
check sequence)
49 H 018 9A1 c r page F2-20
“ 88” flashes displayed

SELECT SW: A
Is terminal voltage at PCME correct at idle? Yes Check BAC valve and replace if
c r page F2-102 necessary c r page F2-53
If OK, go to “ ENGINE STALLS -
3Q terminal: Approx. 6.0V (at idle) IDLE WHEN SHIFTED FROM N or P
TO
OTHER RANGES” in Section K of this
manual
No Try known good PCME and check if
condition improves c r page F2-92
46U0F2-150
F2-133
15 ENGINE STALLS •DRIVEAWAY

• Engine stops unexpectedly upon driveaway
DESCRIP • Idle condition normal
TION
© Injector (3) Fuel filter © Engine coolant temperature sensor
• Fuel leakage from injector(s) • Fuel filter clogged • Poor connection of connector
• Injector(s) clogged ® Distributor
© Pressure regulator • Poor connection of connector
• diaphragm damaged • Cap and/or rotor damaged
Is “ 00” displayed on SST with ignition switch Yes “ 00" displayed
ON?
Go to next step
SELF-DIAGNOSIS ^ Pa 9 e F 2 _ 1 8
CHECKER

displayed
check sequence)
49 H 018 9A1 c r page F2-20
“ 88” flashes
Uing Engine Signal Monitor, do voltage reading Yes Go to next step
and lamp operation change as follows upon
driveaway?
Terminal Condition
• Condition of female terminals in related
2B Voltage gradually increases connector
2E Does not suddenly change • Continuity between injector connector
voltage and PCME connector
3U, 3V, 3W, Flashing of green and red light
3X, 3Y, 3Z becomes quicker
■ ■ K W a i 49 9200 162 g f B M
!
□ i.
49 G 0 18 903
c r page F2-60 Check fuel line pressure while pinching
fuel return hose
265—314 kPa (2.7—3.2 kgf/cm2, 38—46 psi) pressure regulator c r page F2-70
pressure regulator
JUMPER
WIRE
F/P
DATA LINK
CONNECTOR GND
F 2-134
No Replace injector c r page F2-66

c r page F2-92
46U0F2-151
F2-135
16, 17 ENGINE STALLS •ON ACCELERATION/WHILE CRUISING

•Engine stops unexpectedly at beginning of acceleration or during acceleration
DESCRIP • Engine stops unexpectedly while cruising
TION
© Fuel pump © Volume airflow sensor
© Pressure regulator • Measuring core stuck
• Diaphragm damaged © Main relay
© Distributor • Poor connection of connector
• Cap and/or rotor damaged
STEP __________________ INSPECTION___________ ACTION
ON?
SELF-DIAGNOSIS
CHECKER
SYSTEM SELECTOR
displayed
check sequence)
49 H 018 9A1 c r page F2-20
MONITORS
-T -L ^ M P 'i “ 88” flashes
SELECT SW: A
CHECKER FLASHES 88 cr page F2-159
Is a strong blue spark visible at each disconnected Yes Check spark plugs cr Section G
high-tension lead while cranking engine? ■=> If OK, go to next step
If not OK, clean or replace spark
plug
• Distributor cap and rotor cr Section G
• High-tension leads cr Section G
female terminals
Volume are air flow sensor connector terminals Yes Verify that measuring core of volume
good? airflow sensor moves smoothly
• If OK, go to next step
•If not OK, replace air flow sensor
No Repair connector terminal(s)
Ground terminal F/P of data link connector within Yes Go to next step
ignition switch ON;
is operation sound of fuel pump heard?
• Poor connection of fuel pump relay
• Poor connection of fuel pump con
nector
• Melted EGI INJ fuse (30A) cr page F2-124
Refer to “ No.1-MELTS MAIN OR
OTHER FUSE"
DATA LINK • Poor connection of main relay
CONNECTOR • Operation of main relay cr page F2-104
F2-136
cr page F2-70
Fuel line pressure:

210—250 kPa {2.1—2.6 kgf/cm2, 30—36 psi Check pressure regulator cr page F2-70
No
Pressure regulator vacuum hose discon

nected:
2 7 0 -3 1 0 kPa [2.7—3.2 kgf/cm2, 3 9 - 4 5 psi)

cr page F2-92
46U0F2-152
F2—137
18 ENGINE STALLS •ON DECELERATION

• Engine stops unexpectedly at beginning of deceleration or recovery from deceleration
TION
© Fuel pump © Volume airflow sensor
@ Idle speed • Measuring core stuck
• Idle speed too low © Idle air control valve
® Distributor • Idle air control valve stuck
• Poor connection of connector © EGR control valve
• Solenoid valve stuck
• EGR control valve stuck open
is idle speed correct after warm-up?
cr page F2-16
No Remove System Selector and Go to
Idle speed: 600—700 (650 ± 50) rpm next step
Does idle speed drop in following conditions? Yes Check as follows;

•Circuit from idle air control valve to
Condition PCME for open and short cr page F2—38
• Electrical load ON • Idle air control valve for sticking c r page F2-53
• Air conditioner ON
• P/S operating
No Adjust idle speed cr page F2-16

ON?
SELF-DIAGNOSIS
CHECKER

displayed
check sequence)
49 H 018 9A1
cr page F2-20
“ 88” flashes
SELECT SW: A Refer to “ No.38 SELF-DIAGNOSIS
F 2-138
Are switch operation correct when checked by Yes Go to next step
using SST monitor lamp or indicator while igni
tion switch ON?
c r page F2-43
SELF-DIAGNOSIS
CHECKER
SYSTEM SELECTOR specified switch
Check for caused (Refer to specified
check sequence)
c r page F2-45
49 H 0 18 9A1
SELECT SW: A
Are volume airflow sensor connector terminals Yes Verify that the measuring core of vol
and connection good? ume airflow sensor moves smoothly
• If not OK, replace air flow sensor
Connect engine signal monitor to PCME and set Yes Go to next step
to position 2J
Does following terminal voltage at PCME in
crease smoothly when vacuum applied to EGR No Check EGR control valve for sticking
control valve? c r page F2-78
Terminal 2J voltage:
kPa
9) ( (mmHg, inHg]
VACUUM
Are following terminals and connections good? Yes Go to “ ENGINE STALLS - ON
• Distributor connector DECELERATION” in Section K of this
•Fuel pump connector manual
• Main relay
• PCME connector No Repair connector terminal
46U0F2-153
F2-139
19, 20, 21 ENGINE RUNS ROUGH ‘ IDLE AT ANY ENGINE TEMP/DURING FAST IDLE/IDLE AFTER WARM-UP
• Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at any
engine temp.
DESCRIP • Idle speed too slow and excessive engine shake at any engine temp.
TION • Fast idle speed too slow and excessive engine shake during fast idle, but returns to normal after warm-up
• Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle after
warm-up
[TROUBLESHOOTING HINTS] © Distributor
© Injector • Cap and/or rotor damaged
• Injector(s) clogged © Volume airflow sensor
© Fuel pump • Measuring core stuck
•Maximum pressure low © Engine coolant temperature sensor
© Fuel pump relay • Poor connection of connector
• Poor connection of connector © EGR control valve
© Air leakage • EGR control valve stuck
• Leakage in intake air system © BAC valve
• Air valve stuck
ON? • If symptom occurs at idle at any engine
c r page F2-18 temp., go to next step
• If symptom occurs during fast idle op
eration, go to Step 9
SELF-DIAGNOSIS • If symptom occurs at idle after warm
CHECKER up, go to Step 10
SYSTEM SELECTOR
displayed
check sequence)
49 H018 9A1
c r page F2-20
<<3 8 ” flashes
SELECT SW: A CHECKER FLASHES 88”
c r page F2-159
Do Engine Signal Monitor lamps flash for specified Yes Go to next step
terminals while cranking engine?
No Check as follows according to results;
Terminal: 3U, 3V, 3W, 3X, 3Y, 3Z
Do not flash and 0V indicated for in
dividual terminal(s)
• Continuity of injector(s) c r page F2-68
• Continuity between PCME and injec
tors)
49 92 00 162 PCME connector
49 G 01 8 903
F2-140
Is a strong blue spark visible at each disconnected Yes Go to next step
No Check distributor cap and rotor c r Section G

Check as follows;
c r page F2-60
Check fuel line pressure while pinching
fuel return hose
270—310 kPa (2.7—3.2 kgf/cm2, 39—45 psi) pressure regulator c r page F2-70
pressure regulator
DATA LINK
CONNECTOR
Is there air leakage at intake air system com Yes Repair or replace
ponents while racing engine to higher speed
No Go to next step
Connect engine signal monitor to PCME and set to Yes Go to next step
position 2J
Does following terminal voltage at PCME increase
smoothly when vacuum applied to EGR control No Check EGR control valve for sticking
valve? c r page F2-78
Terminal 2J voltage
kPa \
(5 0 ,2 .0 ) (1 0 0 ,3 .9 ) \( mmHg, inHg)]
VACUUM
F2-141

Is engine compression correct? Yes Go to next step
ccr Section B2
Engine compression (minimum): No Check for cause

981 kPa {10.0 kgf/cm2, 143 psi]/250 rpm
cr Section B2
position 2B
Does following terminal voltage in PCME increase
smoothly?
c r page F2-104
• Movement of measuring core in volume
Terminal 2B voltage:
airflow sensor
Approx. 4V (Ignition SW: ON)
• Ground of volume airflow sensor
• Continuity between volume airflow sen
49 92 00 162 sor and PCME connector
• Condition in volume airflow sensor and
49 G 0 18 903
Are spark plugs OK? Yes • If symptom occurs at any engine temp.,
WEAR AND CARBON ^ Section G go to Step 13
•If symptom occurs during fast idle op
BURNT
eration, go to Step 13
PLUG GAP
• If symptom occurs at idle after warm-up,
go to next step
— DAMAGE AND No Clean or replace
DETERIORATION
DAMAGE
Resistance: 10.7— 12.312 (at 20°C (68°F )) No Replace BAC valve c r page F2-48
THROTTLE BODY
11 Try known good BAC valve; does condition Yes Replace BAC valve c r page F2-48
improve?
No Reinstall BAC valve

Go to next step
F 2-142
12 Is heated oxygen sensor operation correct? Yes Go to next step
c r page F2-108
• Poor connection of engine coolant
SELF-DIAGNOSIS temperature sensor connector
CHECKER • Incorrect installation of throttle position
sensor
SYSTEM SELECTOR
M O N IT O R ^
LAMP
SELECT SW: A

No Replace injector cr page F2-66
14 known good PCME; does condition improve?

c r page F2-92
46U0F2-154
F2-143
22, 23 ENGINE ROUGH •IDLE WITH A/C, P/S AND/OR E/L ON

•IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGES
• Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when
DESCRIP A/C, P/S and/or E/L ON
TION • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when
shifted from P or N to other range
© Idle speed © Idle air control valve
• Idle speed too low • Idle air control valve stuck
@ Monitor switch function (SST)
• Blower switch
Correct System Selector to diagnosis connector Yes Go to next step
c r page F2-16 No Adjust idle speed and go to next step c r page F2-16
Idle speed: 600—700 (650 ± 50) rpm
Is “ 00" displayed onSST with ignition switch Yes “ 00” or "No diagnostic trouble
ON? codes” displayed

SELF-DIAGNOSIS
CHECKER
SYSTEM SELECTOR
displayed
check sequence)
49 H 018 9A1
c r page F2-20
MONITOR
- 7 - LAMP '-3L-
“ 88” flashes
SELECT SW: A Refer to “ No.38 SELF-DIAGNOSIS
Are switches correct when checked by using SST Yes • If symptom occurs at idle with P/S ON,
monitor lamp or indicator while ignition switch ON? go to next step
c r page F2-43 • If symptom occurs at idle when shifted
from N or P to other range, go to Step 5
• Blower switch
specified switch
• Selector lever
check sequence)
c r page F2-45
SELF-DIAGNOSIS
CHECKER
SYSTEM SELECTOR
49 H 018 9A1
SELECT SW: A
F 2-144
1N terminal: 12V (steering wheel in straight

ahead position) No Check as follows:
OV (steering wheel turned fully) • Wiring harness between P/S pressure
switch and PCME terminal 1N for open
49 9200 162 circuit
49 GO 18 903
Warm-up engine Yes »If symptom occurs at idle with A/C, P/S
Does idle speed decrease when idle air control valve and/or E/L ON, go to next step
connector disconnected? •If symptom occurs at idle when shifted
from N or P to other range, go to
“ ENGINE RUNS ROUGH - IDLE
WHEN SHIFTED FROM N OR P TO
OTHER RANGE” in Section K of this
manual
No Check idle air control valve for sticking c r page F2-53
Does air conditioner operate continuously with igni Yes Check as follows:
tion switch ON and A/C sensor and blower switch • Malfunction of A/C relay c r Section U
OFF? • Wiring harness between A/C relay and
PCME terminal 1L for short circuit c r page F2-96
No Go to next step

c r page F2-92
46U0F2-155
F 2-145
24 ENGINE RUNS ROUGH •ON DECELERATION

• Engine shakes at beginning of deceleration, during deceleration, or recovery from deceleration
DESCRIP •Exhaust afterburn
TION
© Fuel pump @ Distributor
© Injector © Volume airflow sensor
© Idle speed • Measuring core stuck
• Idle speed too low © Idle air contol valve
• Idle air contol valve stuck
c r page F2-16
No Remove System Selector and go to next
step
Idle speed: 600—700 (650 ± 50) rpm
Does idle speed drop in following conditions? Yes Adjust idle speed
Condition: c r page F2-16
• Electrical load ON No Check as follows:
• Air conditioner ON • Wiring harness from idle air control
• P/S operating valve to PCME for short and open
circuit
c r page F2-38
• Idle air control valve stuck c r page F2-53
Is "00” displayed on SST with ignition switch Yes "00” displayed

ON?
SELF-DIAGNOSIS ^ Pa 9 e F 2 “ 18 Go to next step
CHECKER
SYSTEM SELECTOR
displayed
49 H01 8 9A1 check sequence)
c r page F2-20
<<gg’» flashes
F 2-146
4 Are switches correct when checked by using SST Yes Go to next step
monitor lamp or indicator while ignition switch ON?
c r page F2-43
SELF-DIAGNOSIS
CHECKER No Lamp not ON/OFF with specified switch
Check for caused (Refer to specified
SYSTEM SELECTOR check sequence)
c r page F2-45
'fceo!
MONITOR
LAMP
SELECT SW: A
5 Is there fuel leakage from injector nozzles or injec Yes Reinstall or replace injector
tor holder? c r page F2—67 c r page F2-66
No Go to next step
6 Are volume airflow sensor connector terminal and Yes Verify that the measuring core of volume
connection good? airflow sensor moves smoothly.
• If not OK, replace volume airflow
sensor
7 Are following connections good? Yes Go to next step

• Main relay
• PCME connector
8 Try known good PCME; does condition improve? Yes Replace PCME
c r page F2-92
No Go to "ENGINE RUNS ROUGH - ON
DECELERATION” in Section K of this
manual
46U0F2-156
F 2-1 47
25, 26 POOR ACCELERATION •DRIVEAWAY

•ON ACCELERATION
DESCRIP • Engine speed increases normally but vehicle speed slowly increases during driveaway or acceleration
TION
© Pressure regurator • Cap and/or rotor damage
• Pressure regulator malfunction © Volume airflow sensor
(D Fuel filter • Poor connection of connector
• Clogged filter •Measuring core stuck
ON?
S E L F -D IA G N O S IS
CHECKER

displayed
check sequence)
49 H 018 9A1 c r page F2-20
“ 88” flashes
S E L E C T SW : A CHECKER FLASHES 88 c r page F2-159
Is a strong blue spark visible at each disconnected Yes Check spark plugs
■=> If not OK, clean or replace
spark plug
•Distributor cap and rotor c r Section G
•Condition of distributor connector
femals terminals
Does measuring core in volume airflow sensor move Yes Check condition of volume airflow sensor
smoothly? c r page F2-104 connector female terminals
MESSURING CORE ■=t> If OK, go to next step
■=> If not OK, repair terminal
No Replace volume airflow sensor
Is intake manifold vacuum correct at idle? Yes Go to next step
Vacuum: No Check as follows:

More than 60.0 kPa {450 mmHg, 17.7 inHg)
•Intake air system components and in
stallation
•Vacuum hoses for disconnection and
damage
• Shutter valve actuator for damage
F2—148
c r page F2-70
No Low pressure
Fuel line pressure: Check as follows:
210—250 kPa (2.1—2.6 kgf/cm2, 30—36 psi) • Fuel filter for clogging
• Operation of pressure regulator c r page F2-70
• Fuel leakage from injector (s) c r page F2-67
6 Try known good PCME; does condition Yes Replace PCME

No Go to “ POOR ACCELERATION -
DRIVEAWAY/ON ACCELERATION” in
Section K of this manual
46U0F2-157
F2—149
27 HIGH IDLE SPEED AFTER WARM-UP

• Idle speed continues at fast idle after warm-up
DESCRIP • Engine returns slowly to idle after accelerator is released
TION
© Engine coolant temoerature sensor (3) BAC valve
• Poor connection of connector • Idle air control valve or air valve stuck
© Throttle position sensor
ON?
CHECKER
SYSTEM SELECTOR
displayed
check sequence)
49 H 018 9A1
c r page F2-20
“ 88” flashes
S ELEC T SW : A Refer to “ No.38 SELF-DIAGNOSIS
Connect System Selector to the data link connector Yes Check condition of engine coolant
and set system select to position 1 temperature sensor (CIS) and throttle
Does idle speed decrease with TEST SWITCH set position sensor connector female ter
to SELF TEST? minals
=> If not OK, repair the female con
nector
No Check if idle air control valve or air valve
cti ipk
o If OK, go to Step 4
■=> If not OK, replace BAC valve
Terminal 2F: 0.1—1.1V (throttle valve fully No Adjust or replace throttle position sensor
closed) c r page F2-107
3.1—4.4V (throttle valve fully
open)
49 92 00 162
49 G 0 18 903

c r page F2-92
46U0F2-158
F2-150
TROUBLESHOOTING GUIDE_________________ F2
28 • IDLE FLUCTUATES
• IDLE HUNTS
>Engine speed changes back and forth between specified idle speed and higher speed
DESCRIP
TION
© PCV valve @ Idle air control valve
• PCV valve stuck • Idle air control valve stuck
(2 ) Spark plug
(3) Throttle position sensor
STEP __________________ INSPECTION________ ACTION
Is “ 00" displayed on SST with ignition switch Yes “ 00" displayed
ON?
CHECKER
SYSTEM SELECTOR
displayed
check sequence)
49 H 018 9A1 c r page F2-20
M O N IT O R ';
^7-LAMP i “ 88” flashes
S E L E C T SW : A
Terminal 1T: Below 1.0V (accelerator pedal

released)
•Throttle position sensor adjustment
B + (accelerator pedal c r page F2-107
depressed)
49 92 00 162
49 G01 8 903
Connect System Selector to data link connector Yes Check as follows:

and set system select to position 1 • Idle air control valve for sticking
Does idle hunting stop when test switch to SELF • Poor sealing between throttle body and
TEST? BAC valve
No Go to next step
F2-151

4 Is a strong blue sp ark visible at each disconnected Yes Check spark plug(s)
high-tension lead while cranking engine? =!> If OK, go to next step
e j pi /-jQ pJhP /
5
IP
Is PCV valve stuck?
c r page F2-80
Yes Replace PCV valve
No Go to next step

c r page F2-92
46U0F2-159
29 • HESITATES
• STUMBLES ON ACCELERATION
• Momentary pause at begining of acceleration or during acceleration
DESCRIP
TION
© Injector ® Distributor
© Fuel pump • Cap and/or rotor damage
• Poor connection of connector © High-tension lead(s)
@ Pressure regulator • Lead(s) damaged
• Pressure regulator stuck © Volume airflow sensor
@ EGR control valve • Poor connection of connector
• EGR control valve stuck • Measuring core stuck
© Solenoid valve (EGR, vacuum) © Throttle position sensor
• Solenoid valve stuck • Poor connection of connector
STEP __________________ INSPECTION___________ ACTION
ON?
CHECKER

displayed
check sequence)
49 H 0 1 8 9A1 cr page F2-20
M O N IT O R /
LA M P -~- “ 88” flashes
S E L E C T SW : A
high-tension lead?
• Distributor cap and rotor for damage cr Section G
•High-tension lead(s) for damage cr Section G
• Condition of distributor and PCME
Is fuel line pressure correct at idle? Yes Go to next step

cr page F2-70
No Low pressure
Fuel line pressure:
210—250 kPa (2.1—2.6 kgf/cm2, 30—36 psi] ing fuel return hose
•If pressure quickly increases, check
pressure regulator cr page F2-70
pressure regulator
maximum pressure cr page F2-63
F2-153

Does fuel pressure increase when throttle valve Yes Go to next step
opened?
No Check pressure regulator

c r page F2-70
Disconnect vacuum hose from EGR valve and Yes Check as follows:
plug it; does condition improve? • Solenoid valve (EGR, vacuum) for stick
ing
• Solenoid valve (EGR, vent) for sticking
• Condition of solenoid valve connectors
female terminals
No Go to next step
Connect engine signal monitor to PCME and set Yes Go to next step
the position 2J.
Is following terminal voltage at PCME increase
smoothly when vacuum applied to EGR control No Check EGR control valve for sticking c r page F2-78
valve?
Terminal 2J voltage:
(V)
OUTPUT 3
VOLTAGE2
6.7 13.3 ' I kPa \

(50,2.0) (100, 3.9)UmmHg, inHg)]
VACUUM
Is following terminal voltage at PCME correct? Yes Verify that measuring core of volume air
flow sensor moves smoothly
2B terminal: Approx. 4V (ign switch ON) • If OK, go to next step
Approx. 2.8V (idle) • If not OK, replace volume airflow
sensor
No Check condition of volume airflow sen
sor and PCME connectors female ter
49 92 00 162 minals
• If OK, replace volume airflow sensor
• If not OK, repair female terminal
49 G018 903
F 2-154
Is following terminal 2F voltage at PCME Yes Go to next step
correct?
No Check the female terminal condition in
2F terminal: 0.1—1.1V (throttle valve fully
throttle postion sensor connector and
closed) PCME connector
3.1—4.1V (throttle valve fully
• If OK, replace throttle position sensor c r page F2-107
open)
• If not OK, repair female terminal
49 92 00 162
49 GO 18 903
Is there fuel leakage from injector(s) Yes Check as follows:

• Poor installation of injector
Fuel leakage: Less than 1 drop/2 min. c r page F2-66
No Go to next step
TO FUEL TANK
FROM
FUEL FILTER

c r page F2-92
46U0F2-160

• Momentary minor irregularity in engine output at steady vehicle speed.
DESCRIP
TION
© Injector
© Spark plug
© Volume airflow sensor
• Measuring core stuck
ON?
SELF-DIAGNOSIS
CHECKER

displayed
/I Check for cause (Refer to specified
check sequence)
49 H 018 9A1 cr page F2-20
<<88” flashes
SELECT SW: A CHECKER FLASHES 88 cr page F2-159
position 2B
Does output voltage of volume airflow sensor gradu No Check as follows:
ally increase in conjunction with increase of engine • Smooth movement of measuring core
speed? in volume airflow sensor
49 92 00 162 • Condition of volume airflow sensor and
PCME connectors female terminals
49 G 01 8 903
Does idle become rough when shaking connec Yes Check as follows:
tor of injector? • Condition of injector and PCME
No Go to next step
F 2-156
4 Is a strong blue spark visible at each disconnected Yes Check spark plug(s) for damage
high-tensio n lead while cranking engine? => If OK, go to next step
— 1
5 Try known good PCME; does condition Yes Replace PCME

No Go to “ SURGE WHILE CRUISING” in
Section K of this manual
46U0F2-161
31 LACK OF POWER
• Performance poor under load (i.e., power down when climbing hills)
DESCRIP
TION
© Volume airflow sensor
• Open or short circuit in wiring of intake air temperature sensor (Code No. 10 output) cr page F2-28
© Distributor
• Damaged distributor cap or rotor cr Section G
© Injector
• Injector harness shorted to ground
© Fuel filter
• Clogged filter
© Air cleaner housing
• Clogged element cr page F 2 -1 5
© Three way catalyst
• Clogged three way catalyst cr page F2-73
46U0F2-162

• Fuel economy unsatisfactory
DESCRIP
TION
© A ir leakage
• Poor installation of air intake hose, throttle body, intake manifold and/or EGR valve
• Vacuum hose damaged or disconnected c r page F 2 -7
© Heated oxygen sensor
• Open in harness (Code No. 15, 23 output) c r page F2-30
• Hold fuel pressure high c r page F2-65
• Vacuum hose disconnected or damaged c r page F 2 -7
46U0F2-163

• A/C compressor magnetic clutch does not engage when air conditioning sensor ON
DESCRIP
TION
© A/C relay
• Relay malfunction c r Section U
© Air conditioning sensor or A1C amplifier
• Does not send signal to PCME terminal 10 c r page F2-96
© PCME
• Does not send signal to A/C relay when ignition switch ON c r page F2-96
46U0F2-164
34 • KNOCKING
• PINGING
• Sound produced when air/fuel mixture is ignited by something other than spark plug (i.e., hot spot in combustion
DESCRIP chamber)
TION
Knock sensor
46U0F2-165
35 FUEL ODOR
• Gasoline fuel smell or visible leaks
DESCRIP
TION
© Solenoid valve (purge control)
© Charcoal canister
• Canister full of fuel and leaking
46U0F2-166
36 EXHAUST SULFUR SMELL

• Rotten egg smell (sulfur) from exhaust
DESCRIP
TION
High sulfer content fuel used
36U0F2-285
37 HIGH OIL CONSUMPTION

• Oil consumption excessive
DESCRIP
TION
PCV valve
• PCV valve stuck open c r page F2-80
46U0F2-167
38 SELF-DIAGNOSIS CHECKER FLASHES “ 88”

• Checker flashes 88 with test connector (TEN) grounded
DESCRIP
TION
© Short circuit in wiring between diagnosis connector terminal FEN and PCME terminal 1F
© PCME
• PCME malfunction c r page F2-94
46U0F2-168
39 MIL NEVER ON
• S e lf-D ia g n o sis C h e c k e r in d ica te s S e rvice C o d e N o. o f in p u t d e v ic e b u t M IL n e ve r O N
DESCRIP
TION
® B u lb b u rn t
© P o w e rtra in c o n tro l m o d u le (P C M E ) 1E te rm in a l c irc u it o p e n
46U0F2-169
F 2-160
SERVICE POINTS F2
SERVICE POINTS
OUTLINE
Room Fuse (PCME Memory Power)

• If the circuit is open, the PCME memory function will not operate, and diagnostic trouble codes for inter
mittent malfunctions will not be indicated. Also, the learning control will be canceled, but will not produce
any particular symptom.
• If the circuit is shorted, the ROOM fuse (15A) will burn out.
Ground (Output Devices, Injector)

• If an output device or an injector has an open ground circuit, no particular symptom will be produced.
If a related output device and injectors both have open ground circuits, the engine will not start.
Ground (System, Analogue)

• An open circuit will not produce any symptom.
TEN Terminal (Data Link Connector)

• If the circuit is open, the Self-Diagnosis Checker cannot perform diagnostic trouble code checks and switch
monitoring checks.
• If the circuit is shorted, the opening amount of the idle air control valve will not change, causing hard
starting and rough idle. The ignition timing will be fixed, causing lack of power and poor acceleration.
The Self-Diagnosis Checker cannot perform sensor monitoring checks.
• If the circuit is shorted, the coolant fan operates whenever the throttle valve is opened.
MEN Terminal (Data Link Connector)

• If the circuit is open, the Self-Diagnosis Checker monitor lamp will not illuminate.
• If the circuit is shorted, the Self-Diagnosis Checker monitor lamp will stay on.
FEN Terminal (Data Link Connector)

• If the circuit is open, the Self-Diagnosis Checker can not perform the diagnostic trouble code check.
• If the circuit is shorted, code “ 88” will keep flashing, preventing a diagnostic trouble code check.
Malfunction Indicator Light (MIL)

• If the circuit is open, the MIL will not illuminate with the ignition switch ON.
• If the circuit is shorted, the MIL will not go off after the engine is started.
[Input Device]
Volume Airflow Sensor (With Intake Air Temperature sensor)
• If the intake volume air temperature sensor (within the volume airflow sensor) or circuit has an open or
short, Diagnostic Trouble Code No. 10 is output, and the PCME uses a preprogrammed intake air temper
ature of 20°C {68°Fj.
• If the intake air temperature sensor system fails, no particular symptom will be noticed.
• If the Vs terminal of the air flow sensor has a short circuit, Diagnostic Trouble Code No.08 will be output,
and the throttle position sensor and idle switch signal will be used to adjust the basic injection amount
as to the following three modes.
1) Idle switch ON
2) Small throttle angle
3) Large throttle angle
F2-161
F2 SERVICE POINTS
Throttle Position Sensor (Refer to Section K)
• If the Vref terminal has an open circuit or the TVO terminal has an open or short circuit, Diagnostic Trouble
Code No. 12 is output.
• If the 21 terminal has a short circuit, the engine will not start.
• If the ground terminal has an open circuit, Diagnostic Trouble Code No. 12 is output.
• In the above conditions, the PCME uses a throttle valve wide open throttle program.
• If the throttle position sensor is not properly adjusted or the throttle position sensor system fails, poor ac
celeration or shift shock (ATX) will result.
Idle Switch (In Throttle Position Sensor)

• The switch monitor function of the Self-Diagnosis Checker can confirm the presence of an open or short
circuit.
• If the circuit is open, rough idle or engine stalling may appear because of inoperative idle speed control.
• If the circuit is shorted, fuel will be cut when the accelerator pedal is pressed, causing hunting.

• If sensor output voltage is not generated because of an open or short circuit, Diagnostic Trouble Code
No. 15 (left bank sensor) and/or 23 (right bank sensor) is output.
• If the heated oxygen sensor output voltage condinues unchanged 20 sec. after the engine exceeds 1,500
rpm, Diagnostic Trouble Codes No.17 (left bank sensor) and/or 24 (right bank sensor) is output.
• In the above conditions, no feedback control will be present and no symptom will be noticed.
Crankshaft Position Sensor 2 (NE2 Signal), Crankshaft Position Sensor 1 (NE1, G Singnal)
• If the NE2 signal circuit has an open or short, Diagnostic Trouble Code No.02 is output.
• If the NE1 signal circuit has an open or short, Diagnostic Trouble Code No.04 is output.
• If the G signal circuit has an open or short, Diagnostic Trouble Code No.03 is output.
Input Diagnostic
Fail-safe function Symptom
NE2 signal NE1 signal G signal Trouble code
O O X 03 S im u lta n e o u s in je ctio n L a c k of p o w e r, p o o r a c c e le ra tio n
O X X 04 S e q u e n tia l in je ctio n N o s y m p to m
o X X 0 3, 04 N o in je c tio n /ig n itio n E n g in e d o e s n o t start
X O O 02 S e q u e n tia l in je ctio n N o s ym p to m
X O X 02, 03 S im u lta n e o u s in je ctio n L a c k of p o w e r, p o o r a c c e le ra tio n
X X O 02, 04 N o in je c tio n /ig n itio n E n g in e d o e s n o t start
X X X 02, 04 N o in je ctio n /ig n itio n E n g in e d o e s n o t start
O : N o rm a l x : M a lfu n c tio n
Starter Signal
• A lack of starter signal input will cause hard starting.

• An open or short circuit can cause a momentary drop in engine speed when steering at idle or low-speed
driving.
Air Conditioning Sensor


• If the engine coolant temperature sensor or circuit has an open or short, Diagnostic Trouble Code No.09
is output, and the PCME uses a preprogrammed temperature value of 80°C {176°F}.
• A malfunction in the engine coolant temperature sensor system may cause rough idle, engine stalling,
or hard starting.
F 2-162
SERVICE POINTS F2
Blower Signal (A/C Amplifier)
• The switch monitor funciton of the Self-Diagnosis Checker can confirm the presence of an open or short
circuit.
• If the circuit has an open or short, the idle speed may drop when in the 3rd or 4th position.
Stoplight Signal
circuit.

• If the vehicle speed signal circuit has an open or short, Diagnostic Trouble Code No.06 is output.
• If the circuit is open or shorted, hold mode will not operate.
Park/Neutral Signal (ATX; Refer to Section K)

• If the circuit is open, the idle speed will be slightly low in P and N ranges.
• If the circuit is shorted, the idle speed will be slightly high in R, D, S, and L ranges.
Reduce Torque Signal (ATX; Refer to Section K)

• If a malfunction occurs in the reduce torque signal, the torque reduction control system is inhibited and
line pressure will be high at shifting. Shift shock may be slightly increased.
Knock Sensor
• If the knock sensor or circuit has an open or short, Diagnostic Trouble Code No.05 is output.
• In the above conditions, ignition timing is retarded.
EGR Function Sensor

• If the EGR function sensor or circuit has an open or short, Diagnostic Trouble Code No. 16 is output.
• In the above conditions, the EGR control valve will be fully closed.
Neutral and Clutch Switches (MTX)

circuit.
• If the circuit is open, the idle speed will drop when A/C, P/S, or electrical load is ON.

circuit.
• An open or short circuit can cause a low idle speed when the switch is ON.
Headlight Switch
circuit.
Daytime Running Light (Canada)

circuit.
[Output Device]
Injector
• If the circuit is open, the injector will not operate, causing rough idle and misfiring.
• If the circuit is shorted, the injector will inject fuel constantly, and the engine will not start or will start hard.

• If no IGT signals are input to the igniter because of an open or short circuit, the engine will not start.
F2 SERVICE POINTS
Idle Air Control Valve (BAC Valve)
• If the idle air control valve or circuit has an open or short, Diagnostic Trouble Code No.34 is output.
• If the circuit is open, the idle air control valve will be fully closed, causing rough idle, engine stalling, and
acceleration hesitation when cold.
• If the circuit is shorted, the idle air control valve will be wide opened throttle and the idle speed will be
increased, causing hunting.
Fuel Pump Relay

Purge Solenoid Valve

• If the solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.26 is output.
• If the circuit is shorted, the engine will stall at low speed.
• A short circuit may cause an improper air/fuel ratio, causing rough idle and hard starting.
VRIS Solenoid Valve 1

• If the circuit is open, the solenoid valve will stay OFF and the shutter valves will stay closed, causing a
power drop.
• If the circuit is shorted, the solenoid valve will stay ON and the shutter valves will stay open, causing a
power drop.
VRIS Solenoid Valve 2

• If the circuit is open, the solenoid valve will stay OFF and the shutter valves will stay closed, causing a
power drop.
• If the circuit is shorted, the solenoid valve will stay ON and the shutter valves will stay open, causing a
power drop.
A/C Signal (A/C Relay) and Condenser Fan Low Relay

Torque Reduced Signal (Refer to Section K)

• If a malfunction occurs in the torque reduced signal, the torque reduction control system is inhibited and
the line pressure characteristics will be high shifting. Shift shock may be slightly increased.
EGR Solenoid Valve (Vent)

EGR Solenoid Valve (Vacuum)

• If the circuit is shorted, the EGR control valve will remain open, causing engine stalling and hard starting.
PRC Solenoid Valve

• If the circuit is open, the engine will be hard to start when warm.

• If the relay or circuit has an open or short, Diagnostic Trouble Code No.67 is output.
• If the circuit is open, the coolant fan will not operate until the engine coolant temperature exceeds 100°C
{212°F}.
SERVICE POINTS F2
Coolant Fan Relay No.2 and No.3
• If the circuit is open, the coolant fan will remain OFF when the engine coolant temperature exceeds 108°C
Condenser Fan Low Relay

• If the circuit is shorted, the condenser fan will always operate while the ignition switch is ON.
• If the circuit is open, the condenser fan will remain OFF when engine coolant temperature exceeds 100°C
{212°F}.
Condenser Fan High Relay No.1 and No.2

• If the circuit is shorted, the condenser fan will always operate while the ignition switch is ON.
• If the circuit is open, the condenser fan will remain OFF when the engine coolant temperature exceeds
108°C (226°F).
46U0F2-170
F 2-165
F2 SERVICE POINTS
WIRING DIAGRAM
16E0F2-290
F2-166
SERVICE POINTS F2
PRC SOLENOID VALVE

No.2 SOLENOID
IDLE AIR
CONTROL VALVE
pressure! valve
DATA LINK
CONNECTOR
DISTRIBUTOR
(IGNITER, IGNITION COIL,
AND CRANKSHAFT POSITION SENSOR
No.1)
4r BLOWER SWITCH
F 2-167
F2 SERVICE POINTS
Condition
Circuit
P C M E (1 B)— M ain relay E n g in e w ill n o t start EGI IN J fu se (30A ) b u rn s
o u t w h e n ig n itio n sw itch NA
ON
36U0F2-213

Condition
Circuit
P C M E (1 A )— R o o m fu se N o s y m p to m Room fuse (15A) burns out NA
36U0F2-214

Condition
Circuit
P C M E (3A )— G ro u n d (O u tp u t (O ne sid e o p e n circu it) E n g in e m a y n o t start
d e vice ) N o sy m p to m H a rd sta rtin g
P C M E (3B )— G ro u n d (Injector) (B oth sid e s o p e n circu it)
E n g in e w ill n o t start NA
P C M E (3C )— G ro u n d (System ) N o sy m p to m
P C M E (3D )— G ro u n d (A n a lo g u e )
36U0F2-215
Data Link Connector (TEN terminal)

Condition
Circuit
P C M E (11)— D a ta lin k c o n n e c to r C a n n o t p e rfo rm s e rvice H a rd starting
c o d e c h e c k s a n d sw itch R o u g h id le NA
m o n ito r c h e c k s P o o r a cce le ra tio n
36U0F2-216
Data Link Connector (MEN terminal)

Condition
Circuit
P C M E (1 D)— D a ta lin k c o n n e c to r S e lf-D ia g n o sis C h e c k e r S e lf-D ia g n o sis C h e c k e r
m o n ito r la m p w ill n o t il m o n ito r la m p w ill stay O N NA
lu m in a te
36U0F2-217
Data Link Connector (FEN terminal)

Condition
Circuit
P C M E (1 F)— D a ta lin k c o n n e c to r S e lf-D ia g n o sis C h e c k e r C o d e “ 8 8 ” w ill ke e p
b u zze r w ill n o t s o u n d d u r fla s h in g a n d b u zze r will
in g d ia g n o s tic tro u b le c o n tin u e s o u n d in g d u rin g NA
code check d ia g n o s tic tro u b le c o d e
check
46U0F2-171

Condition
Circuit
P C M E (1 E)— M IL M IL w ill n o t illu m in a te w ith M IL w ill not g o off after
NA
ig n itio n sw itch ON e n g in e is sta rte d
NA: Not applicable 46U0F2-172
F2-168
SERVICE POINTS F2
[Input Device]
Volume Airflow Sensor (Intake Air Temperature sensor Included)
Condition
Circuit
P C M E (2B )— V o lu m e a irflo w se n so r Lack of pow er C o d e N o .0 8 o u tp u t
P o o r a c c e le ra tio n L a ck o f p o w e r
P o o r a cce le ra tio n
P C M E (21)— V o lu m e a irflo w se n so r C o d e N o .0 8 o u tp u t E n g in e stall a n d w ill not
NA
Lack of pow er restart
P o o r a c c e le ra tio n
P C M E (2K )— V o lu m e a irflo w se n so r C o d e N o. 10 o u tp u t C o d e No. 10 o u tp u t
N o sy m p to m N o s y m p to m
P C M E (3 D )— V o lu m e a irflo w s e n so r (O n e sid e o p e n circu it) P o o r a cce le ra tio n
N o sy m p to m
V o lu m e a irflo w s e n s o r— G ro u n d (B o th s id e s o p e n circu it) NA
C o d e N o .0 8 10 o u tp u t
P o o r a c c e le ra tio n
46U0F2-173
Crankshaft Position Sensor No. 2 (NE2 Signal), Crankshaft Position Sensor No. 1 (NE1, G Signal)
Condition
Circuit
P C M E (3 H )— C ra n k s h a ft p o sitio n C o d e N o .0 2 o u tp u t C o d e N o .0 2 o u tp u t
s e n s o r N o. 2 N o s y m p to m N o sy m p to m
P C M E (3F)— C ra n k s h a ft p o sitio n C o d e N o .0 2 o u tp u t
NA
s e n s o r N o. 2 N o s y m p to m
P C M E (3E )— C ra n k s h a ft p o sitio n H a rd sta rt until c o d e H a rd sta rt until c o d e
s e n s o r No. 1 N o .0 4 o u tp u t N o .0 4 o u tp u t
NA
P C M E (3G )— C ra n k s h a ft p o sitio n H a rd sta rt until c o d e H a rd sta rt until c o d e
s e n s o r N o. 1 N o .0 3 o u tp u t N o .0 3 o u tp u t
Lack of pow er Lack of pow er
M a in re la y — C ra n k s h a ft p o sitio n C o d e N o .0 3 o r 0 4 o u tp u t C o d e N o .0 3 o r 0 4 o u tp u t
s e n s o r N o. 1 E n g in e w ill n o t start EGI fu se (30A ) b u rn s o u t
w h e n ig n itio n sw itch O N
C ra n k s h a ft p o s itio n s e n s o r N o. 1 C o d e N o .0 3 o r 0 4 o u tp u t E n g in e m a y not s ta rt
NA
— G ro u n g E n g in e w ill n o t start
S y m p to m d iffe rs w ith c o m b in a tio n s o f N E 2, N E 1, a n d G sig n a l m a lfu n ctio n . (R efer to p a g e F -6 0 .)

Condition
Circuit
P C M E (2E )— E n g in e c o o la n t C o d e N o .0 9 o u tp u t C o d e N o .0 9 o u tp u t
te m p e ra tu re s e n so r R o u g h idle, h a rd sta rtin g R o u g h idle, h a rd sta rtin g
NA
C o o la n t fa n a n d a d d itio n a l C o o la n t fa n a n d a d d itio n a l
fa n o p e ra te c o n tin u o u s ly fa n o p e ra te co n tin u o u s ly
E n g in e c o o la n t te m p e ra tu re C o d e N o .0 9 o u tp u t R o u g h idle
s e n s o r— G ro u n d R o u g h idle, h a rd sta rtin g H a rd sta rtin g
NA
C o o la n t fa n a n d a d d itio n a l C o o la n t fa n a n d a d d itio n a l
fa n o p e ra te co n tin u o u s ly fa n o p e ra te c o n tin u o u s ly
46U0F2-174
F2-169
F2 SERVICE POINTS
Throttle Position Sensor (Idle Switch Included)
Condition
Circuit
PCME (21)—Throttle position sensor Code No. 12 output Code No. 12 output
Poor acceleration Engine will not start
Strong shift shock (ATX)
PCME (2F)—Throttle position Code No. 12 output Code No. 12 output
sensor Poor acceleration Poor acceleration NA
Strong shift shock Strong shift shock
PCME (IT)—‘Throttle position Rough idle Fuel cut when accelerator
sensor pedal is pressed, causing
hunting
Throttle position sensor—Ground Code No. 12 output Poor acceleration
Poor acceleration NA Strong shift shock
Strong shift shock
36U0F2-224

Condition
Circuit
PCME (2C)—Heated oxygen Code No.23 output Code No.23 output
sensor (RH) Poor fuel economy NA
Poor fuel economy
Heated oxygen sensor (RH)— Code No.23 output No symptom
NA
Ground Poor fuel economy
PCME (2D)—Heated oxygen Code No. 15 output Code No. 15 output
sensor (LH) Poor fuel economy NA
Poor fuel economy
Heated oxygen sensor (LH)— Code No. 15 output No symptom
NA
Ground Poor fuel economy
36U0F2-225
Starter Signal (Ignition Switch)

Condition
Circuit
PCME (1C)—Ignition switch Hard starting Starter signal IG KEY fuse
(60A) burns out when NA
cranking
36U0F2-226

Condition
Circuit
PCME (1N)—Steering pressure Engine speed may drop Engine speed may drop Engine speed may momen
sensor when steering at idle or when steering at idle or tarily drop when steering at
low-speed driving low-speed driving idle or low-speed driving
36U0F2-227
Air Conditioning Sensor

Condition
Circuit
PCME (10)—Air conditioning Air conditioner will not Air conditioner will
sensor operate constantly operate with NA
blower ON
46U0F2-175
Blower Signal
Condition
Circuit
PCME (1P)—A/C amplifier Idle speed may be low in Idle speed may be low in
3rd or 4th position 3rd or 4th position NA
36U0F2-229
NA; Not applicable
F2-170
SERVICE POINTS F2
Stoplight Signal (Stoplight Switch)
Condition
Circuit
PCME (1Q)—Stoplight switch No symptom No symptom NA
36U0F2-230

Condition
Circuit
PCME (1M)—Vehicle speed sensor Code No.06 output (ATX) Code No.06 output (ATX)
NA
Hold mode will not operate Hold mode will not operate
36U0F2-231
Park/Neutral Signal (EC-AT CU)

Condition
Circuit
PCME (1R)—PCMT Idle speed slightly lower Idle speed slightly higher
NA
in P and N ranges in R, D, S, and L ranges
46U0F2-176
Reduce Torque Signal (PCMT)

Condition
Circuit
PCME (1S)—PCMT Shift shock may be slight Shift shock may be slight
NA
ly stronger ly stronger
36U0F2-233
Knock Sensor
Condition
Circuit
PCME (2M)—Knock sensor Code No.05 output Code No.05 output
Lack of power Lack of power NA
Knocking Knocking
36U0F2-235
EGR Function Sensor

Condition
Circuit
PCME (2J)—EGR function sensor Code No.16 output Code No. 16 output
NA
36U0F2-235
Neutral and Clutch Switches (MTX)

Condition
Circuit
PCME (1R)—Neutral switch Idle speed drop when No sysmptom
PCME (1R)—Clutch switch A/C, P/S, or electrical NA
load is ON
36U0F2-236
NA: Not applicable
F2-171
F2 SERVICE POINTS
Condition
Circuit
PCME (1 J)—Rear window defroster Idle speed may be low Idle speed may be low
switch when switch ON when switch ON NA
36U0F2-237
Headlight Switch
Condition
Circuit
PCME (1H)—Headlight switch Idle speed may be low Idle speed may be low
when switch ON when switch ON NA
36U0F2-238
Daytime Running Light (Canada)

Condition
Circuit
PCME (2L)—Daytime running light Idle speed may be low No symptom
when switch ON NA
36U0F2-239
[Output Device]
Injector
Condition
Circuit
PCME (3U, 3V, 3W, 3X, 3Y, 3Z)— Rough idle Will not start or hard start
Injector Poor accelation at low Engine rough or stall NA
speed
36U0F2-240

Condition
Circuit
PCME (1G)—Igniter Engine stall and will not Engine stall and will not
NA
Igniter—Ignition coil start start
Igniter—Ground NA Engine will not start
36U0F2-241
Idle Air Control Valve [IN BAC Valve]

Condition
Circuit
PCME (30)—Idle air control valve Code No.34 output Code No.34 output
Rough idle Hunts
Engine stalls Idle speed stays or fluc
Hard start tuates at approx. 1,500
rpm NA
Idle air control valve—Main relay EGIINJ fuse (30A) burns
out when ignition switch
ON
36U0F2-242
Fuel Pump Relay

Condition
Circuit
PCME (3T)—Fuel pump relay Engine stall and will not Fuel pump will operate
restart whenever ignition switch NA
ON
NA: Not applicable 3 6 UOF2-243
F2-172
SERVICE POINTS F2
Condition
Circuit
PCME (20)—Solenoid valve Code No.26 output Code No.26 output
(purge control) No symptom Hard starting
Engine stall at low speed
Solenoid valve (purge control) NA
EGI INJ fuse (30A) burns
—Main relay out when ignition switch
ON
46U0F2-177
VRIS Solenoid Valve No.1

Condition
Circuit
PCME (31)—VRIS solenoid valve 1 Code No.41 output Code No.41 output
VRIS solenoid valve 1—Main relay EGI INJ fuse (30A) burns NA
ON
46U0F2-178
VRIS solenoid Valve No.2

Condition
Circuit
PCME (3J)—VRIS solenoid valve 2 Code No.46 output Code No.46 output
VRIS solenoid valve 2—Main relay EGI INJ fuse (30A) burns NA
ON
46U0F2-179
\ __„ A/C Signal (A/C Relay) and Condenser Fan Low Relay
Condition
Circuit
PCME (1L)—A/C relay Air conditioner will not Air conditioner will operate
NA
operate whenever blower ON
36U0F2-247
Torque Reduced Signal (PCMT)

Condition
Circuit
PCME (2P)—PCMT Shift shock may be slight Shift shock may be slight
NA
ly stronger ly stronger
46U0F2-180
EGR Solenoid Valve (Vacuum)

Condition
Circuit
PCME (3P)—EGR solenoid valve Code No.28 output Code No.28 output
(vacuum) No symptom Engine stalls
Hard start (must depress
accelerator pedal) NA
EGR solenoid valve (vacuum)— EGI INJ fuse (30A) burns
Main relay out when ignition switch
ON
46U0F2-181
NA: Not applicable
F2—173
F2 SERVICE POINTS
EGR Solenoid Valve (Vent)
Condition
Circuit
PCME (30)—EGR solenoid valve Code No.29 output Code No.29 output
(vent) No symptom No symptom
EGR solenoid valve (vent)—Main EGI INJ fuse (30A) burns NA
relay out when ignition switch
ON
46U0F2-182
PRC Solenoid Valve
Condition
Circuit
PCME (3M)—PRC solenoid valve Code No.25 output Code No.25 output
Hard start after heat soak No symptom
PRC solenoid valve—Main relay EGI INJ fuse (30A) burns NA
ON
46U0F2-183
Condition
Circuit
PCME (3L)—Coolant fan relay No.1 Code No.67 output Coolant fan will always
Coolant fan contimues operate while the ignition
OFF when water switch is ON
temperature exceeds NA
Coolant fan relay No.1—Ignition ENGINE fuse (15A) burns
switch 100°C (212°F) out when ignition switch
ON
36UOF2-252
Coolant Fan Relay No.2 and No.3
Condition
Circuit
PCME (2P)—Coolant fan relay No.2 Coolant fan will not op Coolant fan will always
and No.3 erate at high speed when operate while the ignition
water temperature ex switch is ON
ceeds 108°C (226°F) NA
Coolant fan relay No.2 and ENGINE fuse (15A) burns
No.3—Main relay out when ignition switch
ON
36U0F2-252
Condenser Fan Low Relay
Condition
Circuit
PCME (1L)—Condenser fan low Condenser fan continues Condenser fan will always
relay OFF when water operate while the ignition
temperature exceeds switch is ON
100°C (212°F) NA
Condenser fan low relay—Main ENGINE fuse (15A) burns
relay out when ignition switch
ON
46U0F2-204
Condenser Fan High Relay No.1 and No.2
Condition
Circuit
PCME (3N)—Condenser fan high Condenser fan continues Condenser fan will always
relay No.1 and No.2 OFF when water operate while the ignition
temperature exceeds switch is ON
108°C (226°F) NA
Condenser fan high relay No.1 and ENGINE fuse (15A) burns
No.2—Main relay out when ignition switch
ON
NA: Not applicable 46U0F2-184
F 2-174
Before beginning any service procedure, refer to the 1994
626/MX-6 Body Electrical Troubleshooting Manual; see section
S for air bag system service warnings and section J for audio
antitheft system alarm conditions.
FUEL AND EMISSION

CONTROL SYSTEMS (FS ATX)
INDEX..................................................................... F3- 2 POSITIVE CRANKCASE VENTILATION
OUTLINE................................................................. F3- 5 (PCV) SYSTEM..................................................... F3-137
SYSTEM DIAGRAM........................................... F3- 5 DESCRIPTION................................................... F3-137
WIRING DIAGRAM............................................ F3- 6 PCV VALVE........................................................ F3-137
VACUUM HOSE ROUTING DIAGRAM..............F3- 7 FUEL EVAPORATIVE SYSTEM.............................F3-138
SPECIFICATIONS.............................................. F3- 8 DESCRIPTION................................................... F3-138
COMPONENT DESCRIPTIONS.........................F3- 9 SYSTEM OPERATION........................................F3-139
ENGINE TUNE-UP.................................................. F3- 12 PURGE SOLENOID VALVE................................F3-139
PREPARATION.................................................. F3- 12 FUEL VAPOR VALVE.........................................F3-139
BASIC INSPECTION.......................................... F3- 12 CHECK VALVE (TWO-WAY)..............................F3-140
ADJUSTMENT................................................... F3- 13 CHARCOAL CANISTER.....................................F3-140
ON-BOARD DIAGNOSIS SYSTEM.........................F3- 15 FUEL-CUT CONTROL SYSTEM.............................F3-141
DESCRIPTION................................................... F 3- 15 DESCRIPTION................................................... F3-141
PREPARATION.................................................. F3- 15 PREPARATION.................................................. F3-142
DIAGNOSTIC TROUBLE CODE NUMBER........ F3- 22 SYSTEM OPERATION........................................F3-143
INTAKE AIR SYSTEM............................................ F3-111 A/C CUTOFF SYSTEM............................................F3-144
COMPONENT PARTS....................................... F3-111 DESCRIPTION................................................... F3-144
THROTTLE BODY............................................. F3-112 SYSTEM OPERATION........................................F3-144
INTAKE MANIFOLD........................................... F3-112 DECHOKE CONTROL SYSTEM.............................F3-145
RESONANCE CHAMBER No.2..........................F3-112 SYSTEM OPERATION........................................F3-145
ACCELERATOR PEDAL.................................... F3-113 COOLANT FAN CONTROL SYSTEM.....................F3-145
ACCELERATOR CABLE.................................... F3-113 DESCRIPTION................................................... F3-145
IDLE-SPEED CONTROL SYSTEM.........................F3-114 SYSTEM OPERATION........................................F3-146
DESCRIPTION................................................... F3-114 CONTROL SYSTEM............................................... F3-147
SYSTEM OPERATION....................................... F3-115 PREPARATION.................................................. F3-147
IDLE AIR CONTROL VALVE..............................F3-115 STRUCTURAL VIEW..........................................F3-148
AIR VALVE......................................................... F3-115 POWERTRAIN CONTROL MODULE (PCM)..... F3-149
FUEL SYSTEM....................................................... F3-116 MASS AIRFLOW SENSOR.................................F3-160
DESCRIPTION................................................... F3-116 CRANKSHAFT POSITION SENSOR..................F3-161
SYSTEM OPERATION....................................... F3-118 ENGINE COOLANT TEMPERATURE SENSOR. F3-162
FUEL TANK........................................................ F3-120 INTAKE AIR TEMPERATURE SENSOR............ F3-162
FUEL FILTER..................................................... F3-121 THROTTLE POSITION SENSOR....................... F3-163
FUEL PUMP....................................................... F3-122 HEATED OXYGEN SENSOR.............................F3-164
FUEL PUMP RELAY.......................................... F3-125 MAIN RELAY...................................................... F3-165
PRESSURE REGULATOR................................ F3-125 COOLANT FAN RELAYS....................................F3-166
INJECTOR.......................................................... F3-127 STEERING PRESSURE SENSOR.....................F3-166
PRESSURE REGULATOR CONTROL TROUBLESHOOTING GUIDE................................F3-167
SYSTEM................................................................ F3-130 USING THIS SECTION.......................................F3-167
PRESSURE REGULATOR CONTROL DIAGNOSTIC INDEX..........................................F3-169
SOLENOID VALVE.......................................... F3-131 SYMPTOM TROUBLESHOOTING.....................F3-171
EXHAUST SYSTEM............................................... F3-132 SERVICE POINTS........................................... ...... F3-208
COMPONENTS.................................................. F3-132 OUTLINE............................................................ F3-208
OUTLINE OF EMISSION CONTROL ELECTRICAL DIAGNOSIS SUPPORT..............F3-211
SYSTEM................................................................ F3-133 46U0F3-001
STRUCTURAL VIEW......................................... F3-133
EGR FUNCTION CONTROL SYSTEM
DESCRIPTION................................................... F3-134
SYSTEM OPERATION....................................... F3-134
SYSTEM INSPECTION...................................... F3-135
EGR SOLENOID VALVE (VACUUM)..................F3-135
EGR SOLENOID VALVE (VENT)........................F3-135
EGR CONTROL VALVE..................................... F3-135
EGR FUNCTION SENSOR.................................F3-136
F3 INDEX
16E0F1-002
F3-2
INDEX F3
1. Fresh air duct 15. EGR solenoid valve (Vent, Vacuum)
Inspection / Replacement....... page F3-111 Inspection...................... ........ page F3-135
2. Air cleaner element 16. PCV valve
Inspection............................... page F3- 12 Inspection...................... ........ page F3-137
Removal / Installation............. page F3-111 17. Purge solenoid valve
3. Resonance chamber Inspection...................... ........ page F3-139
Inspection / Replacement....... page F3-111 18. Charcoal canister
4. Throttle body Inspection...................... ........ page F3-140
Inspection................................ page F3-112 19. Powertrain control module (PCM)
Replacement........................... page F3-111 Removal / Installation.... ........ page F3-149
5. Idle air control valve Inspection...................... ........ page F3-149
Inspection................................ page F3-115 20. Mass airflow sensor
Replacement........................... page F3-111 Removal / Installation.... ........ page F3-160
6. Air valve Inspection...................... ........ page F3-160
Inspection................................ page F3-115 21. Crankshaft position sensor
Replacement........................... page F3-111 Inspection...................... ........ page F3-161
7. Intake manifold 22. Engine coolant temperature sensor
Removal / Installation..............page F3-111 Removal......................... ........ page F3-162
8. Accelerator cable Inspection...................... ........ page F3-162
Inspection / Adjustment...........page F3-113 Installation...................... ........ page F3-162
9. Fuel filter (High-pressure side) 23. Intake air temperature sensor
10. Fuel pump relay Replacement................. ........ page F3-162
Inspection............................... page F3-125 24. Throttle position sensor
11. Pressure regulator Adjustment.....................
Inspection............................... page F3-125 Replacement................. ........ page F3-163
Replacement........................... page F3-126 25. Heated oxygen sensor
12. Injector Inspection...................... ........ page F3-164
Inspection............................... page F3-127 Replacement................ ........ page F3-164
Removal.................................. page F3-127 26. Main relay
Installation............................... page F3-127 Inspection...... .'......................page F3-165
13. Pressure regulator control solenoid valve 27. Coolant fan relays
Inspection............................... page F3-131 Inspection............................... page F3-165
14. EGR control valve 28. Steering pressure sensor
Inspection / Replacement...... page F3-135 Inspection......................
EGR function sensor Replacement................. ......... page F3-166
Inspection / Replacement...... page F3-136 46U0F3-002
F3-3
F3 INDEX
J ^=»- ©
iffl-—®
46U0F1-023

Removal / Inspection / Inspection..............................page F3-140
Installation............................page F3-120 6. Exhaust system
2. Fuel filter Removal / Inspection /
Replacement..........................page F3-121 Installation............................page F3-132
3. Fuel pump 7. Three way catalyst
Inspection..............................page F3-122 Removal / Inspection /
Removal / Installation............page F3-124 Installation............................page F3-132
4. Fuel vapor valve
Inspection..............................page F3-139
F3-4
(0 O
<
<n
—i
c
PRESSURE REGULATOR CONTROL SOLENOID VALVE m
2
CHARCOAL CANISTER O z
m
>
FUEL VAPOR VALVE o
CRANKSHAFT POSITION n
SENSOR
>
INTAKE AIR
TEMPERATURE
SENSOR (IATS)
o
c
AIR CLEANER
ELEMENT

\ [EGRA]
[EGRV]
THREE WAY CATALYST

HEATED OXYGEN SENSOR (H02S) EGR CONTROL VALVE
36UOF1-004
F3-5
Gd
F3 OUTLINE
46U0F3-003
F3-6
OUTLINE F3
EGR SOLENOID
VALVE (VENT)
[EGRA]
F3
PRESSURE REGULATOR
CONTROL (PRC) SOLENOID VALVE EGR SOLENOID
VALVE (VACUUM)
[EGRV]
CHARCOAL
CANISTER
EGR CONTROL VALVE
16E0F1-006
F3-7
F3 OUTLINE
SPECIFICATION
Engine
Item FS
Idle speed * ' rpm 650— 750 (700 ± 50)
Ignition timing*' BTDC 9— 11 (10 ±1°)
Throttle body
Throat diameter mm {in} 55 {2.2}
Fuel pump
Maximum output pressure kPa {kgf/cm2, psi} 640 {6.5, 92}
Fuel filter
Type
Pressure regulator
Regulating pressure kPa {kgf/cm2, psi} 260—320 {2.6—3.3, 37— 46}
Injector
Type High-ohmic
Resistance n [20°C {68°F}] 12— 16
Volume ml {cc, fl-oz} /15 sec. 47—68 {47—68, 1.41—2.04}
Resistance n [23°C {73°F}] 7.7—9.3
Resistance n [20°C {68°F}] 30—34
Solenoid resistance n [20°C {68°F}] 36.4—42.9
EGR solenoid valve
Solenoid resistance a [20°C {68°F}] 30—45
Type Photo diode
Mass airflow sensor
Type Hot wire
Engine coolant temperature sensor/lntake air temperature sensor
20°C {68°F} 35.473— 39.207
Resistance kn 60°C {140°F} 7.171— 7.925
80°C {176°F} 1.131— 1.251
Fuel tank
Capacity L {US gal, Imp gal} 58.5 {15.5— 12.9}
Air cleaner housing
Fuel
Specification Unleaded— (R+M)/2 method 87 or higher
46U0F3-004
*’ Remove the shorting bar from the double wire SPOUT connector.
F3-8
OUTLINE F3
A/C relay Controls A/C —
Air cleaner housing Filters air entering throttle body • Intake air temperature sensor mounted in
housing
Air valve Supplies bypass air into intake manifold • Engine speed increased to shorten warm-up
(engine cold) period
• Thermowax type
Bypass air control Supplies bypass air into intake manifold • Consist of air valve and idle air control valve
(BAC) valve
Check valve Controls pressure in fuel tank —

(two-way)
Crankshaft position Detects No.1 cylinder TDC; sends signal to • Installed in distributor
sensor PCM (G signal)
[G signal, Ne signal] Detects crank angle at 180° intervals;
sends signal to PCM (Ne signal)
Data link connector Concentrated service connector terminals —
EGR function sensor Detects EGR position to detect EGR • Installed in EGR control valve
control valve open condition; sends signal to
PCM
EGR solenoid valve Controls vacuum and vent to EGR control valve • Controlled by duty signal from PCM
[Vacuum, Vent]
Engine coolant Detects coolant temperature; sends signals to • Installed in engine

temperature sensor PCM
Fuel filter Filters particles from fuel —
Fuel pump Provides fuel to injectors • Operates while engine running

Installed in fuel tank
Fuel pump relay Voltage for fuel pump while engine running —
controlled by PCM
Fuel vapor valve Prevents fuel from flowing into charcoal —

canister
Heated oxygen Detects oxygen concentration; sends signal to • Zirconic and platinum coating
sensor PCM With heater
Idle air control valve Supplies bypass air into intake manifold • Controlled by duty signal from PCM
Ignition control Receives spark signal from PCM and gener —

module ates high voltage in ignition coil
ignition switch Sends engine cranking signal to PCM —

(START position)
Injector Injects fuel into intake port • Controlled by signals from PCM
F3-9
F3 OUTLINE
Intake air Detects intake air temperature; sends signal to • Installed in air cleaner housing
temperature sensor PCM
Main relay Supplies current to output devices and PCM —
Mass airflow sensor Detects amount of intake air; sends signal • Hot wire type
to PCM
Transmission range Detects in-gear condition; sends signal to —

sensor PCM
PCV valve Controls blowby gas introduced into engine —

module (PCM) 1. A/C operation 1. Air condition sensor
3. Braking signal 3. stoplight switch
5. E/L operation 5. Blower motor switch, headlight switch,
and rear window defroster switch
6. Engine coolant temperature 6. Engine coolant temperature sensor
7. Engine speed 7. Crankshaft position sensor (Ne signal)
8. Ignition ON signal 8. Ignition switch
9. In-gear condition 9. Transmission range sensor
10. Intake air amount 10. Mass airflow sensor
12. No.1 position TDC (compression stroke) 12. Crankshaft position sensor (G signal)
14. Test mode signal 14. Data link connector (STI terminal)
16. Vehicle speed 16. Vehicle speedometer sensor
Controls operation of following;

1. A/C (cut-off) 1. A/C relay
2. On-board diagnosis system 2. SUPER STARE tester
3. fuel injection system 3. Injector
5. Ignition system 5. Ignition Control Module
7. EGR control system 7. EGR solenoid valve (EGRA, EGRV)
8. PRC control system 8. PRC solenoid valve
9. Coolant fan control 9. Coolant fan relay
10. Fuel pump control 10. Fuel pump relay
PRC solenoid valve Controls vacuum to pressure regulator control —

valve
Purge solenoid valve Controls vacuum to pressure regulator control —

valve
Resonance chamber R e d u c e s in ta k e a ir s u c tio n n o is e a n d in —

c re a s e s e n g in e to rq u e
Steering pressure D e te c ts P/S o p e ra tio n ; s e n d s s ig n a l to PCM • Steering pressure sensor ON when steering
sensor wheel turned
Stoplight switch D e te c ts b ra k in g ; s e n d s s ig n a l to P C M —
Three way catalyst Reduces HC, CO, NOx by chemical reaction • Monolith type
F3-10
OUTLINE F3
Throttle position D e te c ts th ro ttle v a lv e o p e n in g a n g le ; s e n d s • In s ta lle d on th ro ttle b o d y

sensor s ig n a l to P C M
Vehicle speedometer D e te c ts v e h ic le s p e e d ; s e n d s s ig n a l to P C M —
sensor
46UQF3-005
F3-11
F3 ENGINE TUNE-UP
ENGINE TUNE-UP
PREPARATION
SST
46U0F3-006
BASIC INSPECTION
Coolant
Warning
• Removing the radiator cap or the coolant drain
plug while the engine is running or when the
engine and radiator are hot is dangerous.
Scalding coolant and steam may shoot out and
cause serious injury. It may also damage the
• Turn off the engine and wait until it is cool. Even
then, be vary careful when removing the cap.
Wrap a thick cloth around it and slowly turn it
counterclockwise to the first stop. Step back
while the pressure is gone, press down on the
cap-still using cloth—turn it, and remove it.
46U0F3-007
radiator.
2. Remove the coolant level d ip stick from the coolant
reservoir and verify that the coolant level is between the
F and L marks. Add coolant if necessary.
Battery
Removing the label on the top of the battery or remov
ing the vent caps will void the battery’s warranty.
1. Remove any corrosion on the clamps or battery posts.

2. Verify that the battery top is clean. If necessary, clean
with backing soda and water.
3. Verify that cables are in good condition and not frayed
or corroded. Repair or replace if necessary.
Note
• Because this is a maintenance free battery, it is not
necessary to check the fluid level.
Air Cleaner Element

Inspection
1. Check the air cleaner element for excessive dirt and for
oil and damage.
Caution
• Cleaning the element with compressed air will
reduce the element’s ability to filter the air. Don’t
use compressed air to clean the if necessary
46U0F3-010
F3-12
ENGINE TUNE-UP F3
ADJUSTMENT
Preparation
2. Shift the selector lever to P range.
• Headlight
• Blower
• Power steering
46U0G3-011
Note
• If the climate control panel is in DEFROSTER mode,
the A/C compressor will be on. Do not set this mode
during ignition timing and idle speed adjustment or
self-diagnosis start-up.
Ignition Timing
1. Perform Preparation (Refer to above.)
2. Connect a tachometer to the number one spark plug
wire.
Idle speed (Neutral): 650— 750 (700 ± 50) rpm

SHORTING
4. If not within the specification, adjust the idle speed.
46U0F3-012
5. Remove the shorting bar from the double wire SPOUT

SPOUT connector.
CONNECTOR 6. Verify that the idle speed is within the specification.
Idle speed (Remove the shorting bar):

46U0F3-013 500—800 rpm

8. Verify that the timing mark (yellow) on the crankshaft
pulley and the mark on the tim ing belt cover are
aligned.
Ignition timing: BTDC 9— 11° (10 ± 1°)
46UOF3-O14
9. If the marks are not aligned, loosen the distributor lock
bolts and turn the distributor to make the adjustment.
Tightening torque:
19—25 N m {1.9— 2.6 kgf m, 14—18 ft Ibf}
46U013-015
F3-13
F3 ENGINE TUNE-UP
11. Install the shorting bar to the double wire SPOUT con
nector.
12.. Verify that the ignition timing is within the specification.
Ignition timing: BTDC 6— 18°

46U0F3-016
idle speed
3. Verify that the idle speed is within specification using
the SST.
(1) Activate the Key On Engine Running self-diagnosis
inspection. (Refer to page F3-17.)
(2) After DTC 111 has been displayed, unlatch and
within 4 sec. latch the “HOLD TEST” button.
(3) A single pulse indicates the entry mode. Then,
observe the STO (self-test output) of the SST in the
following.
(A) A constant tone or STO LO readout means idle
speed is within specification.
(B)A beeping tone or STO LO readout at {8 Hz}
indicates that the throttle position sensor is out
of range. Adjust the throttle position sensor.
Note
• Idle speed adjustment may be necessary after throt
tle position sensor adjustment.
(C)A beeping tone or STO LO readout at {4 Hz}

indicates the idle speed is too fast.
(D)A beeping tone or STO LO readout at {1 Hz}
indicates the idle speed is too slow.
4. If not within the specification. Remove the shorting bar
from the double wire SPOUT connector.
Idle speed (Remove the shorting bar):

650—750 (700 ± 50) rpm
6. Install the shorting bar to the connector.

46U0F3-025
F3-14
DESCRIPTION
The Diagnosis system is divided into three specialized diagnosises: Key On Engine OFF-Diagnosis,
Engine Running Diagnosis, and Continuous Diagnosis. The Diagnosis is not a conclusive diagnosis
by itself, but is used as a part of the functional Quick-Test diagnostic procedure. The PCM stores the
Diagnosis program in its permanent memory. When activated it checks the EEC system by testing its
memory integrity and processing capability, and verifies that various sensors and actuators are con
nected and operating properly.
The Key On Engine Off and Engine Running Diagnosises are functional diagnosises which only
detect faults present at the time of the Diagnosis. Continuous Diagnosis is performed during normal
vehicle operation and stores any fault information in Keep Alive Memory (KAM) for retrieval at a later
time.
46U0F3-02Q
PREPARATION
SST
F3-15
Key On Engine Off (KOEO) Self-Test
1. Check vacuum houses for damage and proper connection.
2. Check EEC system wiring harness for proper connection.
3. Service as necessary about 1. and 2.
4. Apply parking brake.
5. Place shift lever firmly in P range.
6. Block drive wheels.
7. Turn off all electrical loads.
8. Connect appropriate test equipment to the Self-Test Connector in order to run Self-Test.
9. Start engine and run until at operating temperature.
10. Turn engine off and wait 10 seconds.
11. Set EEC-1V/MECS Switch to position EEC-1V.
12. Select fast cods mode with the mode selector switch.
13. Turn on the power to the SUPER STAR Dtester.
The tester will briefly display 888. It will also all the prompts on the left side of display and speaker
will beep.
14. Depress the test button on the tester to the test position.
15. Turn on the vehicle ignition key.
16. Record all trouble codes displayed.
46U0F3-022
F3-16
Key On Engine Running (KOER) Self-Test
1. Connect appropriate test equipment to the Self-Test Connector in order to run Self-Test.
2. Start and run engine at 2,000 rpm for two minutes. This action warms up the H02S.
3. Turn engine off and wait 10 seconds.
4. Set EEC-IV/MECS Switch to position EEC-IV.
5. Select fast cods mode with the mode selector switch.
6. Turn on the power to the SUPER STAR Htester.
The tester will briefly display 888. It will also all the prompts on the left side of display and speaker
will beep.
7. Start engine.
8. After the ID code depress and release the brake pedal if appropriate. See Special Note on previous
page.
9. After the ID code click twice on the HOLD switch button.
10. After the ID code, within 1 to 2 seconds, turn the steering wheel at least one-half turn and then
release it, if appropriate. See Special Note above.
11. If a Dynamic Response Code occurs, perform a brief wide-open throttle (WOT).
12. Record all Diagnostic Trouble Codes (DTC’S) displayed.
46U0F3-026
F3-17
After-Repair Procedure
How to Clear the Continuous Memory
1. Run the key On Engine Off Self-Test.
2. When the DTC’S begin to be displayed.
Deactive Self-Test:
—SUPER STAR n: Unlatching the center button
(up position)
3. Continuous Memory will be erased in the PCM.
46U0F3-029
Note
• Do not disconnect battery to clear C ontinuous
Memory. This will erase the Keep Alive Memory
(KAM) information which may cause a driveability
concern.
46U0F3-030
How to Clear THE Keep Alive Memory (KAM)
Disconnect the negative side of the battery for a mini
mum of five minutes.
Note
• The PCM stores information about vehicle operating
conditions and uses this information to compensate
for component tolerance. When an emission related
component is replaced, Keep Alive Memory (KAM)
should be cleared to erase the information stored by
the PCM from the original component.
46U0F3-031
How to Memory the Keep Alive Memory (KAM)
After KAM has been cleared, the vehicle may exhibit
certain driveability concerns. It will be necessary to
drive the vehicle 10 miles or allow the processor to
relearn values for optimum driveability and perfor
mance.
46U0F3-032
F3-18
Code Output Format
The EEC system communicates service information through the Diagnostic Trouble Codes (DTC’s).
These DTC’s are three-digit numbers representing the results of Self-Diagnosis.
The DTC’s are transmitted on the Self-Test Output (STO) circuit found in the Data Link Connector
(DLC). They are in the form of timed pulses, and are read by the technician on a circuit-tester,
SUPER STAR n, Malfunction Indicator Light (MIL) or Hold Indicator Light.
Diagnostic Trouble Code (DTC) Format

1. Key On Engine Off and Continuous Memory DTC Format
2. Engine Running DTC Format
Fast DTC’s / Slow DTC’s

Fast DTC’s are issued prior to slow service DTC’s. These DTC’s contain the identical information as
the slow DTC’s, but are transmitted at 100 times the normal rate. These DTC’s are interpreted by
special equipment at the assembly line by the Body and Assembly Division as well as the SUPER
STAR Htester.
Note
• After Slow DTC’s have been output, Self-Diagnosis should not be exited (remove jumper, unlatch
button, etc) until all the Slow DTC’s have been output. Doing so will erase any Continuous
Memory DTC’s.
F3-19
Continuous Self-Diagnosis
The Continuous Memory DTC’s are separated from the Key On Engine Off DTC’s by a single separa
tor pulse.
Note
• During this mode of testing of testing the PCM continuously monitors inputs for opens and shorts.
The Continuous Memory DTC’s must be retrieved within 80 engine temperature warm up cycles.
On the 81st Engine Temperature cycle, the DTC will be automatically erased. The Continuous
Memory DTC’s can also be erased by deactivating Self-Diagnosis while the DTC’s are being out
putted.
46U0F3-035
Continuous Monitor Diagnostic Test Mode (Wiggle Test)

Special Note:
• The technician can ATTEMPT to re-create and detect an intermittent fault using the Continuous
Monitor DTM (Wiggle Test) procedures.
Key on Engine Off Wiggle Test Procedure

1. Hook up a SUPER STAR HTester
2. Turn the ignition key to the ON position.
3. For SUPER STAR n Tester activate, deactivate and reactivate Self-Test. You are now in the
Continuous Monitor Diagnostic Test Mode (DTM).
4. Tap, move, and wiggle the suspect sensor and / or harness. When a fault is detected, a Continuous
Memory DTC will be stored in memory. This will be indicated as follows depending on the type of
equipment being used:
• SUPER STAR n Tester: Red LED lights and /or continuous tone. (STAR LED)
• Malfunction Indicator Light (MIL): Lights
• Hold Indicator Light
Engine Running Wiggle Test Procedure

Special Note:
• The Engine Running Wiggle Test may be activated any time the engine is running.
1. Hook up a SUPER STAR HTester
2. Key off.
4. For SUPER STAR HTester, activate Self-Test, deactivate and reactivate Self-Test. DO NOT shut
the engine off. You are now in the Engine Running Continuous Monitor DTM.
46U0F3-218
F3-20
5. Tap, move, and wiggle the suspect sensor and / or harness or drive the vehicle. When a fault is
detected, a Continuous Memory DTC will be stored in memory. This will be indicated as follows
depending on the type of equipment being used:
• SUPER STAR n Tester: Red LED lights and / or continuous tone. (STAR LED)
• Malfunction Indicator Light (MIL): Lights
• Hold Indicator Light
46U0F3-219
F3-21
F3_________________ ON-BOARD DIAGNOSIS SYSTEM
Diagnostic Trouble Code (DTC) Number
No. Indicator Light Flash Pattern Diagnosed circuit MIL Diagnosis Page
111 System pass
Pass
112 Intake air temperature F3-28

sensor (IATS)
M
F3-29
113 F3-29
M
F3-30
116 Engine coolant temperature
sensor (ECTS) F3-31
117 F3-28
M
F3-29
118
M F3-30
121 Throttle position sensor (TPS F3-32

F3-33
F3-34
122 F3-35
M
F3-36
123 M F3-37
F3-38
157 Mass airflow sensor (MAF) M F3-40
158 M O F3—43
159
F3-44
172 Heated Oxygen sensor M F3-45

(H02S)
173 M F3-45
179
F3-54
181
F3-54
211 Ignition system

F3-57
212
F3-58
213
F3-61
214 Cylinder identification display M

F3-63
(CID)
244 F3-63
327 EGR function sensor M F3-66

F3-67
332 M F3-69
F3-71
337 M F3-67
F3-72
F3-22
46U0F3-036
Note: M: MIL function
O: Key On Engine Off self-test
C: Continuous self-test
R: Key On Engine Running self-test
F3-23
Troubleshooting
If a diagnostic trouble code number is shown on the SST check for the cause by referring to the related
chart.
CODE No. No DTC’s
DESCRIP If using a SUPER STAR n to run Self-Test, verify that correct procedure is used for your application.
TION
STEF INSPECTION ACTION
1 CHECK VREF VOLTAGE AT DATA LINK
CONNECTOR (DLC)
NOTE: Aftermarket devices such as an alarm Yes Go to Step 3
system may cause Self-Test to abort it wiring is
connected to certain EEC components. PRIOR
TO SERVICING VEHICLE, inform customer that
disconnection of the device is necessary for the
proper diagnosis and function of the EEC sys
tem. Restore EEC system to original configura
tion before proceeding with this Pinpoint Test.
• Key off.
• Disconnect Powertrain Control Module (PCM).
No Go to next Step
Inspect for damaged or pushed out pins, corro
sion, loose wires, etc. Service as necessary.
• Install breakout box and connect PCM to break
out box
• Key on, engine off
• Measure voltage between Test Pin 26 at the
breakout box and SIG RTN circuit in the DLC
• Is voltage between 4.0 and 6.0 volts?
2 CHECK SIG RTN CIRCUIT CONTINUITY

• Key off. Yes Go to Pinpoint Test C Step 1
• Breakout box installed, PCM disconnected «■ page F3-104
• Measure resistance between SIG RTN circuit in
No SERVICE open circuit
the DLC and Text Pin 46 at the breakout box
RECONNECT PCM
• Is resistance less than 5.0 ohms?
RERUN Quick Test
3 CHECK STI CIRCUIT CONTINUITY

• Key off. Yes Go to next Step
* Breakout box installed
• Disconnect PCM No SERVICE open circuit
• Measure resistance between STI circuit in the REMOVE breakout box
Selt-Test single pin pigtail connector and Test RECONNECT PCM
Pin 48 at the breakout box RERUN Quick Test
4 CHECK STO CIRCUIT CONTINUITY

• Breakout box installed, PCM disconnected
• Measure resistance between STO circuit in the
DLC and Test Pin 17 at the breakout box
REMOVE breakout box
RERUN Quick Test
5 CHECK H02S SIGNAL FOR SHORT TO POWER
NOTE: Due to the internal circuitry of the PCM, a Yes Go to next Step
H02S signal short to power could cause EEC
strategy NOT to enter on-demand Self-Test

No Go to Step 7
• Measure voltage between H02S signal Test Pin
29 or 44 and Test Pin 40 or 60 at the breakout
box.
F3-24
6 ISOLATE SHORT TO HARNESS OR H02S
• Breakout box installed, PCM disconnected Yes SERVICE H02S signal circuit for shorts to power
• Disconnect H02S REMOVE breakout box
• Key on, engine off RECONNECT all components
• Measure voltage between H02S signal Test Pin RERUN Quick Test
29 or 44 and Test Pin 40 or 60 at the breakout
No REPLACE H02S
box
REMOVE breakout box
• Is voltage greater than 2.0 volts?
RECONNECT all components
RERUN Quick Test
7 CHECK STO CIRCUIT FOR SHORT TO
GROUND
• Key off Yes SERVICE STO or MIL circuit for short to ground
• Breakout box installed, PCM disconnected REMOVE breakout box
• Measure resistance between STO circuit in the RECONNECT PCM
DLC and engine block ground RERUN Quick Test
No Go to next Step
8 CHECK IF POWER RELAY IS ALWAYS ON

• Key off Yes RECONNECT PCM
• Breakout box installed, PCM disconnected Go to Step 10
• Connect a voltmeter to Test Pin 37 or 57 and to
Test Pin 40 or 60 at the breakout box
• Turn key on and then off. Wait 10 seconds
No Go to next Step
• Does voltage change from greater than 10.5
bolts to less than 1.0 volt?
9 CHECK VPWR CIRCUIT FOR SHORT TO

POWER
• Key off Yes SERVICE VPWR circuit short to power
• Disconnect EEC Power Relay RECONNECT all components
• Measure voltage between Test Pin 37 or 57 and RERUN Quick Test
Test Pin 40 or 60 at the breakout box
No REPLACE EEC Power Relay
• Is voltage greater than 1.0 volt?
REMOVE breakout box
RECONNECT PCM
RERUN Quick Test
10 CHECK MIL FUNCTION
• Are any of these conditions present? Always REMOVE breakout box
Malfunction indicator light (MIL): ON RECONNECT PCM
Go to Pinpoint Test next Step
Always REMOVE breakout box
OFF RECONNECT PCM
Go to Pinpoint Test Step 12
Function REPLACE the PCM
ing RERUN Quick Test
normary
F3-25

11 MALFUNCTION INDICATOR LIGHT (MIL)
ALWAYS ON: CHECK STO/MIL CIRCUIT FOR
SHORTS TO GROUND
NOTE: If vehicle will not start perform Pinpoint Yes SERVICE short circuit between Test Pin 17
Test A Step 1 and Malfunction Indicator Light (MIL), or between Test Pin
«■ page F3-97 17 and the Data Link Connector
REMOVE Breakout Box
• If any Key On Engine Off Diagnostic Trouble RECONNECT PCM
Codes or Continuous Memory Diagnostic RERUN Quick Test
Trouble Codes are present, service before
proceeding. If pass codes are present, con
tinue with this Test Step
• Key off
• Disconnect powertrain Control Module (PCM) No REPLACE PCM
Inspect for damaged or pushed out pins, corro REMOVE Breakout Box
sion, loose wires, etc. Service as necessry RERUN Quick Test
• Install Breakout box, leave PCM disconnected
• Measure resistance between Test Pin 17 and
Test Pin 40 at the Breakout Box
12 MALFUNCTION INDICATOR LIGHT (MIL) NEVER

ON: CHECK FOR B(+) AT MIL FUSE (GROUND
SIDE)
NOTE: If vehicle will not start go to Pinpoint Test Yes Go to Step 14
A Step 1
«■ page F3-97
• If vehicle has electronic instrument cluster, refer

to 1994 626/MX-6 BETM for Manual for
Malfunction indicator light (MIL) diagnostic pro
cedure
• Measure voltage from battery negative post to No Go to next Step
“Ground” side of the MIL fuse
«• section T
• is voltage greater than 10.5 volts?
F3-26
13 CHECK FOR B+ AT MIL FUSE
• Key on, engine off Yes REPLACE the MIL fuse
• Measure voltage from battery negative post to VERIFY service by turning ignition key to the ON position
B+ side of the MIL fuse
No SERVICE open in the MIL/B+ circuit VERIFY service by
turning ignition key to the ON position
14 CHECK FOR B+ AT MIL BULB/SOCKET

• Key on, engine off Yes Go to next Step
• Measure voltage from battery negative post to
B+ side of MIL bulb/socket
No SERVICE open between MIL fuse and MIL bulb
• Is voltage greater than 10.5 volts? VERIFY service by turning ignition key to ON position
15 CHECK MIL BULB RESPONSE TO GROUNDING
• Key off Yes Turn ignition key to OFF position
• Attach one end of jumper wire to battery nega REMOVE jumper wire
tive post or chassis ground Go to next Step
• Attach other end of jumper wire to ground side of
the MIL bulb/socket
No Turn ignition key to OFF position
• Turn ignition key to ON position
REMOVE jumper wire
• Is the MIL on?
REPLACE MIL bulb/socket
VERIFY the service by turning ignition key to ON position
16 CHECK MIL CIRCUIT CONTINUITY
• Key off Yes REPLACE PCM
• Disconnect powertrain control module (PCM) REMOVE breakout box
Inspect for damaged or pushed out pins, corro VERIFY the service by turning ignition key to ON position
sion, loose wires, etc. Service as necessary
• Install breakout box, leave PCM disconnected No SERVICE open in ground side of MIL circuit REMOVE
• Measure resistance between Test Pin 17 at
breakout box
breakout box and MIL RECONNECT PCM
• Is resistance less than 5.0 ohms? VERIFY the service by turning ignition key to ON position
46U0F3-037
F3-27
CODE No. 112 (INTAKE AIR TEMPERATURE SENSOR), 117 (ENGINE COOLANT TEMPERATURE SENSOR)
DESCRIP DTC 117 (ECT) or 112 (IAT) indicates that the corresponding sensor’s signal is less than the Self-Test minimum.
TION The IAT and ECT sensor minimum is 0.2 volts
[Possible Cause]
• Grounded circuit in harness • Faulty sensor
• Faulty Powertrain Control Module (PCM) • Faulty connection
1 DIAGNOSTIC TROUBLE CODE (DTC) 117 OR
112:
INDUCE OPPOSITE CODE 118 OR 113
• Key off. Yes REPLACE sensor
• Disconnect vehicle harness from suspect sensor RECONNECT harness
Inspect for damaged, corroded, pushed out pins RERUN Quick Test
or loose wires, etc. Service as necessary
No Go to next Step
• Run Key On Engine Off Self-Test
• Is DTC 113 or 118 present?
2 CHECK VREF CIRCUIT VOLTAGE AT

THROTTLE POSITION SENSOR (TPS)
• Key off. Yes RECONNECT TPS
• Suspect temperature sensor disconnected Go to next Step
• Disconnect TPS
• Measure voltage between VREF circuit and SIG
No Go to Pinpoint Test C Step 1
RTN circuit at the TPS vehicle harness connec
tor w page F3-104
• Is voltage between 4.5 volts and 5.5 volts?
3 CHECK TEMPERATURE SENSOR SIGNAL

CIRCUIT FOR SHORT TO GROUND
• Key off. Yes REPLACE PCM
• Suspect temperature sensor disconnected REMOVE breakout box
• Disconnect Powertrain Control Module (PCM) RECONNECT all components
Inspect for damaged or pushed out pins, corro RERUN Quick Test
sion loose wires, etc. Service as necessary
• Install breakout box, leave PCM disconnected
No SENSOR short circuit
Measure resistance between Test Pin 7 (EC T)
REMOVE breakout box
or 25 (IAT) and Test Pins 40, 46 and 60 at the RECONNECT all components
breakout box RERUN Quick Test
• Is each resistance greater than 10,000 ohms?
46U0F3-038
F3-28
CODE No. 112,113 (INTAKE AIR TEMPERATURE SENSOR), 117,118 (ENGINE COOLANT TEMPERATURE SENSOR
DESCRIP Continuous Memory DTC’s 118 and 113 indicate that the sensor signal was greater than, the Self-Test maximum
TION of 46 volts. The DTC was generated under normal driving conditions
Continuous Memory DTC’s 117 and 112 indicate that the sensor signal was less than the Self-Test minimum of
0.2 volts. The DTC was generated under normal driving conditions
Sensor Continuous
Memory DTC's
IAT 113 and 112
ECT 118 and 117
[Possible Cause]
• Faulty sensor OPEN circuit in harness
• Grounded circuit in harness Faulty PCM
CONTINUOUS MEMORY DIAGNOSTIC
TROUBLE CODE (DTC) 112, 113, 117, OR 118:
CHECK SENSOR
• Enter Key On Engine Off Continuous Monitor Yes DISCONNECT and inspect connectors
Diagnostic Test Mode (DTM) Refer to Quick Test If OK, REPLACE the sensor
Appendix CLEAR Continuous Memory
«*■ page F3-20 »■ page F3-18
• Observe STAR LED indication of a fault while RERUN Quick Test

performing the following:
— Tap on the sensor to simulate road shock No Go to next Step
— Wiggle the sensor connector
• Is a fault indicated?
CHECK EEC-IV VEHICLE HARNESS

• Still in Key On Engine Off Continuous Monitor Yes ISOLATE fault and SERVICE as necessary
DTM CLEAR Continuous Memory
• Observe STAR LED for fault indication while per ■a- page F3-18
forming the following:
— Grasp the vehicle harness close to the sensor RERUN Quick Test
connector. Wiggle, shake or bend a small
section of the EEC system vehicle harness
while working your way to the dash panel.
No Go to next Step
Also wiggle, shake or bend the EEC system
vehicle harness from the dash panel to the
PCM
• Is a fault Indicated?
CHECK PCM AND VEHICLE HARNESS

CONNECTORS
Key off Yes Unable to duplicate and/or identify fault at this time
Disconnect Powertrain Control Module (PCM) Intermittent Fault Diagnosis
Disconnect sensor connector. Inspect for dam All others, CLEAR Continuous Memory
age, loose or pushed out pins, loose or poorly «■ page F3-18
crimped wires
Is connectors and terminals OK? RERUN Quick Test
No SERVICE as necessary
CLEAR Continuous memory
«• p a g e F 3 -1 8
46U0F3-Q39
F3-29
CODE No. 113 (INTAKE AIR TEMPERATURE SENSOR), 118 (ENGINE COOLANT TEMPERATURE SENSOR)
DESCRIP DTC 118 (ECT) or 113 (IAT) indicates that the corresponding sensor signal is greater than the Self-Test maxi
TION mum. The maximum for ECT and IAT sensors is 4.6 volts
[Possible Cause]
• Open in harness (IAT or ECT) • Faulty connection
• Faulty sensor • Faulty Powertrain Control Module (PCM)
1 DIAGNOSTIC TROUBLE CODE (DTC) 113 OR
118:
INDUCE OPPOSITE DTC 112 OR 117
• Key off. Yes REPLACE suspect sensor
• Disconnect suspect temperature sensor REMOVE jumper wire
• Connect a jumper wire between the sensor sig RECONNECT vehicle harness
nal circuit and SIG RTN circuit at the tempera RERUN Quick Test
ture sensor vehicle harness connector
No REMOVE jumper wire
Go to next Step
• Is DTC 112 or 117 present?
2 CHECK CONTINUITY OF SENSOR SIGNAL AND

SIG RTN CIRCUITS
• Suspect temperature sensor disconnected REMOVE breakout box
• Disconnect Powertrain Control Module (PCM) RECONNECT all components
• Measure resistance between sensor signal cir
cuit at the temperature sensor vehicle harness No SERVICE open circuit
connector and Test Pin 7 (ECT) or 25 (IAT) at REMOVE breakout box
the breakout box RECONNECT all components
• Measure resistance between SIG RTN circuit at RERUN Quick Test
the temperature sensor vehicle harness connec
tor and Test Pin 46 at the breakout box
• Is each resistance less than 5.0 ohms?
46U0F3-040
F3-30
DESCRIP DTC 116 (ECT) indicates that the corresponding sensor is out of Self-Test range. Correct range of measure is
TION 0.3 to 3.7 volts
[Possible Cause]
• Low coolant level (ECT) • Ambient temperature below 10°C {50°F} (IAT)
• Faulty harness connector • Faulty sensor
1 DIAGNOSTIC TROUBLE CODE (DTC) 116:
CHECK OPERATION, INSTALLATION OF
TEMPERATURE SENSOR
• Run engine for two minutes at 2000 rpm Yes Go to next Step
For NO STARTS:
— Go to Step 3
For vehicle STALLS:
— Go to Pinpoint test D Step 1
«■ page F3-107
No SERVICE other DTC’s as necessary
• Check that upper upper radiator hose is hot and
pressurized
• Return Quick Test
• Is DTC 116 present?
2 CHECK VREF CIRCUIT VOLTAGE AT

THROTTLE POSITION SENSOR (TPS)
• Key off Yes RECONNECT TPS
• Disconnect TPS Go to next Step
No Go to Pinpoint Test C Step 1
tor
«• page F3-104
3 CHECK RESISTANCE OF TEMPERATURE

SENSOR WITH ENGINE OFF
• Key off For ECT sensor with a NO START:
• Disconnect suspect temperature sensor Do not service DTC 116 at this time, Go to Pinpoint Test A
• Measure resistance between sensor signal cir Step 1
cuit and SIG RTN circuit at the temperature sen «■ page F3-97
sor. Refer to the corresponding chart at the
beginning of this pin point Test for resistance
specifications.
• Is resistance within specifications?
Note: Engine may have cooled down. Always warm engine before taking ECT sensor resistance measurements. 46U0F3-041
Check for open thermostat.
F3-31
CODE NO. 121 (KOEO) THROTTLE POSITION SENSOR (TPS)

DESCRIP • Throttle Position Sensor’s rotational setting may be out of Self-Test range
TION
[Possible Cause]
• Binding throttle linkage • Damaged Powertrain control Module (PCM)
• TPS may not be seated properly (tightened down) • Damaged TPS
CHECK FOR STUCK THROTTLE PLATE
• Visually inspect carburetor / throttle body and Yes Go to next Step
throttle linkage for binding or sticking
• Verify the throttle linkage is at mechanical /
closed throttle. Check for:
RERUN Quick Test
binding throttle linkage, speed control linkage,
vacuum line / electrical harness interference,
etc.
• Does throttle move freely and return to
closed throttle position?

ATTEMPT TO GENERATE DTC 122
• Disconnect TPS. Inspect for damaged or
pushed out pins, corrosion, loose wires, etc.
No Go to Step 4
Service as necessary
• Rerun Key On Engine OFF Self-Test
• Is DTC 122 present (ignore all other DTCs)?
3 CHECK VREF CIRCUIT VOLTAGE

• Key off. Yes REPLACE TPS
• TPS disconnected RERUN Quick Test
No Key off. RECONNECT all components.
Go to Pinpoint Test C Step 1
w page F3-104
tor
4 CHECK TP CIRCUIT FOR SHORTS TO POWER

• TPS disconnected REMOVE breakout box
• Disconnect Powertrain Control Module (PCM) RECONNECT TPS
No SERVICE short circuit
REMOVE breakout box
Test Pins 26 and 67 at the breakout box
RERUN quick test
• Is each resistance greater than 10,000
ohms?
46U0F3-042
F3-32
CODE NO. 121 THROTTLE POSITION SENSOR (TPS)
DESCRIP • Throttle Position Sensor’s rotational setting may be out of Self-Test range
TION
[Possible Cause]
• Binding throttle linkage • Damaged TPS
• TPS may not be seated properly (tightened down) • Damaged Powertrain Control Module (PCM)
1 ENGINE RUNNING DIAGNOSTIC TROUBLE
CODE (DTC) 121:
CHECK FOR OTHER DTCs
• Check for DTC in Key On Engine Running Self- Yes PROCEED as directed with
Test DTC 327
• Are either of the above DTCs present with page F3-67
Code 121?
No Go to next Step
2 DIAGNOSTIC TROUBLE CODE (DTC):

CHECK FOR STUCK THROTTLE PLATE
• Visually inspect carburetor / throttle body and Yes Go to next Step
throttle linkage for binding or sticking
• Verify the throttle linkage is at mechanical / No SERVICE as necessary
closed throttle. Check for: RERUN Quick test
binding throttle linkage, speed control linkage,
vacuum line / electrical harness interference,
etc.
• Does throttle move freely and return to
closed throttle position?

• Key off Yes Go to next Step
• Disconnect TPS. Inspect for damaged or
No Go to Step 5
Service as necessary.
• Rerun Key On Engine Off Self-Test
• Is DTC 122 present (ignore all other DTCs)?

• Key off Yes REPLACE TPS
• Key on, engine off RERUN Quick test
No Key off. RECONNECT all
tor
components. Go to Pinpoint
• Is voltage between 4.5 and 5.5 volts? Test C Step 1
«*■ page F3-104
5 CHECK TPS CIRCUIT FOR SHORTS TO POWER

• Disconnect Powertrain Control Module (PCM) RECONNECT TPS
No SERVICE Short circuit
REMOVE breakout box
RERUN Quick Test
• In each resistance greater than 10,000
ohms?
46U0F3-043
F3-33
CODE NO. 121 (Cont) MASS AIRFLOW SENSOR

DESCRIP Continuous Memory Diagnostic Trouble Code (DTC) 121 indicates throttle position was inconsistent with MAF
TION value
1 THROTTLE POSITION SENSOR INTEGRITY
• Disconnect Powertrain Control Module (PCM)
No VERIFY TPS
properly installed to
the throttle body. If OK,
out box
REPLACE TPS
• Connect a voltmeter from Test Pin 47 to Test
REMOVE breakout box
Pin 46 at the breakout box
RECONNECT PCM
RERUN Quick Test
• Rotate throttle slowly to WOT, release throttle
slowly to closed position
• Does the voltage change smoothly between
0.4 and 4.5 volts?
2 CHECK MAF SENSOR

• Key off. Yes Sometime during the last 80
• Disconnect Powertrain Control Module (PCM) warm-up cycles the MAF
Inspect for damaged or pushed out pins, corro sensor signal indicated out of
sion, loose wires, etc. Service as necessary range. However, at this time
• Install breakout box and connect PCM to break EEC system is operating OK
out box REMOVE breakout box
• Start engine and allow to idle until engine is at RECONNECT PCM. RERUN
normal operating temperature Quick Test
• Measure voltage between MAF signal and Test No REPLACE MAF sensor
Pin 40 / 60 REMOVE breakout box
• Is voltage within the acceptable range? RECONNECT PCM
RERUN Quick Test
Note: If further description is required for the In-Range Test, refer to page F3-15.
F3-34
DESCRIP • Throttle Position Sensor (TPS) signal is less than the Self-Test minimum value
TION
[Possible Cause]
• TPS way not be seated properly (tightened down) • Grounded harness
• Damaged TPS • Damaged Powertrain control Module (PCM)
• Open harness
ATTEMPT TO GENERATED DTC 123 OR 121
• Disconnect TPS. Inspect for damaged or REMOVE jumper
pushed out pins, corrosion, loose wires, etc. RERUN Quick test
• Jumper VREF circuit to TP circuit at TPS vehicle
harness connector
No REMOVE jumper
Go to next Step
NOTE: If no DTC’s are generated, immediately
remove jumper and go directly Go to Step 4
• Is DTC 123 or 121 present (ignore all other

DTC’s)?

• TPS disconnected
• Key on engine off
No KEY off. RECONNECT all
components, go to Pinpoint
TestC Step 1
tor
«• page F3-104
3 CHECK TP CIRCUIT CONTINUITY

• TPS disconnected
• Disconnect Powertrain control Module (PCM)
Inspect for damaged or pushed out pins, corro No SERVICE open circuit
sion, loose wires, etc. Service as necessary REMOVE breakout box
• Install breakout box, leave PCM disconnected RECONNECT all components
• Measure resistance between TP circuit at the RERUN Quick Test
TPS vehicle harness connector and Test Pin 47
at the breakout box
• Is the resistance less than 5.0 ohms?
4 CHECK TP CIRCUIT FOR SHORTS TO GROUND

• Disconnect Powertrain control Module (PCM) RECONNECT all components
sion, loose wires, etc. Service as necessary No SERVICE short circuit
• Install breakout box, leave PCM disconnected REMOVE breakout box
• Measure resistance between Test Pin 47 and RECONNECT all components
test Pins 40, 46, and 60 at the breakout box R E R U N Q uick Test
ohms?
46U0F3-045
F3-35
CODE NO. 122 (Cont) THROTTLE POSITION SENSOR (TPS) CIRCUIT

DESCRIP- • Throttle position sensor (TPS) signal is less than Self-Test minimum value
TiOhi
1 CONTINUOUS MEMORY DIAGNOSTIC
TROUBLE CODE (DTC) 122:
MONITOR TP CIRCUIT UNDER SIMULATED
ROAD SHOCK
• Enter Continuous monitor Diagnostic Test Mode Yes Key off. Inspect connectors
(DTM). Refer to Quick Test Appendix If connectors and terminals are
• Connect STAR LED to STO good, REPLACE TPS,
• Observe STAR LED for indication of a fault REFER to Fuel / Engine Group
while performing the following: in Service Manual, CLEAR
— Move throttle slowly to WOT position Continuous Memory
— Release throttle slowly to closed position «■ Page F3-18
— Lightly tap on TPS (simulate road shock)
— Wiggle TP harness connector RERUN Quick Test
No Go to next Step
2 CHECK EEC VEHICLE HARNESS

• Still in Key On Engine OFF continuous Monitor Yes ISOLATE fault, SERVICE as
DTM necessary. REFER to appropi-
• Observe STAR LED for a fault indication while ate figure, CLEAR continuous
performing the following: Memory
— Grasp the vehicle harness close to the sen gf Page F3-18
sor connector. Wiggle, shake or bend a
small section of the EEC system vehicle har RERUN Quick Test
ness while working your way to the dash
No Go to next Step
panel. Also wiggle, shake or bend the EEC
PCM
3 CHECK PCM AND HARNESS CONNECTORS

• Key off Yes SERVICE as necessary
• Disconnect PCM. Inspect for damaged or CLEAR Continuous Memory
pushed out pins, corrosion, loose wires, etc. «• Page F3-18
• Are connectors and terminals?
RERUN Quick Test
No Unable to duplicate and / or identify
fault at this time. For further
diagnosis, REFER to page F3-167
Intermittent Fault Diagnosis all
others, CLEAR Continuous
Memory
«*■ Page F3-18
RERUN Quick Test
46U0F3-046
F3-36
CODE NO. 123 (KOEO) THROTTLE POSITION SENSOR (TPS) CIRCUIT
DESCRIP • Throttle Position Sensor (TPS) signal is greater than the Self-Test maximum value
TION
[Possible Cause]
• TPS may hot be seated properly (tightened down) • Short to Power in harness
• Damaged TPS • Damaged Powertrain control module (PCM)
• Disconnect TPS. Inspect for damaged of
pushed out pins, corrosion, loose wires, etc
No Go to Step 3
• Is DTC 122 present (Ignore all other DTCs)?

• TPS disconnected RERUN Quick Test
• Key on engine off
No Key off. RECONNECT all
components. Go to Pinpoint
Test C Step 1
tor
**• Page F3-104
3 CHECK TP CIRCUIT FOR SHORTS TO POWER

• Disconnect Powertrain Control Module (PCM), RECONNECT TPS
No SERVICE Short circuit
REMOVE breakout box
RERUN Quick Test
ohms?
46U0F3-047
F3-37

DESCRIP • Throttle position sensor circuit above maximum voltage
TION
MONITOR TP CIRCUIT UNDER SIMULATED
ROAD SHOCK
• Enter Key On Engine Off Continuous Monitor Yes Go to next Step
Diagnostic Test Mode (DTM).
page F3-18
• Connect STAR LED to STO

• Observe STAR LED for indication of a fault
while performing the following:
No Go to Step 3
— Move throttle slowly to WOT position
— Release throttle slowly to closed position and
lightly tap on TPS (simulate road shock)
— Wiggle TP harness connector
2 MEASURE THROTTLE POSITION CIRCUIT

VOLTAGE WHILE EXERCISING TP SENSOR
• Key off Yes Key off, DISCONNECT
• Disconnect powertrain Control Module (PCM) and INSPECT Connectors
Inspect for damaged or pushed out pins, corro If connectors and terminals
sion, loose wires, etc. Service as necessary are good, REPLACE TPS
• Install breakout box and connect PCM to break REFER to Fuel / Engine Group
out box in Service Manual
• STAR LED still connected to STO CLEAR Continuous Memory
• Connect a voltmeter from Test Pin 47 to Test «• page F3-18
• Key on, engine off RERUN Quick Test
• While observing voltmeter and STAR LED,
No Throttle position Sensor over
repeat Step 1
travel may have caused the
• Does the fault occur below 4.25 volts?
continuous Memory DTC 123
VERIFY vehicle harness integrity,
Go to next Step
3 CHECK EEC VEHICLE HARNESS

• Still in Key On engine Off Continuous Monitor Yes ISOLATE fault
DTM SERVICE as necessary
• Observe STAR LED for a fault indication while REFER to appropriate figure
performing the following: CLEAR Continuous Memory
— Grasp the vehicle harness close to the sen «*■ page F3-18
sor connector. Wiggle, shake or bend a
small section of the EEC system vehicle har RERUN Quick Test
ness while working your way to the dash
No Go to next Step
panel. Also wiggle, shake or bend the EEC
PCM
• Is a fault code indicated?
F3-38
• Key off. Yes SERVICE as necessary
• Disconnect Powertrain Control Module (PCM) CLEAR Continuous Memory
Inspect for damaged or pushed out pins, corro **■ page F3-18
• Are connectors and terminals OK? RERUN Quick Test
No Unable to duplicate and / or
Identify fault at this time. For
further diagnosis
REFER to page F3-167
Intermittent Fault Diagnosis
Memory
es- page F3-18
RERUN Quick Test
46U0F3-048
F3-39
CODE NO. 157 (Cont) MASS AIRFLOW SENSOR (MAF) CIRCUIT

DESCRIP • Continuous Memory DTC 167 indicates that the Mass Airflow sensor (MAF) signal went below 0.4 volt
TION sometime during the last 80 warm-up cycles
[Possible Cause]
• Poor continuity in MAF harness or connectors • Open VPWR circuit to MAF
• Intermittent open or short in MAF or harness • Open PWR GND circuit to MAF
• Damaged MAF • Open MAF RTN circuit to MAF
• Idle Air Control (IAC) system (possible closed throttle posi • MAF circuit shorted to ground
tion indication) • Air leak before or after MAF
• Open MAF circuit • MAF disconnected
1 CHECK FOR INTERMITTENT SENSOR
• Clear Continuous Memory Yes Go to Step 4
is- page F3-18
• Start engine and run at idle for approximately 5

No Go to next Step
to 10 minutes
• Is continuous Memory DTC 157 present?
2 MONITOR MAF CIRCUIT UNDER SIMULATED

ROAD SHOCK
• Key off Yes DISCONNECT and INSPECT
• Disconnect Powertrain Control Module (PCM) MAF connector
Inspect for damaged or pushed out pins, corro If OK, REPLACE MAF
sion, loose wires, etc. Service as necessary CLEAR continuous Memory
• Install breakout box, reconnect PCM «ap page F3-18
• Connect a voltmeter between Test Pin 50 and RERUN Quick Test
Test Pin 9 at the breakout box
• Key on, engine running
No LEAVE the voltmeter and PCM
• Lightly tap on MAF and wiggle harness connec
connected
tor to simulate road shock
Go to next Step
NOTE: MAF voltage is normally above 0.4 volt A
sudden change down from this minimum limit
indicates a fault
3 CHECK VEHICLE HARNESS FOR

INTERMITTENT OPENS OR SHORTS
• Key on, engine off Yes ISOLATE fault and SERVICE
DVOM connected between Test Pin 50 and Test as necessary. CLEAR Continuous
Pin 9 at the breakout box Memory
— Grasp the vehicle harness closest to the MAF is- page F3-18
sensor connector. Shake and bend a small RERUN Quick Test
section of the vehicle harness while working No RECONNECT all components
your way to the dash panel, also wiggle, Unable to duplicate and / or
shake and bend the vehicle harness from the identify fault at this time
dash panel to the PCM For further diagnosis, Refer to page F3-167
4 AIR LEAK AT MAF SENSOR

Yes SERVICE as necessary
• Check for broken / loose air outlet tube clamps RECONNECT all components
(throttle body and air cleaner assembly ends), RERUN Quick Test
cracks / holes in air outlet tube, worn gaskets
between MAF and air cleaner assembly No Go to next Step
F3-40
5 CHECK CONTINUITY OF MAF AND VPWR
CIRCUITS
REMOVE breakout box
• Measure resistance between VPWR circuit at
RERUN Quick Test
the MAF vehicle harness connector and Test
Pins 37 and 57 at the breakout box
• Measure resistance between MAF circuit at the
MAF sensor vehicle harness connector and Test
6 CHECK MAF CIRCUIT FOR SHORTS TO

GROUND AND MAF RTN CIRCUIT
• MAF disconnected
No SERVICE short circuit(s)
REMOVE breakout box
Test Pins 9, 40 and 60 at the breakout box
RERUN Quick Test
ohms?
7 CHECK PWR GND CIRCUIT CONTINUITY

• Measure resistance between PWR GND circuit
REMOVE breakout box
at the MAF vehicle harness connector and bat
tery negative post
RERUN Quick Test
• Is resistance less than 10 ohms?
8 CHECK MAF RTN CIRCUIT CONTINUITY

• Measure resistance between MAF RTN circuit at
REMOVE breakout box
the MAF sensor vehicle harness connector and
RERUN Quick Test
9 CHECK MAF CIRCUIT FOR SHORT TO GROUNC

• Key off. Yes RECONNECT SUPER STAR H
• MAF disconnected Go to next Step
• Breakout box installed No REPLACE PCM
• Connect PCM to breakout box REMOVE breakout box
• Disconnect SUPER STAR nfrom data link con RECONNECT MAF
nector RERUN Quick Test
• Measure resistance between test Pin 50 and
• Is resistance less than 10,000 ohms?
10 CHECK MAF CIRCUIT OUTPUT

• Reconnect MAF
• Breakout box installed, PCM connected REPLACE MAF assembly
No
• Key on, engine running REMOVE breakout box
RECONNECT PCM
breakout box and negative battery post RERUN Quick Test
F3-41

11 CHECK MAF CIRCUIT OUTPUT
• Reconnect MAF REMOVE breakout box
Breakout box Installed, PCM connected RERUN Quick Test
Key on, engine running
No REPLACE MAF sensor
Measure voltage between Test Pin 50 and Test
REMOVE breakout box
RECONNECT PCM
RERUN Quick Test
46U0F3-049
F3-42
CODE No. 158 MASS AIRFLOW SENSOR (MAF) CIRCUIT
DESCRIP • DTC 158 indicates that the Mass Airflow sensor (MAF) signal went above 4.5volts during normal engine
TION operation (continuous) or during self test
RERUN SELF-TEST WITH MAF SENSOR
DISCONNECTED
• Key off Yes REPLACE MAF
• Disconnect MAF RERUN Quick test
• Start engine, idle one minute
• Key off
No Go to next Step
2 CHECK MAF CIRCUIT FOR SHORT TO VPWR

• MAF disconnected REMOVE breakout box
• Disconnect Powertrain Control Module (PCM) RECONNECT MAF
• Disconnect SUPER STAR I from data link con
nector
REMOVE breakout box
• Measure resistance between MAF circuit and
VPWR circuit at the MAF vehicle harness con
RERUN Quick Test
nector.
• Is resistance greater than 10,000 ohms?
46U0F3-050
NOTE: DTC 158 could be generated by foreign material blocking the Mass Airflow sensor screen causing an air flow restric
tion. If contaminants are found on the screen, check air filter installation in air cleaner tray and proper sealing of air
cleaner/tube before proceeding.
F3-43
CODE No. 159 MASS AIRFLOW SENSOR (MAF)

• DTC 159 indicates that the Mass Airflow sensor (MAF) is out of Self-Test range and that the MAF signal was
DESCRIP greater than 0.70 volts during Key On, Engine Off self test.
TION • Engine running DTC 159 indicates that the MAF signal was not between 0.20 and 1.5 volts during Key On
Engine Running Self-Test.
[Possible Cause]
• Damaged idle Air Control (IAC) solenoid.
• Damaged MAF sensor.
• MAF sensor partially connected.
• Damaged Powertrain Control Module (PCM).
• Air leak before or after MAF.
CHECK VPWR CIRCUIT VOLTAGE
• Is DTC 411/412 Present? Yes For DTC 411 Go to Step 1 «■ page F3-73
For DTC 412 Go to Step 1 «■ page F3-75
No Go to next Step
2 CHECK VPWR CIRCUIT VOLTAGE

• Disconnect MAF
• Measure voltage between VPWR circuit at the
No SERVICE open in VPWR circuit
MAF vehicle harness connector and battery RERUN Quick Test
negative post.
3 CHECK MAF SENSOR GROUND

• Key on, engine off Yes Go to Step 4
• MAF sensor disconnected
• Measure voltage between VPWR circuit and
No SERVICE open PWR GND circuit
PWR GND circuit at the MAF vehicle harness
RECONNECT MAF
connector RERUN Quick test
46U0F3-051
NOTE: DTC 159 could be generated by the garage exhaust ventilation system. Remove ventilation system and properly vent
to outside atmosphere, Rerun KOEO Self-Test.
F3-44
CODE No. 172 HEATED OXYGEN SENSOR, 173 HEATED OXYGEN SENSOR (H02S)
DESCRIP 172: Heated oxygen sensor not switching indicates lean condition
TION 173: Heated oxygen sensor not switching indicates rich condition
[Possible Cause]
• Fuel injectors • H02S
• PCV/House • Vacuum
• Electronic Ignition Coil Failure • CANP (Purge solenoid valve)
1 CHECK FOR FUEL DILUTED ENGINE OIL
• Key off Yes REINSTALL PCV valve
• Remove the PCV valve from the valve cover. Go to next Step
Inspect both rocker cover hole and PCV for
damage, sludge build up, blockage and move
ment of valve plunger. Service as necessary.
• Run KOEO, KOER Quick Test.
• Address any continuous ignition DTC’s before
No CHANGE engine oil and filter
servicing KOER DTCs.
REINSTALL PCV valve
DRIVE vehicle 5 miles/55 mph
NOTE: For a No Start Go directly to nest Step
Rerun Quick Test
• Are any of the above DTC’s present In
KOER Quick Test?
2 CHECK FUEL PRESSURE

WARNING: THE FUEL SYSTEM WILL Yes Go to next Step
REMAIN PRESSURIZED WHEN ENGINE IS
NOT RUNNING. TO PREVENT INJURY OR
FIRE USE CAUTION WHEN WORKING ON
THE FUEL SYSTEM.
»
• Key off
• Install fuel pressure gauge
• Verify that manifold vacuum is connected to the
fuel pressure regulator if applicable.
If engine will start:
No CHECK the Fuel system
• Start and run engine at idle. Note fuel pressure.
• Increase engine speed to 2000 rpms and main o- page F3-116
tain for one minute. Note fuel pressure.
• Refer to Fuel Pressure Specification
« ' page F3-125
If engine will not start:

• Cycle the key off and on several times. Note
fuel pressure.
ra- page F3-125
• Is fuel pressure within specification for the

engine being tested?
F3-45

3 CHECK SYSTEM'S ABILITY TO HOLD FUEL
PRESSURE
• Pressurize fuel system per Step 2 Yes For No Starts:
• Visually look for fuel leaking at the injector 0- Go to next Step
ring, fuel pressure regulator, and the fuel lines For Service Codes or other Symptoms:
to the fuel charging assembly. Service as nec Go to Step 5
essary.
No INSPECT the Fuel system
• Does fuel pressure remain at specification
m’ page F3-116
for 5 minutes?
4 FUEL DELIVERY TEST

• Key off Yes The EEC system is not the case of the No Start
• Fuel pressure-gauge installed REMOVE the fuel pressure gage
• Run the fuel pressure hold inspection REFER to page F3-167
cr page F3-118
No REMOVE fuel pressure gauge
Go to Step 6
• The fuel pressure OK?
5 CYLINDER BALANCE DIAGNOSTIC TEST

MODE (DTM):
The DTM switches each injector OFF and ON one Yes Go to nest Step
at a time. Diagnostic Trouble Codes (DTC) corre
spond to the cylinder number (i.e., Service DTC 30
indicates a problem with cylinder No.3, a DTC 90
indicates a pass.) The Cylinder Balance (DTM) is
designed to aid in the detection of a weak or non
contributing cylinder. The Pinpoint Test Steps are
designed to isolate only EEC related problems. No For DTC 173:
a- page F3-20 Go to Step 18
For all others:
• Run the Engine Running Quick Test Go to Step 9
• After the last repeated code, wait 5-10 seconds
• "Goose" throttle lightly (not wide-open-throttle)
• Cylinder Balance (DTM) will be performed.
Time of test is approximately 2-3 minutes.
• Are there any DTCs requiring service?
F3-46
6 CHECK RESISTANCE OF INJECTORS
AND HARNESS
• Key off Yes Go to Step 14
NOTE: This erases Continuous Memory

• Measure resistance between the suspect «
INJECTOR circuit Test Pin and TEST Pin 37 at
the breakout box. Record resistance. No For No START:
• For No Starts: SERVICE open in VPWR circuit
— Pick any injector and measure resistance
between that INJECTOR circuit’s Test Pin For others:
and Test Pin 37 at the breakout box. Go to next Step
Record resistance.
• Refer to Injector Resistance Specification
s- page F3-129
• Is each resistance within specification for the

appropriate engine?
7 CHECK CONTINUITY OF FUEL INJECTOR

HARNESS
• Disconnect injector vehicle harness connector
at the suspect injector
• Measure resistance between Test Pin 37/57 at
the breakout box and the VPWR pin the injector
vehicle harness connector No SERVICE open circuit
• Measure resistance between the injector test REMOVE breakout box
pin(s) at the breakout box and the same injector RECONNECT PCM and injectors
circuit signal pin at the each injector vehicle DRIVE vehicle 5 miles/55 mph
harness connector RERUN Quick Test
8 CHECK INJECTOR HARNESS CIRCUIT FOR

SHORT TO POWER OR GROUND
• Key off Yes REPLACE injector per Cylinder Balance DTM fault code
• Breakout box installed, PCM disconnected RERUN Quick Test
• Suspect fuel injector vehicle harness discon
nected
• Measure resistance between the injector test No SERVICE short circuit
pin(s) and Test Pin 37/57, 40, 46 and 60 at the
REMOVE breakout box
breakout box RECONNECT PCM and injectors
• Measure resistance between the injector test DRIVE vehicle 5 miles/55 mph
pin(s) at the breakout box and chassis ground RERUN Quick Test
F3—47

9 CHECK H02S INTEGRITY
H02S always lean, slow to switch or lack of Yes Go to next Step
switching; fuel at adaptive limit could be caused
by:
— Moisture inside the H02S harness connector
resulting in a short to ground
— H02S coated with contaminants
— H02S circuit open
— H02S circuit shorted to ground
• Key off
• Inspect the H02S harness for chafing, burns or
No Go to Step 15
other indications of damage. Service as neces
sary.
• Inspect H02S and connector for indication of
submerging in water, oil coolant, etc. Service
as necessary.
• Run engine at 2000 rpm for two minutes
• Key off
• Run Engine Running Self Test
• Are fault codes present?
F3-48
10 CHECK H02S
NOTE: The purpose of this test is to verify the Yes Go to next Step
H02S can generate greater than 0.5 volt during
Engine Running Quick Test.
Any vacuum/air leaks in non-EC areas could

also cause DTC 172. Check for:
— Leaking vacuum actuator (e.g. A/C control
motor)
— Engine sealing
— EGR system
— PCV system
— Unmetered air leak between Mass Airflow
sensor (MAF) and throttle body
— Lead contaminated H02S
No REPLACE H02S
• Key off
• Disconnect appropriate H02S from vehicle har RERUN Quick Test
ness
— Connect a voltmeter to H02S circuit and
H02S SIG RTN or H02S GND at the H02S
connector
• Run engine at approximately 2000 rpm for two
minutes
• Rerun Engine Running Quick Test and monitor
H02S voltage
• Does the indicate greater than 0.5 volt at the
end of Quick Test?
V
11 CHECK CONTINUITY OF H02S AND H02S

GROUND CIRCUITS «
• Disconnect suspect H02S from vehicle har
ness. Inspect both ends of connector for dam
aged or pushed out pins, moisture, corrosion,
loose wires, etc. Service as necessary.
• Measure resistance between H02S circuit Test
Pin at the breakout box and H02S circuit at the
vehicle harness connector.
Remove breakout box
— Measure resistance between SIG RTN Test
RECONNECT PCM, H02S, and any other components
Pin at the breakout box and H02S SIG RTN
that have been disconnected.
at the vehicle harness connector
— Where applicable measure resistance
RERUN Quick Test
between H02S GND and SIG RTN at the
breakout box
12 CHECK H02S CIRCUIT FOR SHORT TO

GROUND
• H02S disconnected
• Measure resistance between the H02S circuit
REMOVE b reakout box
Test Pin at the breakout box and Test Pin 40,
RECONNECT PCM, H02S, and any other components
46 or 49 where applicable at the breakout box
that are disconnected.
RERUN Quick Test
F3-49

13 CHECK H02S FOR SHORT TO GROUND
• Key off Yes REMOVE breakout box
• Breakout box installed, PCM disconnected RECONNECT H02S
• H02S disconnected REPLACE PCM
• Measure resistance between PWR GND and DRIVE vehicle 5 miles/55 mph
H02S circuit at the H02S connector. RERUN Quick Test
• Also measure resistance between H02S GND
and/or SIG RTN at the H02S connector.
No REPLACE H02S
REMOVE breakout box
RECONNECT PCM
DRIVE vehicle 5 miles/55mph
RERUN Quick Test
14 CHECK INJECTOR DRIVER SIGNAL

Requires standard non-powered 12 volt test Yes REMOVE breakout box
lamp RECONNECT PCM
• Key off Inspect the Fuel system «■ page F3-116
• Breakout box installed
• Connect PCM to breakout box Also refer to ignition section for other possible causes
— Connect test lamp between Test Pin 37 and After any servicing, DRIVE vehicle 5 miles/55 mph
the suspect injectors Test Pin at the break RERUN Quick Test and Cylinder Balance DTM
out box.
• Crank or start engine
No No light/Bright light:
REPLACE PCM
NOTE: Properly operating systems will show a
REMOVE breakout box
dim glow on the lamp
RERUN Quick Test
• Is glow on lamp dim?
15 CHECK RESISTANCE OF HEATER ELEMENT

ON H02S
• Disconnect suspect H02S from vehicle harness
• Inspect both ends of the connector for dam
loose wires, etc. Service as necessary
• Measure resistance between KEY PWR circuit
No REPLACE H02S
and PWR GND circuit at H02S connector
RERUN Quick Test
page F3-164
— Room temperature resistance specification

is approx. 6 ohms
• Is resistance within specification?
16 CHECK FOR POWER AT H02S HARNESS

CONNECTOR
• Key on, engine off. Yes RECONNECT H02S
• H02S disconnected H02S system OK
• Measure voltage between KEY POWER circuit Fuel delivery is OK
and PWR GND circuit at the H02S vehicle har H02S sensor may have cooled prior to Engine Running
ness connector Quick Test. If symptom persists, problem is in an are com
«■ page F3-164 mon to all cylinders, i.e. air/vacuum leak, fuel contamina
tion, EGRA. Check ignition system etc. Service as
• Is voltage greater than 10.5 volts? necessary.
No Go to next Step
F3-50
17 CHECK CONTINUITY OF POWER GROUND
CIRCUIT
• Key off. Yes SERVICE open in KEY PWR circuit
• H02S disconnected RECONNECT H02S sensor
• Measure resistance between PWR GND circuit RERUN Quick Test.
at the H02S vehicle harness connector and
battery negative post
No SERVICE open in PWR GND circuit
RECONNECT H02S sensor
RERUN Quick Test
18 CHECK H02S SIGNAL FOR SHORT TO POWER

H02S always rich could be caused by: Yes Go to Step 20
— Moisture inside H02S harness connector
resulting in a short to power.
— H02S circuit shorted to power
• Key off
• Disconnect the suspect H02S from vehicle har
ness
• Inspect both ends of the connector for dam
No Go to next Step
loose wires, etc. Service as necessary
• Measure voltage between H02S circuit and
PWR GND at the H02S vehicle harness con
nector
ra* page F3-164
• Is voltage less than 0.5 volt?
19 CHECK FOR SHORT TO POWER

• Inspect H02S GND and H02S circuit harness REMOVE breakout box
for chaffing, burns or other indications of short RECONNECT H02S
to power. Service as necessary. DRIVE vehicle 5 miles/55 mph
• Disconnect Powertrain Control Module (PCM). RERUN Quick Test
Inspect for damaged, or pushed out pins, corro
sion, loose wires etc. Service as necessary. No SERVICE short to power
• Install breakout box, leave PCM disconnected REMOVE breakout box
• Measure resistance between H02S circuit, and RECONNECT PCM
KEY PWR at the breakout box DRIVE vehicle 5 miles/55 mph
• Is the resistance greater than 10,000 ohms?
RERUN Quick Test
20 CHECK H02S FOR SHORT TO IGNITION FUN

CIRCUIT
• Measure resistance between KEY PWR circuit No REPLACE H02S
and H02S SIG circuit at the H02S connector DRIVE vehicle 5 miles/55 mph
«■ page F3-164 RERUN Quick Test
F3-51

21 ATTEMPT TO GENERATE DTC 172
• Key off Yes REMOVE jumper wire
• H02S disconnected Go to next Step
• Jumper H02S circuit at the H02S vehicle har
ness connector to battery negative post
No REMOVE jumper
• Rerun Engine Running Quick Test
RECONNECT H02S
DISCONNECT PCM 60 pin connector. Inspect for dam
aged or pushed out pins, corrosion, loose wires, etc.
SERVICE as necessary. If OK REPLACE PCM. DRIVE
vehicle 5 miles/55 mph.
RERUN Quick Test
22 H02S CHECK
— Connect a voltmeter to H02S circuit and
H02S GND or SIG RTN at the H02S con
nector
• Create a vacuum leak to cause H02S to go
lean
• Disconnect any vacuum hose from the manifold
No REPLACE H02S
vacuum tree
RECONNECT vacuum hoses
• Start engine and run at approximately 2000 rpm
• Does the voltmeter indicate less than 0.4
RERUN Quick Test
volt within 30 seconds?
23 CHECK CONTINUOUS MONITOR DIAGNOSTIC

TEST MODE (DTM)
• Key off Yes ISOLATE fault and SERVICE as necessary
• Verify engine at operating temperature REMOVE breakout box
• Start engine and run at 2000 rpm for two min CLEAR Continuous Memory
utes «■ page F3-18
• With engine rpm at idle enter Engine Running
Continuous Monitor (DTM) RERUN Quick Test
**■ page F3-20
No REMAIN in Engine
• Observe STAR LED for indication of fault
Running Continuous Monitor DTM
• Wiggle, shake or bend a small section of the
Go to next Step
EEC harness while working your way from the
H02S to the PCM
• Wiggle, shake or bend a small section of the
EEC harness while working your way from the
H02S GND to the PCM
F3-52
24 CONTINUOUS MONITOR DTM TEST DRIVE
CHECK
• Remain in Engine Running Continuous Monitor Yes ISOLATE fault and SERVICE as necessary
DTM REMOVE breakout box
• Test drive vehicle at 55 mph with minimum road CLEAR Continuous Memory Code.
load for five miles «*■ page F3-18
• Continue to drive on a rough road at 55 mph for
five miles RERUN Quick Test
• If possible drive vehicle through a pool of water
on the road to shower the H02S and/or con No EXIT Engine Running Continuous Monitor DTM
nector Go to next Step
25 CHECK H02S SWITCHING

• Key off Yes Unable to duplicate or identify fault at this time
• Inspect EEC wire harness for proper routing Clear Continuous Memory DTCs
and insulation; burnt, chafed, intermittently «*■ page F3-18
shorted or open. Service as necessary.
• Disconnect PCM 60 pin connector and inspect For futher diagunosis, REFER to page F3-167
for damaged or pushed out pins, corrosion,
loose wires, etc. Service as necessary.
• Inspect the H02S terminal voltage No REPLACE H02S
«■ page F3-164 REMOVE breakout box
RECONNECT PCM
• Did H02S voltage switch? RERUN Quick Test
46U0F3-052
F3-53
CODE No. 179 (Cont) FUEL SYSTEM

181 (Cont) FUEL SYSTEM
DESCRIP 179: Adaptive fuel lean limit reached at part throttle, system rich
TION 181: Adaptive fuel rich limit reached at part throttle , system lean
[Possible Cause]
• Fuel pressure • Fuel injector • Air intake
• Fuel injector electrical circuit • Vacuum • Air cleaner element
• Fuel filter
1 CHECK FOR OTHER DIAGNOSTIC TROUBLE
CODES (DTC’S)
• Are any other DTC’s present? Yes SERVICE them as required
No Go to next Step
WARNING: THE FUEL SYSTEM WILL Yes Go to next Step

REMAIN PRESSURIZED WHEN ENGINE IS
NOT RUNNING. TO PREVENT INJURY OR
FIRE USE CAUTION WHEN WORKING ON
THE FUEL SYSTEM
• Key off No VERIFY integrity of fuel pressure regulator, vacuum line,

• Install fuel pressure gauge fuel filter and fuel lines
• Verify that manifold vacuum is connected to the is- page F3-116
fuel pressure regulator if applicable
• Start and run engine at idle. Note fuel pressure
• Is fuel pressure within specification?
3 CHECK SYSTEM’S ABILITY TO HOLD FUEL

PRESSURE
• Cycle the key on and off several times. Note the Yes VERIFY integrity of air intake air filter, no vacuum leaks,
fuel pressure EGR control valve closed
• Visually lock for fuel leaking at the injector Go to next Step
O-ring, fuel pressure regulator, and the fuel lines No INSPECT the Fuel system
to the fuel charging assemble. Service as nec <sr page F3-116
essary
• Does fuel pressure remain at specification
for 5 minutes?
F3-54
4 DIAGNOSTIC TEST MODE (DTM)
The DTM switches each injector OFF and ON one Yes Go to next Step
at a time. Diagnostic Trouble Codes (DTC) corre
spond to the cylinder number, (i.e. DTC 30 indi
cates a problem with cylinder No.3, a DTC 90
indicates a pass.) The DTM is designed to aid in
the detection of a weak or non-contributing cylin
der. The Pinpoint Test Steps are designed to iso
late only EEC related problems
ra- page F3-20
No Go to next Step
• Run the Engine Running Self-Test
• After the lest repeated code, wait 5-10 seconds
• “Goose" throttle lightly (not wide-open-throttle).
• DTM will be performed. Time of test is approxi
mately 2-3 minutes
• Is Code 90 pressure?
5 CHECK RESISTANCE OF INJECTORS AND

HARNESS
NOTE: This erases Continuous Memory

No Go to next Step
• Measure resistance between the suspect
INJECTOR circuit Test Pin and Test Pin 37 at
the breakout box. Record resistance
• Is each resistance within specification?
6 CHECK CONTINUITY OF FUEL INJECTOR

HARNESS
• Disconnect injector vehicle harness connector at
the suspect injector
• Measure resistance between Test Pin 37/57 at
the breakout box and the VPWR pin at the injec
tor vehicle harness connector No SERVICE open circuit
• Measure resistance between the injector test REMOVE breakout box
pin(s) at the breakout box and the same injector RECONNEC PCM and injectors
circuit signal pin at the each injector vehicle har DRIVE vehicle 5 miles/55 mph
ness connector RERUN Quick Test
F3-55

7 CHECK INJECTOR HARNESS CIRCUIT FOR
SHORT TO POWER OR GROUND
• Key off. Yes REPLACE injector per Cylinder Balance DTM fault code
• Breakout box installed, PCM disconnected RERUN Quick Test
• Suspect fuel injector vehicle harness disconnect
ed
• Measure resistance between the injector test
pin(s) and Test Pin 37/57, 40, 46 and 60 at the
breakout box
• Measure resistance between the injector test
REMOVE breakout box
pin(s) at the breakout box and chassis ground
RECONNECT PCM and injectors
RERUN Quick Test
8 CHECK INJECTOR DRIVER SIGNAL

Requires standard non-powered 12 volt test Yes REMOVE breakout box
light. RECONNECT PCM
• Key off. Also refer to section G for other possible causes
• Breakout box installed. After any servicing, DRIVE vehicle 5 miles/55 mph
• Connect PCM to breakout box RERUN Quick Test and Cylinder Balance DTM
— Connect test lamp between Test Pin 37 and
the suspect injectors Test Pin at the breakout
box
No No light/Bright light: REPLACE PCM
• Crank or start engine
REMOVE breakout box
DRIVE vehicle 5 miles/55 mph.
NOTE: Properly operating systems will show a
RERUN Quick Test
dim glow on the light
• Is glow on light dim?
46U0F3-Q53
F3-56
CODE No. 211 PROFILE IGNITION PICKUP (PIP) CIRCUIT
DESCRIP DTC 211 indicates two successive erratic Profile Ignition Pickup (PIP) pulses occurred, resulting in a possible
TION engine miss or stall
[POJisible Cause]
• Lc>ose wires/connectors • Audio system ( if equipped)
• At cing secondary ignition components (coil, cap, rotor,
w res, plugs, etc.)
ERRATIC IGNITION
• Verify a radio and condenser installations Yes SERVICE as necessary
Carefully follow manufacturer’s installation CLEAR Continuous Memory
instructions regarding the routing of antenna and ■®- page F3-18
power leads
• Are any of the above present? RERUN Quick Test
No For No starts
Go to 1
«■ page F3-97
All others
Go to Code No. 212 Step 1
«*■ page F3-58
46U0F3-Q54
F3-57
CODE No. 212 (Cont) LOSS OF IGNITION DIAGNOSTIC MONITOR (IDM) CIRCUIT
DESCRIP DTC 212 indicates a loss of IDM input to the PCM
TION
[Possible Cause]
• Open harness circuit • Damaged Powertrain Control Module (PCM)
• Damaged Ignition Control Module (ICM) • Shorted harness circuit
TROUBLE CODE (DTC) 212
• Is vehicle a No Start? Yes INSPECT the Engine Electrical system
■s- section G
No Go to next Step

CHECK IDM CIRCUIT CONTINUITY
• Disconnect Ignition Control Module (ICM)
REMOVE breakout box
• Measure resistance between Test Pin 4 at the
RECONNECT PCM
breakout box and IDM circuit at the ICM vehicle
CLEAR Continuous Memory
harness connector
«■ page F3-18
RERUN Quick Test
3 CHECK IDM CIRCUIT FOR SHORTS TO POWER
i
(EXCLUDING VREF)
• Key off Yes SERVICE short circuit
• Breakout box installed REMOVE breakout box
• PCM and ICM disconnected RECONNECT all components
• Measure voltage between Test pin 4 at the RERUN Quick Test
breakout box and battery negative post
No Go to next Step
• Measure voltage between Test pin 4 and Test
• Is any voltage reading greater than 10.5
volts?
F3-58
4 CHECK IDM CIRCUIT FOR SHORTS TO VREF
AND PIP
• Key off. Yes RECONNECT SUPER STAR I
• Breakout box installed, PCM disconnected Go to next Step
• ICM disconnected
• Disconnect SUPER STAR I from Data Link
Connector
NOTE: For proper results of this test, the

Breakout box must be disconnected. Due to the
circuitry of the SUPER STAR Hand the vehicle,
voltage can be fed to the VREF circuit giving the No SERVICE short circuit
REMOVE breakout box
false indication of a short to power
RECONNECT all components and SUPER STAR n
RERUN Quick Test
For Shorts To VREF:
— Measure resistance between Test Pin 4 and
For Shorts To PIP circuit:
5 CHECK IDM CIRCUIT FOR SHORT TO GROUND

NOTE: During this check when H02S is con Yes Go to next Step
nected to the vehicle harness a short to SIG
RTN (Pin 46) may be indicated in conjunction
with an actual PWR GND short
• Key off.
No REMOVE breakout box
SERVICE short to ground in IDM circuit
• ICM disconnected
Test Pins 20, 40, 46 and 60 at the breakout box
RERUN Quick Test
• Is each resistance above 10,000 ohms?
6 CHECK ICM
• Key off. Yes DISCONNECT and INSPECT connectors
• Breakout box installed If connector and terminals are good, REMOVE breakout
• Connect PCM to breakout box box, RECONNECT all components Inspect Electrical igni
• Reconnect ignition coil and ICM tion system
• Connect a voltmeter between Test Pin 4 and <&■ section G
• Start engine
• Observe voltmeter when voltage is allowed to
stabilize
• Lightly tap on ICM to simulate road shock
No Go to next Step
• Wiggle ICM connector
• A sudden charge in voltage indicates a fault
F3-59

7 CHECK EEC HARNESS
• The voltmeter still connected between Test Pin 4 Yes ISOLATE fault and SERVICE as necessary
and Test Pin 16 at the breakout box REMOVE breakout box
• Key on, engine running RECONNECT all components
• While observing a voltage change like in Step 5 CLEAR Continuous Memory
perform the following: «■ page Fa-18
— Grasp vehicle harness closest to ICM connec
tor RERUN Quick Test
Shake and bend a small section of the EEC
harness while working your way to the dash
No Goto next Step
panel. Also wiggle, shake and bend the EEC
harness from dash panel to PCM

sion, loose wires, etc.
REMOVE breakout box
• Are connectors and terminals OK?
«*• page F3-18
RERUN Quick Test

9 CHECK PCM FOR SHORT TO POWER
• PCM connected to breakout box RECONNECT all components
• Disconnect Crankshaft Position sensor RERUN Quick Test
• Measure voltage between Test Pin 4 and chas
sis ground
No Go to next Step
• Measure voltage between Test Pin 4 and Test
• Is any voltage reading greater than 10.5
volts?
10 CHECK PCM FOR SHORT TO GROUND

• Breakout box installed RECONNECT all components
• PCM connected to breakout box Inspect the Electronic ignition system
• ICM and CPS sensor disconnected (Refer to section G)
• Measure resistance between Test Pin 4 and REPLACE PCM
No
Test Pins 40, 46 and 60 at breakout box
REMOVE breakout box
• Is each resistance greater than 10, 000
ohms? RERUN Quick Test
46U0F3-055
F3-60
CODE No. 213 (ER) NO SPARK CONTROL [SPOUT CKT OPEN]

1 CHECK FOR POWER TO PCM
NOTE: Before proceeding with this Pinpoint Yes Go to next Step
Test, verify that the base timing check in
Pinpoint Test F Step 4 has been performed.
«■ page F3-110
• Key off
sion, loose wires, etc. Service as necessary No Go to Pinpoint B Test Step 1
• Install breakout box, leave PCM disconnected «■ page F3-102
• Is each voltage greater than 10.5 volts?
2 CHECK SPOUT CIRCUIT CONTINUITY

• Disconnect Ignition Control Module (ICM)
breakout box and SPOUT circuit at the ICM
REMOVE breakout box
vehicle harness connector
CHECK timing as in Step 4
ear page F3-110
3 CHECK SPOUT CIRCUIT FOR SHORT TO B+

(EXCLUDING VREF)
• Key off Yes SERVICE short circuit
• ICM disconnected RECONNECT all components
• Key on, engine off RERUN Quick Test
• Measure voltage between Test Pin 36 and Test No INSPECT the throttle body and the fuel system
Pin 40 or 60 at the breakout box ra- page F3-112
• Is voltage reading greater than 10.5 volts?
«• page F3-116
F3-61

4 CHECK SPOUT CIRCUIT FOR SHORT TO VREF
GROUND AND PIP
• Key off. Yes RECONNECT all components
• Breakout box installed, PCM disconnected INSPECT the electronic ignition system
• ICM disconnected <9- section G
For Short to Ground:
Test Pins 16, 20, 40, 46 and 60 at the break No SERVICE Short circuit
out box REMOVE breakout box
For Short to PIP: RECONNECT all components
RERUN Quick Test
ohms?
46U0F3-056
F3-62
CODE NO. 214 (CONT) CYLINDER IDENTIFICATION DISPLAY (CID) CIRCUIT 244 (KOER) CID CIRCUIT
DESCRIP • Continuous Memory DTC 214 indicates an error has been detected in the Cylinder Identification Display (CID)
TION input signal. The error could be due to a “hard fault” or an intermittent condition
[Possible Cause]
• Open or shorted harness • Damaged Ignition Control Module (ICM)
• Damaged Crankshaft Position sensor (CPS) • Damaged Powertrain Control Module (PCM)

TROUBLE CODE 214:
DIAGNOSTIC CIA TSC
• Will engine start? Yes Go to next Step
No Go to Step 8
2 CLEAR AND ATTEMPT TO RE-GENERATE

DTC: 214
• Clear Continuous Memory Yes Go to next Step
page F3-20
• Start engine
• Increase rpm to greater than 1500 rpm for 10
No DTC 214 is intermittent
seconds. Repeat two times
Go to Step 9
• Key off
• Is Continuous Memory DTC 214 present?
3 CHECK CID CIRCUIT CONTINUITY TO PCM

REMOVE breakout box
• Install breakout box. Leave PCM disconnected
• Disconnect Crankshaft Position sensor RERUN Quick Test
• Measure resistance between the CID / CID(+)
Signal Test Pin at the breakout box and the CID
CID(+) circuit at the crankshaft position sensor
4 CHECK CID CIRCUIT FOR SHORT TO POWER

• Key off Yes Key off
• Breakout box installed, PCM disconnected Go to next Step
• Crankshaft position sensor disconnected
No SERVICE short to power
• Disconnect SUPER STAR I
REMOVE breakout box
RERUN Quick Test
SUPER STAR I must be disconnected. Due to
the circuitry of the SUPER STAR I and the vehi
cle, a CID signal short to SIG RTN could appear
as a CID short to power
• Key on
• Measure voltage between the CID / CID(+)
Signal Test Pin and Test Pin 40 at the breakout
box
F3-63

5 CHECK CID CIRCUIT FOR SHORT TO GROUND
• Disconnect SUPER STAR D
REMOVE breakout box
RECONNECT PCM
RERUN Quick Test
SUPER STAR I must be disconnected. Due to
the circuitry of the SUPER STAR I and the vehi
cle, a CID signal short to SIG RTN could appear
as a CID short to power
• Key on
• Measure voltage between the CID / CID(+)
Signal Test Pin and Test Pin 40 at the breakout
box
6 CHECK FOR SHORTS IN PCM

• Connect PCM to breakout box
No REPLACE PCM
REMOVE breakout box
Test Pins 37, 67, 40, 46 and 60 at the breakout
RERUN Quick Test
box
• Is each resistance greater than 500 ohms?
7 CHECK CKP SENSOR OUTPUT

• Breakout box installed, PCM connected REMOVE breakout box
• Reconnect crankshaft position sensor RECONNECT all components
• Measure voltage between Test Pins 24 and 40 RERUN Quick Test
at the breakout box while varying engine rpm
• Does CPS voltage correct?
No REPLACE crankshaft position sensor
is- page F3-152
REMOVE breakout box
RERUN Quick Test
8 CHECK FOR VPWR TO CRANKSHAFT

POSITION SENSOR
• Key off. Yes RECONNECT crankshaft position sensor
• Disconnect crankshaft position sensor INSPECT the electronic ignition system
• Key on, engine off «• section G
• Measure voltage between the VPWR circuit at
No SERVICE open VPWR circuit
the crankshaft position sensor vehicle harness
between crankshaft position sensor and power relay
connector and the battery negative post
RECONNECT crankshaft position sensor
RERUN Quick Test
F3-64
9 CHECK CID WIRING
• Enter Engine Running continuous Monitor diag Yes ISOLATE fault SERVICE
nostic Test Mode (DTM) as necessary
• Observe STAR LED for a fault indication while CLEAR continuous Memory
performing the following: «■ page F3-18
CAUTION: While performing this test, do not RERUN Quick Test

touch any moving engine parts
No Key off
For further diagnosis, REFER to 1994 626/MX-6 BETM
— Shake, wiggle, bend the crankshaft position
sensor wiring form the PCM to as close as
possible to the crankshaft position sensor
— If possible, lightly tap on the crankshaft posi
tion sensor / connector (to simulate road
shock)
46U0F3-057
F3-65
CODE NO. 327 (KOEO / ER) EGR FUNCTION CIRCUIT

DESCRIP • DTC 327 indicates the EGR function sensor signal is less than the Self-Test minimum
TION
[Possible Cause]
• Damaged EGR function sensor • Damaged Powertrain Control Module (PCM)
• Open in sensor harness circuit • Damaged EGR control valve
• Short to ground in sensor harness circuit
• Key off. Yes REPLACE the EGR function sensor /
• Disconnect EGR function sensor EGR valve assembly
Jumper VREF circuit to EGR function sensor REMOVE jumper
signal circuit at the sensor vehicle harness con RERUN Quick Test
nector
No REMOVE jumper
• Rerun Key On Engine Off (KOEO) and Key On
Engine Running (KOER) Self-Test Go to next Step
• Is DTC 337 present (ignore all other DTC out
put)?

• Key on, engine off. Yes Go to next Step
• EGR function sensor disconnected
RTN circuit at the EGR function sensor vehicle No Go to Pinpoint Test C Step 1
harness connector «■ page F3-104
3 CHECK EGR CIRCUIT CONTINUITY

• EGR function sensor disconnected
• Disconnect PCM. Inspect for damaged or
pushed out pins, corrosion, loose wires, etc. No SERVICE open circuit
Service as necessary REMOVE breakout box
• Install breakout box, leave the PCM disconnect RECONNECT all components
ed RERUN Quick Test
• Measure resistance between EGR function cir
cuit at the EGR function sensor vehicle harness
connector and Test Pin 27 at the breakout box
• Is resistance less than 5 ohms?
4 CHECK EGR CIRCUIT FOR SHORT TO

GROUND
• Key off. Yes REPLACE the PCM
• EGR function sensor disconnected REMOVE breakout box
• Breakout box installed, PCM disconnected RECONNECT all components
• Measure resistance between Test Pin 27 and RERUN Quick Test
• Is each resistance greater than 10,000 No
SERVICE open circuit
ohms? REMOVE breakout box
RERUN Quick Test
NOTE: Because the EGR function sensor is preloaded when attached to the EGR control valve, a failure in the 46U o g x - os8
EGR valve causing the EGR function sensor to lose the preload may also set DTC 327.
F3-66
CODE NO. 327 (Cont) EGR CIRCUIT
337 (Cont) EGR CIRCUIT
Continuous memory DTC 327 indicates that the EGR function sensor input to the Powertrain Control Module
(PCM) was below the minimum acceptable voltage sometime during vehicle operation
DESCRIP
TION Continuous memory DTC 337 indicates that the EGR function sensor input to the Powertrain Control Module
(PCM) was above the maximum acceptable voltage sometime during vehicle operation
[Possible Cause]
DTC 327: DTC 337:
• Damaged EGR function sensor / EGR control valve • Damaged EGR function sensor / EGR control valve
assembly assembly
• Intermittent open in EGR function signal circuit • Intermittent open in EGR signal return circuit
• Intermittent short to ground in EGR function signal circuit • Intermittent short to power in EGR function signal circuit
• Intermittent open in EGR VREF circuit
TROUBLE CODE (DTC) 327 OR 337:
CHECK FOR INTERMITTENT SENSOR
DAMAGE
• Enter KOEO Continuous Monitor DTM. (Refer to Yes INSPECT EGR function sensor
Quick Test Appendix) connector and connector
• Observe STAR LED for indication of a fault terminals
while performing the following: If OK, REPLACE the EGR function
Lightly tap on the EGR function sensor and wig sensor / EGR control valve assembly
gle the sensor vehicle harness connector to sim CLEAR continuous Memory
ulate road shock ■s- page F3-18
RERUN Quick Test
No Go to next Step
2 CHECK FOR INTERMITTENT HARNESS

DAMAGE
• Still in KOEO Continuous Monitor DTM Yes ISOLATE fault and SERVICE as necessary
• Observe STAR LED for indication of a fault CLEAR Continuous Memory
while performing the following: <&• page F3-18
— Grasp the vehicle harness closest to the EGR
function sensor vehicle harness connector RERUN Quick Test
Wiggle, shake or bend a small section of the
No Go to next Step
EEC-IV vehicle harness while working your
way towards the dash panel
Also wiggle, shake and bend the EEC-IV vehi
cle harness from the dash panel to the PCM
F3-67

3 CHECK PCM CONNECTOR
• Key off. Yes SERVICE as necessary
• Disconnect PCM connector CLEAR Continuous Memory
• Inspect both connectors and connector termi «*■ page F3-18
nals for damaged or pushed out pins, corrosion,
loose wires, etc
No Unable to duplicate fault at
• Is damage detected?
this time
For farther diagnosis, REFER to page F3-167
46U0F3-059
F3-68
CODE NO. 332 (ER) EGR SYSTEM CONTROL
DESCRIP DTC 332 indicates that the EGR function sensor input did not change after the Powertrain Control Module (PCM)
TION commanded the EGR control valve to be opened
[Possible Cause]
• Damaged vacuum lines • Damaged EGR function sensor / EGR control valve
• Damaged EGRV solenoid assembly
• Damaged EGRA solenoid
1 CHECK VACUUM AT EGR CONTROL VALVE
• Key off. Yes REMOVE vacuum gauge
• Disconnect EGR vacuum line at the EGR control REPLACE the EGR function sensor /
valve EGR control valve assembly
• Connect a vacuum gauge to the EGR vacuum RERUN Quick Test
line No REMOVE vacuum gauge
• Return Key On Engine Running (KOER) Self- Go to next Step
Test while observing the vacuum gauge
• Does vacuum increase above 1 in-Hg {3.4
kPa}?
2 CHECK EGR CONTROL VALVE VACUUM LINE

• EGR control valve vacuum line disconnected Yes RECONNECT EGR control valve vacuum
• Inspect the EGR control valve vacuum line from line
the EGR control valve to the EGRV / EGRA Go to next Step
solenoids for obstructions, cracks, kinks and No SERVICE EGR control valve vacuum line
loose connections, etc as necessary
• Is EGR control valve vacuum line in good RERUN Quick Test
condition?
3 CHECK VACUUM TO EGRV SOLENOID

• Key off Yes REMOVE vacuum gauge
• Disconnect the EGRV solenoid input port vacu RECONNECT vacuum line
um source line Go to next Step
• Install a vacuum gauge at the input port vacuum No CHECK vacuum source line
source line to the EGRV solenoid
• Key on, engine idling SERVICE as necessary
• Observe the vacuum gauge reading RERUN Quick Test
• Is vacuum greater than 10 in-Hg {33 kPa}?
4 CHECK EGRV SOLENOID-VALVE FUNCTION

• Key off Yes REMOVE vacuum gauge
• Disconnect the EGRV solenoid input port vacu Go to next Step
um line at the solenoid output port No REMOVE vacuum gauge
• Install a vacuum gauge at the output port of the REPLACE the EGRV solenoid assembly
EGRV solenoid RECONNECT all components
• Rerun Key On Engine Running (KOER) RERUN Quick Test
Self-Test while observing the vacuum gauge
• Does vacuum increase above 1.0 in-Hg {3.4
kPa}?
5 CHECK EGRV SOLENOID OUTPUT PORT

VACUUM LINE
• EGRV solenoid output port vacuum line discon Yes RECONNECT the
nected vacuum line
• Inspect the EGRV solenoid output port vacuum Go to next Step
line for obstructions, cracks, kinks and loose No SERVICE vacuum line
connections, etc as necessary
• Is the vacuum line in good condition? RERUN Quick Test
F3-69

6 CHECK EGRA SOLENOID VACUUM LINE
• Disconnect the EGRA solenoid vacuum line Yes REPLACE the EGRA
• Inspect the EGRA solenoid vacuum line for solenoid assembly
obstructions, cracks, kinks and loose connec RECONNECT the EGRA
tions, etc solenoid vacuum line
• Is the vacuum line in good condition? RERUN Quick Test
No SERVICE vacuum line
as necessary
RERUN Quick Test
46U0F3-060
F3-70
CODE No. 332 (Cont) EGR SYSTEM CONTROL
DESCRIP Continuous memory DTC 332 indicates that the EGR control valve did not open when load and EGR requested
TION conditions had been met sometime during vehicle operation.
[Possible Cause]
• Damaged EGR function sensor/EGR control valve assem- • Damaged EGRA solenoid vacuum line
bly
• Damaged EGR control valve vacuum line
• Damaged EGRV solenoid vacuum lines
1 CHECK EGR CONTROL VALVE FUNCTION
• Key off Yes REMOVE vacuum pump
• Disconnect and plug EGR control valve vacuum UNPLUG vacuum line
line at the EGR control valve Go to next Step
• Connect a hand vacuum pump to the EGR con
No REMOVE the EGR function sensor/EGR control valve
trol valve
assembly
• Apply 10 in-Hg (34 kPa) of vacuum to the EGR
INSPECT the EGR control valve for blockage, binding,
control valve and release while observing valve
contamination and leakage, etc.
for movement
SERVICE as necessary
• Does the EGR control valve function proper
ly?
page F3-18
RERUN Quick Test

2 CHECK EGR CONTROL VALVE VACUUM LINE
• EGR control valve vacuum line disconnected at Yes RECONNECT EGR control valve vacuum line
both ends Go to next Step
• Inspect the EGR control valve vacuum line from
the EGR control valve to the EGRV/EGRA
solenoids for obstructions, cracks and kinks,
No SERVICE EGR control valve vacuum line as necessary
etc.
• Is EGR control valve vacuum line in good
**■ page F3-18
condition?
RERUN Quick Test
3 CHECK EGRA SOLENOID VACUUM LINE AND

EGRV SOLENOID INPUT/OUTPUT PORT
VACUUM LINES
• Vacuum lines disconnected one at a time Yes RECONNECT the vacuum lines
• Inspect the vacuum lines for obstructions, Go to next Step
cracks and kinks, etc.
No SERVICE vacuum lines as necessary
• Is each vacuum line in good condition?
<3- page F3-18
RERUN Quick Test
4 CHECK EGRV/EGRA SOLENOIDS AND

HARNESS CIRCUITS FOR INTERMITTENT
FAULT
• Key off Yes ISOLATE fault and SERVICE or REPLACE as necessary
• Disconnect vacuum line at the EGR control RECONNECT all components
valve and connect vacuum line to a vacuum CLEAR Continuous Memory
gauge ■a- page F3-18
• Key on, engine idling
• Look for on increase in vacuum while perform RERUN Quick Test
ing the following: No Unable to duplicate and/or identify fault at this time
— Tap the EGRV and EGRA solenoids INSPECT the EGR function control system
— Wiggle the EGRV and EGRA solenoid vehi ■a- page F3-134
cle harness connectors and harness circuits
• Does the EGR vacuum increase?
46U0F3-061
F3-71
CODE No. 337 (KOEO/ER) EGR (FUNCTION) CIRCUIT

DESCRIP DTC 337 indicates that the EGR function sensor signal is greater than the Self-Test maximum
TION
[Possible Cause]
• Damage EGR function sensor
• Short to power in sensor harness circuit
• Open in sensor harness SIG RTN circuit
• Damaged Powertrain Control Module (PCM)
• Disconnect EGR function sensor
• Rerun Key On Engine Off (KOEO) and Key On
No Go to Step 3
Engine Running (KOER) Self test
• Is DTC 327 present (ignore all other DTC
output)?

• Key on, engine off Yes REPLACE the EGR function sensor/EGR control valve
• EGR function sensor disconnected assembly
• Measure voltage between VREF circuit and RERUN Quick Test
SIG RTN circuit at the EGR function sensor
No RECONNECT all components
Go to Pinpoint Test C Step 1
page F3-104
3 CHECK EGR CIRCUIT FOR SHORT TO
POWER
• EGR function sensor disconnected REMOVE breakout box
• Disconnect PCM. Inspect for damaged or RECONNECT the EGR function sensor
pushed out pins, corrosion, loose wires, etc. RERUN Quick Test
REMOVE breakout box
• Measure the resistance between Test Pin 27
and Test Pins 26 and 37/57 at the breakout box
RERUN Quick Test
• Is each resistance that 10,000 ohms?
46U0F3-062
F3-72
CODE No. 411 (ER) UNABLE TO CONTROL RPM DURING SELF TEST LOW RPM CHECK
DESCRIP DTC 411 indicates that during Engine Running Self-Test, engine rpm could not be controlled with the Self-Test
TION lower limit band.
[Possible Cause]
• Improper idle air flow set • Damage IAC solenoid
• Throttle linkage blinding • Vacuum leaks
• Improper ignition timing • Throttle plates open
• IAC solenoid contamination • IAC circuit short to ground
1 CHECK IDLE
• Does engine idle speed appear normal? Yes REMOVE IAC solenoid and INSPECT for contamination. If
contamination is present
No contamination present or solenoid cannot be cleaned:
REPLACE IAC solenoid
RERUN Quick Test
Solenoid is contaminated and can be cleaned:
CLEAN as necessary
ra-page F3-18
RERUN Quick Test. If DTC/symptom is still present,

REPLACE IAC solenoid.
No RESET idle airflow to specification
REFER to page F3-14 for idle speed adjust procedure. If
UNABLE to RESET idle to specification, Go to next step.
2 CHECK FOR CONDITIONS AFFECTING IDLE
• Check engine vacuum hoses for leaks. Refer Yes Go to next Step
to vacuum hose routing diagram
page F3-7
• Check throttle linkage and/or speed control link

age for binding
• Check for induction system leaks, (i.e. IAC
solenoid to throttle body gasket, EGR flange
gasket, loose IAC/EGR/PCV, etc.)
• Check idle-speed control system for proper
RERUN Quick Test
operation
a- page F3-114
• Verify ignition timing is to specification

■s- page F3-13
• Verify that purge solenoid valve is not stuck

open
• Are all the above checks OK?
3 CHECK FOR INTERNAL SHORT TO IAC

SOLENOID CASE
• Disconnect IAC solenoid
• Measure resistance from either IAC solenoid
pin to IAC housing No REPLACE IAC solenoid
• Is resistance greater than 10,000 ohms? RERUN Quick Test
F3-73

4 CHECK IAC CIRCUIT FOR SHORT TO GROUND
• IAC solenoid disconnected
• Disconnect the Powertrain Control Module
(PCM). Inspect for damaged or pushed out
pins, corrosion, loose wires, etc. Service as
necessary
REMOVE breakout box
RERUN Quick Test
• Are all resistances greater than 10,000 ohms?
5 CHECK PCM OUTPUT

• Reconnect PCM to breakout box
• Reconnect IAC solenoid
• Connect a voltmeter between Test Pin 21 and REPLACE PCM
No
Test Pin 40 at the breakout box REMOVE breakout box
• Is voltage correct? RERUN Quick Test
i®- page F3-152
6 CHECK FOR PROPER ENGINE COOLANT

FLOW TO BYPASS AIR (BPA) VALVE
• Verify that engine coolant is warming up prop Yes REMOVE BAC valve solenoid and INSPECT for contami
erly nation
• Check for proper engine coolant level No contamination present or solenoid cannot be cleaned:
• Check engine coolant hoses to and from the air REPLACE BAC valve solenoid RERUN Quick Test
valve for kinks, leaks, blockage, etc. Solenoid is contaminated and can be cleaned:
• Are the above checks OK? CLEAN as necessary
RERUN Quick Test. If DTC/symptom is still present,
REPLACE BAC valve solenoid
REMOVE breakout box
RECONNECT PCM
7 LACK OF HIGH IDLE WITH COLD ENGINE:

VERIFY THAT BAC VALVE IS NOT STUCK
CLOSED
• Key off Yes REFER to page F 3-115
• Remove the BAC valve from the engine
• When the valve is cold (room temperature), low No REPLACE BAC valve
through the air passage and check if air flows RE-EVALUATE symptom
freely
• Does air flow freely through the valve when
it is at room temperature?
46U0F3-063
F3-74
CODE No. 412 (ER) UNABLE TO CONTROL RPM DURING SELF TEST HIGH RPM CHECK
DESCRIP DTC 412 indicates that during Engine Running Self-Test, engine running Self-Test, engine rpm could not be con
TION trolled within the Self-Test upper limit band.
[Possible Cause]
• Open or shorted circuit • Items external to Idle Air Control system that could affect
• Throttle linkage binding engine rpm
• Improper idle airflow set • Damaged IAC solenoid
• IAC solenoid contamination • Damaged PCM
1 DIAGNOSTIC TROUBLE CODE (DTC) 412
CHECK FOR RPM DROP
• Connect the engine tachometer
• Start the engine
No Go to Step 3
• Disconnect IAC harness connection
• Does rpm drop or stall?
2 CHECK FOR OTHER DTCS

Are DTCs 213, 327, 332 present? Yes RECONNECT IAC solenoid
page F3-114
No Go to next Step
3 CHECK FOR OTHER DTCS

Are DTCs 172,173, present? Yes RECONNECT IAC solenoid
«• page F3-114
No Go to next Step
4 MEASURE IAC SOLENOID RESISTANCE

• Measure solenoid resistance
No REPLACE IAC solenoid
• Is resistance between 7.7 and 9.3 ohms (at
RERUN Quick Test
23°C {73°F})?
5 CHECK FOR INTERNAL SHORT TO IAC

SOLENOID CASE
• Measure resistance either IAC solenoid pin to
IAC housing
No REPLACE IAC solenoid
• Is resistance greater than 10 kft?
RERUN Quick Test

• Measure voltage between VPWR circuit at the
IAC solenoid vehicle harness connection and
RERUN Quick Test
battery ground
7 CHECK IAC CIRCUIT CONTINUITY

• Disconnect PCM and inspect both 60 pin con
nectors for damaged or pushed out pins, corro
• Install brake out box, leave PCM disconnected No SERVICE open circuit
• Measure resistance between test pin 21 at the REMOVE breakout box
breakout box and IAC circuit at IAC solenoid RECONNECT all components
vehicle harness connector RERUN Quick Test
l
• is resistance less than 5.00?
F3-75

8 CHECK IAC CIRCUIT FOR SHORTED GROUND
• Break out box installed, PCM disconnected
• Measure resistance between Test pin 21 and
REMOVE breakout box
Test pin 40, 46 and 60 at the breakout box
• Is each resistance greater than 10k£2?
RERUN Quick Test
9 CHECK IAC CIRCUIT FOR SHORTED POWER

• IAC solenoid disconnected No SERVICE short circuit
• Mesure voltage between Test pin 21 at the
REMOVE breakout box
breakout box and chassis ground
• Is voltage less than 1.0 volts? RERUN Quick Test
If DTC or symptom is present, REPLACE PCM
10 CHECK FOR IAC SIGNAL FROM PCM
• Reconnect IAC solenoid
• Connect a voltmeter between Test pin 21 and
No REMOVE IAC solenoid and VERIFY that it is not stuck
Test pin 40 at breakout box
open. If OK, REPLACE PCM.
• Start the engine REMOVE breakout box
• Slowly increase rpm to 3,000 rpm RERUN Quick Test
• Is voltage between 7 and 11.0V?
11 CHECK IDLE
Does engine idle speed appear normal? Yes REPLACE IAC solenoid
RERUN Quick Test
No Go to next Step
12 CHECK FOR PROBLEMS AFFECTING PROPER

ENGINE SPEED
• Check throttle linkage and/or speed control link Yes REPLACE IAC solenoid
age for binding RERUN Quick Test
• Inspect throttle body for proper operation
»*■ page F3-112
REMOVE breakout box
• Check engine vacuum hoses
RECONNECT PCM
«■ page F3-7
RERUN Quick Test
• Check for leaks around IAC solenoid
(i.e. mounting gasket, etc.)
• Are all the above check OK?
46U0F3-064
F3-76
CODE No. 452 INSUFFICIENT INPUT FROM VEHICLE SPEEDOMETER SENSOR (VSS)
DESCRIP Continuous Memory 452 indicates that sometime during the last 40 or 80 warm-up cycles, the PCM detected an
TION error in the vehicle speed sensor output signal
[Possible Cause]
• Damaged vehicle speedometer sensor
• Damaged harness circuit
• Damaged PCM
1 COMPLETE VSS DRIVE CYCLE:
VERIFY DTC OR DRIVE COMPLAINT
• Perform VSS Drive Cycle at least three times Yes Go to nest Step
as outlined below
VEHICLE SPEEDOMETER SENSOR (VSS)
DRIVE CYCLE:
— Record and clear Continuous Memory DTCs
— Worm engine to operating temperature
— Place gear selection in D range
— Obey all local traffic laws. Accelerate heavi
No Unable to duplicate and/or identify fault at this time
ly to 35 mph.
— Coast down to an idle and stop the vehicle For further diagnosis, REFER to page F3-167
— Shut the engine off
All others, CLEAR Continuous Memory
— After the drive cycle is completed, run KOEO
self-test and record the continuous Memory «• page F3-18
DTCs displayed
• Did Continuous Memory DTC 452 repeat?
2 CHECK CONTINUITY OF VSS HARNESS

CIRCUIT
pushed out pins, corrosion, loose wives, etc,
service as necessary.
• Install breakout box. PCM disconnected.
• Disconnect VSS
REMOVE breakout box
• Measure resistance between test pin 3 at the
breakout box and VSS (+) circuit at VSS vehi
cle harness connector REPEAT Step 1 INSPECTION to verify elimination of DTC
or the drive complaint
• Is each resistance within specification?
«• 1994 626/MX-6 BETM
3 CHECK VSS SIGNAL HARNESS CIRCUITS FOR

SHORTS TO POWER OR GROUND
• Key off Yes RECONNECT the PCM
• VSS disconnected Go to next Step
REMOVE breakout box
Test Pin 6,37 and 40 at breakout box
• Is each resistance within specification? RECONNECT all components
«• 1994 626/MX-6 BETM REPEAT Step 1 INSPECTION to verify the elimination of
DTC or drive complaint
4 CHECK VSS RESISTANCE
• VSS disconnected REPEAT Step 1 INSPECTION to verify the elimination of
• Measure the resistance of the VSS DTC or drive complaint
■S’ 1 9 9 4 b Z b /M A -b O t 1M
No REPLACE VSS
REMOVE breakout box
REPEAT Step 1 INSPECTION to verify the elimination of
DTC or drive complaint
46U0F3-217
F3-77
CODE No. 512 (Cont) ELECTRONIC CONTROL ASSEMBLY (ECA) (KAM) TEST
DESCRIP Continuous Memory DTC 512 indicates that the PCM has experienced a power interrupt in its Keep Alive
TION Memory (KAM) circuit
[Possible Cause]
• Powertrain Control Module (PCM) • Harness circuit: KPWR
1 CHECK KAPWR TO PCM
• Key off Yes SERVICE open circuit
• Disconnect PCM Inspect for damaged or REMOVE breakout box
pushed out pins, corrosion, loose wires, etc. RECONNECT PCM
Service as necessary RERUN Quick Test
No RECONNECT PCM
Pin 40 or 50 at the breakout box
Go to next Step
• While observing a voltmeter, grasp the EEC-IV
harness and wiggle, shake or bend a small sec
tion while working your way from the PCM to
the dash panel.
• Does the voltmeter indicate less than 10.5V?
2 INSPECT ENGINE COMPARTMENT WIRING

FOR PROPER ROUTING
• Inspect EEC-IV wiring for closeness to ignition Yes Replace PCM
components or wires. If EEC-IV wiring is close, REMOVE breakout box
reroute as necessary RERUN Quick Test
• Clear Continuous Memory DTC
■s- page F3-18
No REMOVE breakout box
RECONNECT PCM
• Wait five minutes to allow DTC 512 reset.
SERVICE other DTC’s as necessary
• Rerun Key On Engine Off Self-Test If none, testing is complete
• Is DTC 512 still present on retest?
NOTE: If KAPWR is interrupted to the PCM, for example when installing a breakout box, or when battery is dis- 46U0F3-065
connected, DTC 512 may be stored in Continuous Memory.
F3-78
CODE No. 519 (KOEO) STEERING PRESSURE SENSOR (SPS) CIRCUIT
DESCRIP DTC 519 indicates that the SPS circuit is closed
TION
[Possible Cause]
• Damaged SPS • Open harness
• Damaged PCM
1 DIAGNOSTIC TROUBLE CODE 519:
ATTEMPT TO ELIMINATE DTC 519
• Disconnect SPS
• Jumper SPS circuit to SIG RTN circuit at the
SPS switch vehicle harness connector
No REPLACE SPS
• Rerun Key On or Engine Off Self-Test
RERUN Quick Test
test Pin 46 at the breakout box
• Is DTC 519 still present?
2 CHECK SPS CIRCUIT FOR SHORTS

• Key off Yes SERVICE shot in harness
• SPS disconnected REMOVE breakout box
• Disconnect PCM inspect for damaged or RECONNECT all components
pushed out pins, corrosion, loose wires, etc. RE-EVALUATE symptom
No REPLACE PCM
REMOVE breakout box
• Measure resistance between Test pin 28 and
Test pin 46 at the breakout box
RE-EVALUATE symptom
rar section P
46U0F3-066
F3-79
CODE No. 521 (ER) STEERING PRESSURE SENSOR (SPS)

DESCRIP DTC 521 indicates that the SPS did not change state due to the switch staying either open or short
TION
[Possible Cause]
• Damaged SPS • Damaged PCM
• Open or shorted harness • Wheels turned not centered?
1 DTC CODE 521:
VERIFY OPERATOR INTERACTION
• Did you turn the steering wheel at least one- Yes Go to next Step
half turn within one to two seconds after
engine ID DTC?
No RERUN Quick Test
2 DETERMINE IF THE PCM CAN IDENTIFY A

CLOSED CIRCUIT
• Key off Yes REMOVE jumper
• Disconnect SPS Go to Step 4
• Jumper SPS circuit to SIG RTN circuit at the
SPS vehicle harness connector
No REMOVE jumper
• Run Key On Engine Off Self-test
Go to next Step
3 CHECK CONTINUITY OF SPS CIRCUITS

• SPS disconnected REMOVE breakout box
• Disconnect PCM Inspect for damaged or pushed RECONNECT all components
out pins, corrosion, loose wires, etc. Service as RE-EVALUATE symptom
necessary
• Install breakout box, leave PCM disconnected No SERVICE open in harness
REMOVE breakout box
breakout box and SPS circuit at the SPS vehicle RECONNECT all components
harness connector. RERUN Quick Test
• Is each resistance less than 5.0ft?
F3-80
4 CHECK SPS SWITCH STATE WITH ENGINE
RUNNING AND LOAD VS. NO LOAD
• Engine speed at idle Yes REMOVE breakout box
• Breakout box installed PCM connected Testing completed
• SPS switch connected
No REPLACE SPS
• Turn the steering wheel at least on-half turn then
REMOVE breakout box
back to center position
RERUN Quick Test
• Inspect SPS
«*■ page F3-116
• SPS OK?
46U0F3-072
F3-81
CODE No. 536 BRAKE SWITCH CIRCUIT FAILURE
DESCRIP DTC 536 indicates that when the brake pedal was depressed and released during Engine Running Self-Test the
TION stoplight switch signal did not cycle high and low
[Possible Cause]
• Brake pedal not depressed and released during the • Open brake switch/Stoplight circuit
Engine Running Self-Test • Short to GROUND or POWER
• Brake pedal depressed during entire Engine Running Self • Damaged stoplight switch
test • Damaged PCM
1 DIAGNOSTIC TROUBLE CODE 536 VERIFY
BRAKE WAS PRESSED
NOTE: It is necessary to depress and release Yes Go to next Step
the brake after the Dynamic Response Code 10
but before the brief WOT.
No RERUN Engine Running Self-Test
• Did you press brake during the Engine PRESS brake once during test
Running Self-Test?
2 CHECK OPERATION OF STOPLIGHTS

• Key on Yes Go to next Step
• Check stoplamp operation
• Does stoplights operate normally No If stoplights never on Go to Step 4
If stoplights always on Go to Step 5
3 CHECK FOR BOO CIRCUIT CYCLING
• Disconnect PCM Inspect for damaged or pushed REMOVE breakout box
out pins, corrosion, loose wires, etc. Service as RERUN Quick Test
necessary
• Measure voltage between brake switch Test Pin SERVICE open in stoplight switch circuit between PCM
No
and Test Pin 40 at the breakout box while and stoplight switch connection to stoplight circuit
depressing and releasing brake RERUN Quick Test
• Dose the voltage cycle?
4 CHECK FOR POWER TO BRAKE SWITCH

NOTE: Using a 12V test light, verify integrity of Yes VERIFY operation of stoplight switch. If OK, SERVICE
related fuses in fuse panel and check condition open circuit between stoplight switch and stoplight ground
of stoplight bulbs RECONNECT stoplight switch connector
RERUN Quick Test
• Key off
• Disconnect stoplight switch (located on brake
No SERVICE open B+ circuit to brake switch
pedal)
RECONNECT stoplight switch connector
• Measure voltage between B+ input to stoplight
RERUN Quick Test
switch and chassis ground
• Is voltage greater than 10 volts?
5 VERIFY BRAKE SWITCH IS NOT ALWAYS

CLOSED
• Stoplight switch disconnected
• Key on, engine off No VERIFY proper installation of brake switch. If OK,
• Are stoplights still on? REPLACE stoplight switch. RECONNECT harness con
nector. RERUN Quick Test
6 CHECK FOR SHORT TO POWER IN PCM

• Stoplight switch disconnected
• Disconnect Powertrain Control Module (PCM) No REPLACE PCM
• Key on, engine off RECONNECT stoplight switch
• Are stoplights still on? RERUN Quick Test
F3-82
7 CHECK FOR SHORT TO POWER IN
SHIFTLOCK ACTUATOR
• Key off Yes SERVICE short to power in stoplight switch/Stoplight circuit
• PCM disconnected RECONNECT PCM stoplight switch and accessories
• Stoplight switch disconnected RERUN Quick Test
• Disconnect shiftlock actuator, cruise control
module and ABS module (if equipped) to isolate
No SERVICE short in accessories (i.e. shiftlock actuator, ABS
stoplight switch wiring
module, etc.)
• Are stoplights still on?
RERUN Quick Test
46UQF3-067
F3-83
CODE No. 538 (ER) CYLINDER BALANCE TEST

DESCRIP Invalid cylinder balance test due the throttle movement
TION
SYSTEM FAILED TO RECOGNIZE BRIEF WOT
• Rerun Engine Running Self-Test. Be sure oper Yes Go to next Step
ator is familiar with the Engine Running format
which proceeds as follows:
— Activate Engine Running Self-Test
— Start engine
— ID Code start of test
No Dynamic Response Test passed
— Dynamic Response code 10; perform brief
SERVICE any other DTC(s) received as necessary
WOT
— Testing over
— DTC output begins
• Is DTC 538 still present?
2 DID ENGINE ACHIEVE GREATER THAN

2000 RPM
• During the WOT in the Dynamic Response Yes REPLACE PCM
Test, did the engine achieve greater than RERUN Quick Test
2000 rpm?
No CHECK for conditions that would prevent engine form
achieving greater than 2000 rpm (binding throttle linkage,
etc.) REFER to 1994 626/MX-6 BETM
46U0F3-068
F3-84
CODE No. 539 (KOEO) A/C, REAR WINDOW DEFROSTER ON DURING SELF-TEST
DESCRIP DTC 539 indicates that the A/C demand input to the Powertrain Control Module (PCM) was low (A/C on) during
TION KOEO Self-Test
CHECK A/C INPUT
• A/C off
• Disconnect Low pressure (LP) switch
No VERIFY operation of A/C demand switch
• Measure resistance between A/C demand
REFER to 1994 626/MX-6 BETM
switch side of LP switch vehicle harness connec
If OK, SERVICE short to ground
tor and chassis ground
RE-EVALUATE symptom
2 CHECK LOW PRESSURE (LP) SWITCH
• LP switch disconnected
• Measure resistance between chassis ground
No REPLACE LP switch
and both pins of LP switch
• Are both resistances greater than 10,000
RE-EVALUATE symptom
ohms?
3 CHECK ACD CIRCUIT TO PCM FOR SHORT TO

GROUND
• LP switch disconnected RECONNECT all components
• Disconnect Powertrain Control Module (PCM) RE-EVALUATE symptom
No SERVICE short to ground
• Measure resistance between PCM side of the
LP switch vehicle harness connector and chas
RE-EVALUATE symptom
sis ground
NOTE: Before entering this test, verify A/C selector is off. If A/C was on, rerun KOEO Self-Test. If DTC 539 is 46U0F3-069
present, continue with this test.
F3-85
CODE NO. 554 (KOEO) PRESSURE REGULATOR CONTROL (PRC) CIRCUIT FAULT
DESCRIP DTC 554 indicates a failure in the Pressure Regulator Control (PRC) solenoid circuit
TION
[Possible Cause]
• Damaged PRC solenoid • Short (to power or ground) in harness
• Damaged Vacuum hose(s) • Damaged PCM
• Open in harness
1 KOEO DTC 554: ENTER OUTPUT STATE
DIAGNOSTIC TEST MODE (DTM)
• Key off. Yes REMAIN in Output
• Disconnect electrical connector on the speed State DTM
control servo, if equipped Go to next Step
• Connect a voltmeter negative test lead to STO
circuit at Data Link connector (DLC) and posi
tive test lead to battery positive
• Jumper STI circuit to SIG RTN at DLC No DEPRESS throttle to
WOT and RELEASE
• Perform Key On Engine Off Self-Test until com
If STO voltage does not
pletion of Continuous Test Memory DTCs
• The voltmeter will indicate less than 1.0 volt go high leave equipment
hooked up and Go to
when test is completed
Step 8
• Depress and release throttle
• Does voltage increases?
2 CHECK FUEL PRESSURE REGULATOR

CONTROL SOLENOID ELECTRICAL
OPERATION
• Key on, engine off. Yes RECONNECT PRC
• Disconnect PRC solenoid solenoid
• Connect a voltmeter positive test lead to VPWR REMOVE jumper wire
pin and negative test lead to PRC circuit at the Go to next Step
PRC solenoid vehicle harness connector
• While observing the voltmeter depress and
release throttle several times to cycle solenoid
No REMOVE jumper wire
output
Go to Step 5
• Does PRC solenoid output voltage change
greater than 1.0 volt?
3 CHECK VACUUM SIGNAL BETWEEN FUEL

PRESSURE REGULATOR AND FPRC
SOLENOID
• Key off. Yes REMOVE vacuum gauge
• Disconnect and inspect vacuum hose between INSPECT the Pressure Regulator
fuel pressure regulator and PRC solenoid for «■ page F3-125
blockage, kinks, etc. Service as necessary
• Start and idle engine for about five minutes to
allow it to reach normal operating temperature
• Key off
No Remove vacuum gauge
• Tee in a standard vacuum gauge between fuel
Go to next Step
pressure regulator and PRC solenoid
• Start and idle engine while observing vacuum
gauge needle. Observe vacuum gauge needle
for about five minutes
• Did va cu um s ig n a l appear after a b o u t tw o
minutes o f engine idle?
F3-86
4 CHECK VACUUM SIGNAL BETWEEN FPRC
SOLENOID AND MANIFOLD VACUUM SOURCE
• Key off. Yes REPLACE FPRC solenoid
• Tee in a standard vacuum gauge between the REMOVE vacuum gauge
PRC solenoid and manifold vacuum source RERUN Quick Test and /
• Start and idle engine while observing the vacu or VERIFY elimination of
um gauge needle drive symptom
• Was any vacuum signal present?
No REPLACE vacuum hose
between PRC solenoid
and source vacuum
REMOVE vacuum gauge
RERUN Quick Test and /
or VERIFY elimination of
drive symptom
5 CHECK FPRC SOLENOID VPWR

• PRC solenoid disconnected
No SERVICE open in VPWR
• Measure voltage between VPWR at PRC
harness circuit
solenoid vehicle harness connector and battery
RECONNECT PRC
ground
solenoid
RERUN Quick Test and /
or VERIFY elimination
of drive symptom
6 CHECK FPRC CIRCUIT CONTINUITY
• PRC solenoid disconnected
sion, loose wire, etc. Service as necessary
REMOVE breakout box
RERUN Quick Test and / or
breakout box and PRC circuit at solenoid vehi
VERIFY elimination of drive
cle harness connector
symptom
• Is resistance less and 5.0 ohms?
7 CHECK FPRC CIRCUIT FOR SHORT TO

POWER AND GROUND
• PRC solenoid disconnected REMOVE breakout box
• Breakout box installed, PCM disconnected RECONNECT all
• Measure resistance between Test Pin 32 and components
Test Pins 37 and 57 at the breakout box RERUN Quick Test and /
• Measure resistance between Test Pin 32 and or VERIFY elimination of
Test Pins 40, 46 and 60 at the breakout box drive symptom
ohms?
REMOVE breakout box
RERUN Quick Test and / or
VERIFY elimination of drive
symptom
F3-87

8 CHECK FOR DIAGNOSTIC TROUBLE CODES
(DTC) 121, 122 or 123
• Key off. Yes Go to Quick Test and
• Perform Key On Engine Off Self-Test SERVICE appropriate
• Are any of these DTC’s (121,122 or 123) pre DTC as instructed
sent?
DTC Go to next step
n
No Go to Pinpoint Test A
DTCs Step 1
is- page F3-108
9 CHECK THROTTLE LINKAGE
• Check throttle and throttle linkages for sticking Yes REPLACE TPS
and binding RERUN Quick Test
• Is throttle OK?
RERUN Quick Test
NOTE: If vehicle is equipped with speed control, the speed control servo must be electrically disconnected. This 46Uofx -o75
prevents the speed control system from affecting the throttle plate movement daring Output State DTM.
Quick Test or Output State DTM.
F3-88
CODE No. 559 (KOEO) AIR CONDITIONING ON RELAY (ACON) CIRCUIT
DESCRIP DTC 559 indicates an A/C relay primary circuit fault
TION
[Possible Cause]
• Open or shorted circuit
• Damaged A/C relay
• Damaged Powertrain Control Module (PCM)
CHECK FOR IGN RUN VOLTAGE TO A/C RELAY
• Disconnect A/C relay
• Key on
No VERIFY condition of related fuses
• Measure voltage between IGN RUN circuit at
If OK, SERVICE open circuit
A/C relay vehicle harness connector and chas
sis ground
RERUN Quick Test.
2 CHECK A/C RELAY

• A/C relay disconnected
• Check A/C relay coil resistance:
— Measure resistance between ACON pin and
IGN RUN pin at the A/C relay
• Check A/C relay for internal shorts:
— Measure resistance between ACON pin and
the following pins at the A/C relay: B+, No REPLACE A/C relay
power-to-clutch, ground RECONNECT all components
• Are all resistance checks OK? RERUN Quick Test
<3-1994 626/MX-6 BETM
3 CHECK ACON CIRCUIT FOR SHORT TO POWER

sion, loose wire, etc. Service as necessary.
REMOVE breakout box
RERUN Quick Test
• Is voltage specification?
o ' 1994 626/MX-6 BETM
4 CHECK ACON CIRCUIT FOR SHORT TO

GROUND
No SERVICE short to ground
REMOVE breakout box
• I s r e s is t a n c e gre a te r th a n 10,0 0 0 o h m s ?
RERUN Quick Test

5 CHECK ACON CIRCUIT CONTINUITY
• A/C relay disconnected REMOVE breakout box
• Measure resistance between Test Pin 54 at RERUN Quick Test
breakout box and ACON circuit at A/C relay
REMOVE breakout box
RERUN Quick Test
46U0F3-078
F3-90
CODE No. 563 (KOEO) HIGH SPEED ELECTRODRIVE FAN (HEDE) CIRCUIT
564 (KOEO) LOW SPEED ELECTRODRIVE FAN (EDF) CIRCUIT
DESCRIP DTC 563 indicates an High Fan Control (HFC) primary circuit failure
TION DTC 564 indicates an Low Fan Control (LFC) primary circuit failure
[Possible Cause]
• Open or short circuit
• Damaged fan relay
« Damaged Powertrain Control Module (PCM)
DIAGNOSTIC TROUBLE CODE (DTC)
NOTE: During diagnosis, use the chart below to Yes Go to next Step
determine the correct pin number, circuit and
relay being tested
Circuit/
Code Test Pin Number
Relay
563 HFC 31
564 LFC 13
No VERIFY integrity of fuse/fuse link for IGN Start/Run voltage
supply to LFC/HFC relay
If OK, SERVICE open circuit
• Key off
RECONNECT LFC/HFC relay
• Disconnect LFC or HFC relay
RERUN Quick Test
• Key on
• Measure voltage between IGN Start/Run circuit
at the LFC/HFC relay vehicle harness connec
tor and chassis ground
• Is voltage greater than/0.5 volts?
ENTER OUTPUT STATE DIAGNOSTIC TEST

MODE (DTM)____________________________
NOTE: USE VOM/DVOM for this Step Yes REMAIN in Output State DTM
Go to next Step
Key off, wait 10seconds
DVOM on 20 volt scale
Disconnect electrical connector on the speed
control servo, if equipped
Connect a voltmeter negative test lead to STO
at the Data Link Connector (DLC) and positive
No DEPRESS throttle to WOT and RELEASE
test lead to the battery positive post
If STO voltage does not go high, leave equipment hooked
Jumper STI to SIG RTN at the Data Link
up and Go to Step 7
Connector
Perform Key on Engine off Self-Test until the
completion of the Continuous Memory DTCS
The voltmeter will indicate less than 1.0 volt
when test is complete
Depress and release throttle
Does voltage increase to greater than 10.5
volts?
F3-91

3 CHECK FOR LFC/HFC CIRCUIT CYCLING
• Key off Yes REPLACE LFC or HFC relay
• LFC or HFC relay disconnected REMOVE jumper
• DVOM on 20 volt scale RERUN Quick Test
• Connect a voltmeter positive test lead to the
LFC or HFC circuit at the LFC/HFC relay vehi
cle harness connector
• Depress and release throttle to cycle outputs off
• While observing DVOM, depress throttle again.
For LFC, wait until the MIL flashes once No REMOVE jumper
(10seconds). For HFC, wait until the MIL flash Go to next Step
es twice (15 seconds). Release throttle. The
LFC or HFC output is now “on”. To cycle “off”,
depress and release throttle.
• Does voltage cycle high ad low (about 1.0
volt change)?
4 CHECK CONTINUITY OF LFC/HFC CIRCUIT

• LFC or HFC relay disconnected
• For DTC 563:
— Measure resistance between applicable Test
REMOVE breakout box
Pin at the breakout box and HFC circuit at
the HFC relay vehicle harness connector
RERUN Quick Test
• For DTC 564:
— Measure resistance between applicable Test
Pin at the breakout box and LFC circuit at
the LFC relay vehicle harness connector
5 CHECK LFC/HFC CIRCUIT FOR SHORT TO

POWER
• LFC or HFC relay disconnected
• Measure voltage between applicable Test Pin
REMOVE breakout box
(HFC or LFC) at the breakout box and battery
negative post.
RERUN Quick Test
• Is voltage less than 1.0 volts?
If DTC is still present
REPLACE PCM
F3-92
6 CHECK LFC/HFC CIRCUIT FOR SHORT TO
GROUND
• LFC or HFC relay disconnected RECONNECT all components
• Measure resistance between applicable Test RERUN Quick Test
Pin (LFC or HFC) and Test Pins 40 and 60 at
the breakout box.
• Is resistance greater than 10,000 ohms? No SERVICE short circuit
REMOVE breakout box
RERUN Quick Test

• Check throttle and throttle linkages for sticking Yes Replace TPS
• Is throttle OK?
RERUN Quick Test
46U0F3-079
F3-93
CODE No. 565 (KOEO) PURGE SOLENOID VALVE CIRCUIT FAULT

DESCRIP DTC 565 indicates a failure in the purge solenoid valve circuit
TION
[Possible Cause]
• Damaged purge solenoid valve • Shorted (power or ground) harness
• Open harness • Damaged Powertrain Control Module (PCM)
CHECK PURGE SOLENOID VALVE
RESISTANCE
• Disconnect appropriate purge solenoid valve
• Inspect purge solenoid valve?
No REPLACE purge solenoid valve
• Purge solenoid valve OK?
RERUN Quick Test
page F3-139

• Appropriate purge solenoid valve disconnected
• Measure voltage between VPWR at the purge
solenoid valve vehicle harness connector and No SERVICE open harness circuit
battery ground RECONNECT purge solenoid valve
• Is voltage greater than 10.5 volts? RERUN Quick Test
3 CHECK CONTINUITY OF PURGE SOLENOID

VALVE CIRCUIT
• Install breakout box, leave PCM disconnected No SERVICE open circuit
• Measure resistance between Test Pin 11, (15, REMOVE breakout box
31 or Pin 54 refer to schematic) at the purge RECONNECT all components
solenoid valve vehicle harness connector RERUN Quick Test
4 CHECK PURGE SOLENOID VALVE CIRCUIT

FOR SHORT TO GROUND
• Measure resistance between Test Pin 11 (15,
31 or Pin 54 refer to schematic) and Test Pins No SERVICE short to ground
40, 46 and 60 at the breakout box. REMOVE breakout box
• Is each resistance greater than 10,000 RECONNECT all components
ohms? RERUN Quick Test
5 CHECK PURGE SOLENOID VALVE CIRCUIT

FOR SHORT TO POWER
• Purge solenoid valve disconnected REMOVE breakout box
• Measure resistance between Test Pin 11 (15, RERUN Quick Test
31 or Pin 54 refer to schematic) and Test Pins
37 and 57 at the breakout box
REMOVE breakout box
ohms? RECONNECT all components
RERUN Quick Test
46U0F3-080
F3-94
CODE No. 571 (KOEO) EGR SOLENOID VALVE (VENT) OUTPUT CIRCUIT
572 (KOEO) EGR SOLENOID VALVE (VACUUM) OUTPUT CIRCUIT
DESCRIP DTC 571 indicates a failure in the solenoid circuit
TION DTC 572 indicates a failure in the EGRV solenoid circuit
[Possible Cause]
• Damaged EGRA/EGRV solenoid • Open in harness circuit
• Short in harness circuit • Damaged Powertrain Control Module (PCM)
1 DIAGNOSTIC TROUBLE CODE (DTC) 571 AND
DIAGNOSTIC TROUBLE CODE (DTC) 572:
CHECK EGR/EGR SOLENOID RESISTANCE
• Key off Yes Go to nest Step
• Disconnect EGRA/EGRV solenoid
• Inspect solenoid valves
No REPLACE appropriate solenoid
• Solenoid valves OK?
RERUN Quick Test
«■ page F3-135

• Solenoid disconnected
• Measure resistance between battery negative No SERVICE open circuit
post and VPWR circuit at the solenoid vehicle RECONNECT solenoid
harness connector RERUN Quick Test
3 CHECK SOLENOID CIRCUIT CONTINUITY

• Solenoid disconnected
For EGRA solenoid:

breakout box and EGRA circuit at the solenoid
REMOVE breakout box
RERUN Quick Test
For EGRV solenoid:
breakout box and EGRV circuit at the solenoid


4 CHECK SOLENOID CIRCUIT FOR SHORT TO
POWER AND GROUND
• Solenoid disconnected REMOVE breakout box
• Breakout box installed, PCM disconnected RECONNECT solenoid
RERUN Quick Test
For EGRA solenoid:
Test Pins 40,46 and 60 at the breakout box
For EGRV solenoid: REMOVE breakout box
• Measure resistance between Test Pin 33 and RECONNECT all components
Test Pins 40, 46 and 60 at the breakout box RERUN Quick Test

ohms?
46U0F3-081
F3-96
Pinpoint Test A
1 ATTEMPT TO CRANK ENGINE
• Does engine crank? Yes Go to next Step
No INSPECT the starter and the ignition switch

«*■ section G
«■ section T
2 CHECK FOR VREF AT THROTTLE POSITION
(TP) SENSOR
• Key off Yes RECONNECT TPS
• Disconnect TPS Go to next Step
RTN circuit at the TPS vehicle harness connec No Go to Pinpoint Test C Step 1
«• page F3-104
tor
3 CHECK FOR SPARK AT PLUGS

• Disconnect the spark plug wire to any accessible Yes Go to next Step
cylinder
• Connect spark tester between spark plug wire
and engine ground
• Crank engine and check for spark No Go to Step 11
• Reconnect the spark plug wire to the spark plug
• Was spark present and consistent?
4 SPOUT SIGNAL VERIFICATION

out box No Go to next Step
• Ensure timing switch is in “Computed” position
on breakout box
Pins 40 and 60 at the breakout box during crank
F3-97

5 CHECK SPOUT AND PIP CIRCUIT FOR SHORT
TO POWER
• Key off Yes SERIVCE short circuit to the START circuit or to the VPWR
• Breakout box installed circuit in the harness
• Disconnect PCM REMOVE breakout box
• Disconnect ICM and CPS RECONNECT all components
• Key on RERUN Quick Test
• Measure voltage between Test Pin 36 (SPOUT)
at breakout box and battery negative post
No Go to next Step
• Measure voltage between Test Pin 56 (PIP) at
breakout box and battery negative post
6 CHECK SPOUT AND PIP CIRCUITS FOR

SHORTS TO GROUND
• Disconnect PCM
• Disconnect ICM and CPS
• Measure resistance between Test Pin 36
(SPOUT) and Test Pins 16, 20, 40, 46, 60 (short
REMOVE breakout box
to GROUND) and 56 (short to PIP) at breakout
box
RERUN Quick Test
• Measure resistance between Test Pin 56 (PIP)
If vehicle does not start
and Test Pins 16, 20, 46, 60 (short to GROUND)
Go to next Step
at breakout box
7 ISOLATE SHORT(S) IN PCM

• Key off Yes RECONNECT all components
• Breakout box installed Go to next Step
• Disconnect PCM to breakout box
• Disconnect ICM and CPS
(SPOUT) and Test Pins 37 and 57 (short to
POWER). Also Test Pins 40 and 60 (short to
No REPLACE PCM
GROUND) at breakout box
REMOVE breakout box
• Measure resistance between Test Pin 56 (PIP)
and Test Pins 37 and 57 (short to POWER) at
RERUN Quick Test
breakout box
8 CHECK CONTINUITY OF PIP CIRCUIT

• Measure voltage between Test Pin 56 and Test RECONNECT all components
Pin 40 /60 at breakout box at idle. RERUN Quick Test
• Is voltage approx. 7 volts?
No Go to next Step
F3-98
• Disconnect PCM •a- section G
• Disconnect ICM and CPS sensor
breakout box and PIP circuit at the following
REMOVE breakout box
connectors as appropriate: ICM, CPS sensor
RERUN Quick Test

WARNING: IF FUEL STARTS LEAKING, TURN Yes Go to Pinpoint Test D Step 1
KEY OFF IMMEDIATELY. NO SMOKING «*■ page F3—107
• Connect fuel pressure gauge

• Note initial pressure reading
• Observe pressure gauge as you pressurize fuel
system. (Turn key to RUN for one second, then No TURN key OFF
turn key to OFF. Wait 10 seconds. Repeat five REFER to the Fuel / Engine group in the Service Manual
times.)
• Does fuel pressure increase?

• Disconnect Crankshaft Position (CPS) sensor
• Measure voltage between VPWR circuit at CPS No Go to Step 21
sensor vehicle harness connector and battery
negative post.
12 CHECK FOR SPARK AT COIL

• Remove high tension coil wire from distributor Yes CHECK the electronic ignition system
and install spark tester es- section G
• Check for spark while cranking
• Reconnect high tension coil wire to distributor
No Go to next Step
• Was spark present during crank?
13 CHECK CONTINUITY OF IGN GND CIRCUIT

• Disconnect Powertrain Control Module (PCM) 60
pin connector. Inspect for damaged or pushed
out pins, corrosion, loose wires, etc. Service as
necessary
• Disconnect ICM module connector
REMOVE breakout box
breakout box and ICM or CPS sensor vehicle
RERUN Quick Test
harness connector IGN GND circuit
14 ISOLATION OF PROBLEM TO SPOUT CIRCUIT

• Reconnect ICM and CPS sensor, as applicable Yes Timing switch to “Computed” position on breakout box
• Breakout box installed Go to Step 19
• Connect PCM to breakout box
• Timing switch to “DIST" position on breakout box
No Go to next Step
• Attempt to start vehicle
• Does the vehicle start?
F3-99

15 CHECK SPOUT SIGNAL
• Key on, engine off Yes EEC system OK
• Timing switch to “DIST" position on breakout box RECONNECT all components
• Measure voltage between Test Pin 36 at break CHECK the electronic ignition system
out box and battery negative post during crank «■ section G
No REPLACE timing switch to “Computed" position and go to
next Step
16 CHECK SPOUT AND PIP CIRCUITS FOR SHOR1
TO POWER
• Key off Yes SERVICE short circuit to the START circuit or to the
• Breakout box installed START circuit or to the VPWR circuit in the harness
• Disconnect PCM REMOVE breakout box
• Disconnect ICM and CPS sensor RECONNECT all components
• Key on RERUN Quick Test
• Measure voltage between Test Pin 36 (SPOUT)
No Go to next Step
at breakout box and battery negative post
• Measure voltage between Test Pin 56 (PIP) at
breakout box and battery negative post.
17 CHECK SPOUT AND PIP CIRCUITS FOR

SHORTS TO GROUND
• Disconnect PCM
(SPOUT) and Test Pins 16, 20, 40, 60 (short to No SERVICE short circuit
GROUND) and 56 (short to PIP) at breakout box REMOVE breakout box
• Measure resistance between Test Pin 56 (PIP) RECONNECT all components
and Test Pins 16, 20, 40, 46, 60 (short to RERUN Quick Test
GROUND) at breakout box If vehicle does not start, Go to next Step
18 ISOLATE SHORTS IN PCM

• Key off Yes RECONNECT all components
• Breakout box installed Go to next Step
(SPOUT) and Test Pins 37 and 57 (short to
POWER). Also Test Pins 40 and 60 (short to
No REPLACE PCM
GROUND) at breakout box REMOVE breakout box
• Measure resistance between Test Pin 56 (PIP) RECONNECT all components
and Test Pins 37 and 57 (short to POWER).
RERUN Quick Test
Also Test Pins 40 and 60 (short to GROUND) at
breakout box
F3-100
19 CHECK PIP SIGNAL
• Breakout box Installed, PCM connected REMOVE breakout box
• Measure voltage between Test Pin 56 and Test RECONNECT all components
Pin 40 / 60 at breakout box RERUN Quick Test
• Crank engine, record reading
No Go to next Step

• Disconnect PCM CHECK the electronic ignition system
• Disconnect ICM and CPS sensor section G
breakout box and PIP circuit at the following
REMOVE breakout box
connectors as appropriate: ICM, SPS sensor
and / or GCM
RERUN Quick Test
21 CHECK VPWR CONTINUITY

• Key off Yes Go to Pinpoint Test B Step 1
• Disconnect Powertrain Control Module (PCM) «■ page F3-102
• Install breakout box, leave PCM disconnected No SERVICE open circuit
• CPS disconnected REMOVE breakout box
• Measure resistance between VPWR circuit at RECONNECT all components
Test Pin 37 / 57 at the breakout box RERUN Quick Test
46U0F3-082
F3-101
Pinpoint Test B
1 CHECK BATTERY VOLTAGE
• Measure voltage across battery terminals
No SERVICE discharged battery
REFER to Charging / Electrical Group

out box
• Measure resistance between battery negative No SERVICE open in PWR GND circuit
post and Test pins 40 and 60 at the breakout REMOVE Breakout box
box RECONNECT PCM
• Is each resistance less than 5.0 ohms? RERUN Quick Test
3 CHECK FOR OPEN BETWEEN SIG RTN AND

PWR GND CIRCUITS AT PCM
• Breakout box installed, PCM connected
• Measure box installed, PCM connected
No REPLACE PCM
REMOVE breakout box
RERUN Quick Test
4 CHECK SIG RTN CIRCUIT CONTINUITY

• Measure resistance between Test PIP 46 at the
breakout box and SIG RTN circuit in the Data No SERVICE open in SIG RTN circuit
Link Connector (DLC) REMOVE breakout box
• Is resistace less than 5.0 ohms RECONNECT PCM
RERUN Quick Test
5 CHECK KAPWR CIRCUIT VOLTAGE AT EEC
POWER RELAY
• Disconnect EEC power relay
• Measure voltage between KAPWR circuit at the No SERVICE open in KAPWR circuit between EEC power
EEC power relay connector and battery negative relay and battery positive post
post REMOVE breakout box
• Is voltage greater than 10.5 volts? RECONNECT all components
RERUN Quick Test
F3-102
6 CHECK IGNITION CIRCUIT VOLTAGE AT EEC
POWER RELAY
NOTE: Vehicles equipped with Power Yes Go to next Step
Distribution (Network) Boxes have a diode that
serves as power surge protection for the Ignition
Control Module (ICM) and ignition switch. A
continuity check across this diode may be nec
essary for a No Start / No DTC situation before
proceeding with this Pinpoint Test
No SERVICE open in ignition switch circuits
• Breakout box installed, PCM connected. REMOVE breakout box
• EEC power relay disconnected
RERUN Quick Test
• Measure voltage between the battery negative
post and ignition switch circuit at the EEC power
relay connector

• Breakout box installed, PCM connected.
• EEC power relay disconnected
• Measure resistance between PWR GND circuit
at the EEC power relay vehicle harness connec No SERVICE open circuit
tor and battery vehicle harness connector and REMOVE breakout box
battery negative post RECONNECT all components
• Is the resistance less than 10 ohms? RERUN Quick Test
8 CHECK VPWR CIRCUIT CONTINUITY

• Breakout box installed, PCM connected.
• EEC power relay disconnected No SERVICE open in VPWR circuit between the EEC power
• Measure resistance between Test Pin 37 / 57 at relay connector and PCM
the breakout box and the VPWR terminal of the REMOVE breakout box
EEC power relay connector RECONNECT all components
• Is resistance less than 5.0 ohms? RERUN Quick Test
9 CHECK VPWT CIRCUIT VOLTAGE

• Key off Yes SERVICE open or short to ground in VPWR circuit
• Breakout box installed, PCM connected. between PCM and EEC power relay
• Install EEC power relay REMOVE breakout box
• Key on, engine off RECONNECT PCM
• Measure voltage between Test Pin 37 / 57 and RERUN Quick Test
Test pins 40 / 60, at breakout box No REPLACE EEC power relay
• Is voltage greater than 10.5 volts? REMOVE breakout box
RECONNECT PCM
RERUN Quick Test
46U0F3-082
F3-103
Pinpoint Test C
1 CHECK VEHICLE BATTERY POWER CIRCUIT
• Inspect for damaged or pushed out pins, corro
out box
No Key off, RECONNECT sensor
breakout box and SIG RTN circuit in the Data
Link Connector. Note voltage Go to Step 1
• Measure voltage across battery terminals. Note «■ page F3-102
voltage
• Are both voltages greater than 10.5 volts, and
are both voltages within 1.0 volt of each
other?
2 CHECK VREF VOLTAGE

• Key on, engine off Greater than 6.0 Go to Step 4
• Breakout box installed, PCM connected volts
Less than 4.0 Go to Step 5
Pin 46 at the breakout box volts
• What is the voltage?
Between 4.0 Go to next Step
volts and 6.0 volts
3 CHECK VREF AND SIG RTN CIRCUITS FOR
CONTINUITY
• Key off Yes Reference voltage OK
• Sensor that sent you here disconnected REMOVE breakout box
• Disconnect PCM RERUN Quick Test
breakout box and VREF circuit at vehicle har
No SERVICE open in VREF or SIG RTN circuits
ness connector of the sensor that sensor you
REMOVE breakout box
here
RERUN Quick Test
breakout box and SIG RTN circuit at vehicle har
ness connector of the sensor that sent you here
F3-104
4 CHECK FOR EXCESS VOLTAGE ON VREF
CIRCUIT
• Disconnect PCM RECONNECT all components
• Disconnect SUPER STAR n Tester RERUN Quick Test

SUPER STAR n must be disconnected. Due to
the circuitry of the STAR Tester and the vehicle,
voltage can be fed to the VREF circuit giving the No SERVICE short to power in vehicle harness
false indication of a short to power REMOVE breakout box
RECONNECT PCM and sensor
RERUN Quick Test
breakout box and battery ground
5 CHECK FOR SHORTED THROTTLE POSITION

SENSOR (TPS)
• Key off Yes Key off, RECONNECT TPS:
• Disconnect Throttle Position sensor (TPS) from For vehicle equipped with EGR function sensor:
vehicle harness go to Step
• Measure voltage between Test Pin 26 and Test For all other vehicles:
Pin 46 at the breakout box go to Step 7
• Is voltage less than 4.0 volts? No REPLACE TPS
REMOVE breakout box
RERUN Quick Test
6 CHECK FOR SHORTED EVP / PFE / DPFE
SENSOR
• Key off Yes Key off, RECONNECT EGR function sensor;
• Breakout box installed, PCM connected go to next Step
• Disconnect EGR function sensor
No REPLACE EGR function sensor
REMOVE breakout box
RERUN Quick Test

7 CHECK VREF CIRCUIT FOR SHORT TO
GROUND
• Key off Yes SERVICE short to ground
• Disconnect PCM RECONNECT all components
• Disconnect TPS RERUN Quick Test
• Disconnect EGR function sensor if so equipped
No REPLACE PCM
REMOVE breakout box
Test Pins 20, 40, 46 and 60 at the breakout box
• Is any resistance less than 1000 ohms?
RERUN Quick Test
46U0F3-084
F3-106
Pinpoint Test D
1 IAC CHECK
• Attempt to start engine at part throttle Yes Go to Code No. 412
• Will engine run smooth at part throttle? (Step 4)
•a- page F3-75
No Go to next Step
2 CHECK FOR RPM DROP

• Key off Yes Reconnect IAC solenoid
• Connect engine tachometer Go to next Step
• Start engine
No Go to Code No.412
• Disconnect IAC solenoid
(Step 4)
• Does rpm drop or stall?
page F3-75
3 CHECK EGR VACUUM
NOTE: The next two test steps will attempt to Yes For vehicles with EGRV
determine if the EGR system is the cause of the sensors:
current symptom and / or NO START Go to Step 5
• Disconnect vacuum line at EGR control valve,

and plug the vacuum line
• Start engine
NOTE: When verifying drive symptom, a DTC

No Go to next Step
may possibly be stored in memory; erase
Continuous Memory before proceeding with
procedure.
«• page F3-20
For Drive Symptom:

- Was drive symptom eliminated?
For No Start:
- Does engine start?
4 CHECK EGR CONTROL VALVE

• Check EGR control valve for housing leaks or Yes RECONNECT original
EGR gasket blow-by. Service as necessary EGR control valve
• Remove EGR control valve and check for prop Go to Code No 172
er seating and 173 (Step 2)
• Does EGR control valve seat properly (fully «• page F3-45
closed)? No RECONNECT original
EGR control valve
INSPECT EGR control valve
page F3-135
5 CHECK VACUUM HOSE BETWEEN EGRV

SOLENOID AND EGR CONTROL VALVE
• Carefully check EGR vacuum hose from EGR Yes CHECK EGRV solenoid
control valve to EGRV solenoid for obstructions, filter for obstructions
cracks, loose connectors, blockage, kinks, REPLACE as necessary
leaks, etc If OK, REPLACE EGRV
• Is vacuum hose in good condition? solenoid assembly
RECONNECT vacuum
hose. RERUN Quick Test
No SERVICE vacuum hose
as necessary
RERUN Quick Test
46U0F3-085
F3-107
Pinpoint Test E

1 CHECK FOR DIAGNOSTIC TROUBLE CODES
(DTC) 121,122 or 123
NOTE: If vehicle is equipped with speed control, Yes Go to Quick Test and
the speed control servo must be electrically dis SERVICE appropriate
connected. This prevents the speed control DTC as instructed
system from affecting the throttle plate move
ment during Output State DTM. Rerun Quick
Test or Output State DTM
DTC Go to next Step
• Key off.
111
• Perform Key On Engine Off Self-Test
NOTE: If additional information is required on

Output State DTM No CHECK the wiring from data link connector to PCM
page F3-20 DTCs
• Are any of these DTC’s 121,122 or 123) pre

sent?

• Check throttle and throttle linkages for sticking Yes REPLACE TPS
• Is throttle OK?
RERUN Quick Test
46U0F3-Q86
F3-108
Pinpoint Test F
1 VEHICLE PREPARATION AND EQUIPMENT
HOOKUP
• Apply parking brake Yes Go to next Step
• Place shift lever firmly in PARK
• Block drive wheels
• Turn off all electrical loads
• Connect appropriate test equipment to the Data
Link Connector in order to run Self-Test
No REPEAT this test Step
NOTE: If additional information is required for
vehicle Preparation and Equipment Hookup,
refer to page F3-15
• Is vehicle prepared to run Self-Test?
2 PERFORM KOEO SELF-TEST

• Start engine and idle until vehicle is at operating Yes Go to next Step
temperature. If engine does not start or stalls,
continue to perform KOEO Self-Test
• Key off, wait 10 seconds
• Activate KOEO Self-Test
No Go to the EEC-IV DTC charts at the
NOTE: If additional information is required for
end of this section for Pinpoint Test
KOEO Self-Test, refer to page F3-15
direction
• Record all KOEO and Continuous Memory
Diagnostic Trouble Codes (DTC’s)
• Key off
• Is a PASS DTC “ 111” present in KOEO Self-
Test?
3 CHECK BASE TIMING

• Transaxle in PARK
• Turn off electrical loads (A/C, heater, etc.)
• Disconnect the in-line SPOUT connector
• Start engine (do not use a remote starter, only
use the ignition key to start engine)
NOTE: If engine stalls, reconnect SPOUT con

nector and go to Pinpoint Test Step 2
«■ page F3-107
No ADJUST as necessary and
If engine is now a NO START (will not “Fire” at RERUN Quick Test. If unable
all), reconnect SPOUT connector and CHECK to adjust to specification, check
the electronic ignition system proper distributor orientation,
«■ section G timing chain / belt, etc.
«■ section B
«■ section G
• Check ignition timing. (For use exhaust side
plug. If timing light does not “light”, go to Step
5)
page F3-13
• Is base timing within specification?

**■ page F3-13
46U0F3-216
F3-109

4 VERIFY PCM CONTROL OF TIMING
• In-line SPOUT connector disconnected Yes Go to Diagnostic next Step
• Start engine and let idle
• Reconnect the in-line SPOUT connector
• Does timing change from base timing when No Go to Diagnostic next Step
the SPOUT connector is reconnected? While performing the Engine
Running (ER) Self-Test, CHECK
for DTC 213
If ER DTC 213 is present:

Disregard any other codes. Refer
to the EEC-IV DTC charts for proper
Pinpoint Test Step direction for the
DTC 213
If ER DTC 213 is NOT present:
Continue as directed in Diagnostic
next Step
5 PERFORM ENGINE RUNNING SELF-TEST

• Start engine and idle until vehicle is at operating Yes Go to Diagnostic next Step
temperature
• Turn engine off
• Activate Engine Running Self-Test
• Start engine
NOTE: If engine stalls during Engine Running

Self-Test, go to Pinpoint Test D Step 2.
page F3-107
No Go to the EEC-IV DTC charts
If additional information is required for Engine
at the end of this section for
Running Self-Test refer to page F3-17
Pinpoint Test direction
FMEM: Failure Mode Effects Management
• Record all service codes displayed
NOTE: Engine Running DTC 998 indicates

vehicle is in FMEM mode and Engine Running
Self-Test cannot be performed. Go to the EEC-
IV DTC charts at the end of this section for DTC
998 direction (Refer to section K2)
• Is a PASS DTC (111) received during Engine

Running Self-Test?
6 ADDRESS CONTINUOUS MEMORY DTC

• Was a Continuous Memory PASS DTC (111- Yes Refer to page F3-167
10-111) received during Key On Engine Off
Self-Test?
No Go to the EEC-IV DTC charts at
the end of this section for Pinpoint
Test direction
46U0F3-216
F3-110
INTAKE AIR SYSTEM
COMPONENT PARTS
2. Inspect the intake air system components and repair or replace them as necessary.
1. Fresh air duct 7. Resonance chamber No.2

Inspect for damage Inspect for damage
2. Resonance chamber No.1 Installation note................. ....page F3-112
Inspect for damage 8. Accelerator cable
3. Air cleaner hosing Inspection / Adjustment..... ....page F3-113
Inspect for excessive dirt and damage 9. Throttle body
4. Air cleaner element Inspection......................... ....page F3-112
Inspection............................. . page F3- 12 10. BAC valve
5. Mass airflow sensor Inspection.......................... .... page F3-115
Inspection............................. . page F3-160 11. Intake manifold bracket
6. Air hose 12. Intake manifold
Inspect for damage Removal note.................... page F3-112
F3—111
THROTTLE BODY
Inspection
1. Check the throttle body for wear, deposits, and coolant
leakage.
2. Verify that the throttle valve moves smoothly when the
throttle lever is moved from fully closed to fully open.
3. Replace the throttle body if necessary.
Caution
• Do not rem ove the thin seal c o a tin g form the
throttle valve or bore.
INTAKE MANIFOLD
Removal Note
1. Tighten the bolts in the order shown in the figure.
Tightening torque:
19— 25 N m {1.9— 2.6 kgf m, 14— 1 8 ftlb f}
2. Refill the radiator with the specified engine coolant.

3. Check for engine coolant leakage.
16E0F1-084
RESONANCE CHAMBER No.2
Installation Note
1. Slide the hose clamp onto the hose and push it onto
resonance chamber No.2.
16E0F1-360
2. Rotate the hose and hook it securely onto the locating
knob.
16E0F1-362
F3-112
ACCELERATOR PEDAL
16E0F1-086
1. Accelerator cable 4. Clip

Inspection / Adjustment.....................below 5. Accelerator pedal
2. Cruise actuator cable 6. Return spring
Adjustment.................................. section T 7. Bracket
3. Retainer
ACCELERATOR CABLE
Free play: 1.5— 4.0mm {0.06— 0.16 in}
3. If not as specified, adjust the cable free play by turning

stopper B while pressing lock button A with the throttle
valve fully closed.
F3-113
DESCRIPTION
■BAC VALVE
THROTTLE
POSITION
SENSOR
STEERING
PRESSURE
SENSOR
DATA LINK
■CONNECTOR (STO)
DATA LINK
CONNECTOR
(STI)
D IS T R IB U T O R
TRANSMISSION RANGE SENSOR
36U0F1-246
improve startability, warm-up, idle smoothness, and drivability.
This system replaces the dashpot to control deceleration.
F3-114
SYSTEM OPERATION
Air Valve
Note
• This inspection must be done with the engine cold.—
Engine coolant below 20°C {68°F}.

2. Verify that the idle speed decreases gradually as the
engine warms up.
46UOF3-089
Idle Air Control Valve

1. Verify that the idle speed is within specification.
(Refer to page F3-14).
3. If the engine speed does not decrease, replace the
BAC valve.
4. Perform the after-repair procedure.
(Refer to page F3-18)
46UOF3-090
Inspection
2. Measure resistance of the valve.
Resistance: 7.7— 9.3Q (at 23°C {73°F})
36U0F1-248
AIR VALVE
Inspection
1. Remove the BAC valve. (Refer to page F3-111.)
2. Cool the BAC valve to below 0°C {32°F}.
3. Heat the BAC valve at point A by using a blow drier,
and verify that part B moves in the direction of the
arrow in the figure.
16E0F1-093
F3-115
F3 FUEL SYSTEM
FUEL SYSTEM
DESCRIPTION
PRESSURE REGULATOR
INJECTOR
^ ► T O FUEL TANK
FROM FUEL PUMP
FUEL FILTER
FUEL PUMP
FUEL FILTER
VALVE (TWO-WAY)
FUEL TANK
36U0F1-249
This system supplies the fuel to the fuel injectors at a constant pressure. Fuel is metered and inject
ed into the intake manifold according to injection control signals from the PCM. The system consists
of the fuel tank, fuel pump, fuel filters, pressure regulator, pressure regulator control solenoid valve,
fuel injectors, and fuel pump relay.
F3-116
FUEL SYSTEM F3
PREPARATION
SST
49 L018 901 For

inspect of
Checker, injector injector
35U0FX-049
Fuel Pressure and Servicing Fuel System
Warning
• Fuel vapor is hazardous. It can vary easily ignite,
causing serious Injury and damage. Always keep
Fuel in the fuel system remains under high pressure

when the engine is not running.
Warning
• Fuel line spills and leaks are dangerous. Fuel
can ignite and cause serious injuries or death
and damage. Fuel can also Irritate skin and eyes.
To prevent this, alw ays com plete the follow ing
“Fuel Line Safety Procedures”.
46U0F3-091
Fuel Line Safety Procedure

A. Release the fuel pressure before disconnecting a fuel
line.
3. After the engine stalls, turn ignition switch to OFF.
B. Avoid leakage
1. When disconnecting a fuel line hose, wrap a rag
around it to product against fuel leakage.
C.Use a fuel pressure gauge correctly; install hose
clamps to secure the fuel pressure gauge to the fuel fil
ter and the main hose prevent leakage.
46U0F3-093
F3-117
F3 FUEL SYSTEM
SYSTEM OPERATION
Warning
• Fuel vapor is hazardous, it can very easily ignite,
causing serious injury and damage.
Always keep sparks and flames away from fuel.
46U0F3-094
2. Install a fuel pressure gauge between the fuel filter and
the fuel main hose. (Install clamps as shown.)
16E0F1-099
4. Ground fuel pump terminal of the DLC by using jumper
wire as shown.
5. Turn the ignition switch ON for 10 sec. to operate the
fuel pump.
6. Turn the ignition switch OFF and disconnect the jumper
wire.
Fuel pressure:
More than 150 kPa {1.5 kgf/cm2, 21 psi}

• Fuel pump hold pressure. (Refer to page F3-124.)
• Injector fuel leakage. (Refer to page F3-128.)
F3-118
FUEL SYSTEM F3
Warning
• Fuel vapor is hazardous, it can very easily ignite,
46U0F3-096

2. Install a fuel pressure gauge between the fuel filter and
the fuel main hose. (Install clamps as shown.)

wire as shown.
Fuel line pressure:

260— 320 kPa {2.6—3.3 kgf/cm2, 37— 46 psi}

• Fuel pump maximum pressure.
• Fuel line clogging and restriction.
• Fuel filter clogging and restriction.
F3-119
F3 FUEL SYSTEM
FUEL TANK
Warning
• Fuel v a p o r is h a za rd o u s . It can very e a s ily ig n ite, c au sin g s e rio u s in ju ry and
damage. Always keep sparks and flames away from fuel.
and dam age. Fuel can also irritate skin and eyes. To prevent this, always com plete the
“Fuel Line Safety Procedures” on page F3-117.
• R e p a irin g a fu e l tan k that has not been p ro p e rly steam clean e d can be d an g ero u s.
Explosion or fire may cause death on serious injury. Always properly steam clean a fuel
tank before repairing it.
1. Suck up the fuel from the fuel tank. (Refer to Removal Note, on page F3-121.)
GASKET, REPLACE
N-m {kgfm, ftlbf)

46U0F3-116
1. Pre-silencer 5. Evaporative hoses

2. Insulator Installation N ote....................page F3-121
3. Connector 6. Fuel tank straps
4. Fuel hoses 7. Fuel tank
Installation N o te ....................page F3-121 Inspect for cracks and corrosion
F3-120
FUEL SYSTEM F3
Removal Note
1. Remove the filler cap and insert a hose into the fuel
tank through the filler pipe.
2. Start the pump and suck up the fuel into a container.
Note
Outer diameter: 13mm {0.51 in}
Length: 2160mm {85.0 in}
Installation Note
1. Push the ends of the main fuel hose, fuel return hose,
and evaporative hoses onto the fuel tank fittin g s at
least 25mm {1.0 in}.
2. Push the fuel filler hoses onto the fuel tank pipes and
filler pipes at least 35mm {1.4 in}.
16E0F1-105
FUEL FILTER
Replacement
16E0F1-106
High-pressure side
The fuel filter must be replaced at the intervals outlined in
the maintenance schedule.
1. Disconnect the fuel hoses from the fuel filter.
Tightening torque:
7.9—10.7 N m {80—110 kgf cm, 70— 95.4 in lbf}

4. Verify that the fuel hoses are pushed fully onto the fuel
filter nozzles.
F3-121
F3 FUEL SYSTEM
FUEL PUMP
Inspection
Fuel pump operation
wire as shown.
2. Remove the fuel filler cap.
4. Listen at the filler inlet for the operational sound of the
fuel pump.
5. Install the fuel filler cap.
6. If no sound was heard, measure the voltage between

the fuel pump connector terminal No.1 to a ground.
Voltage: Approx. 12V
7. If not correct, check the fuel pump relay and related

wiring harness. (Refer to page F3-125.)
8. If the voltage is normal, check for continuity between
fuel pump connector terminal No.1 and 2.
9. If there is continuity, replace the fuel pump.
10. If there is none, repair the ground circuit.
Hold pressure
Perform this inspection if the fuel pressure hold inspec
tion is not as specified. (Refer to page F3-118.)
46U0F3-101
the outlet of the gauge as shown. (Install clam ps as
shown.)
16E0F1 -111
wire as shown.
fuel pump.
wire.
7. Observe the fuel pressure after 5 min..
Fuel pressure:
46U0F3-102 8. If not as specified, replace the fuel pump.

F3-122
FUEL SYSTEM F3
the outlet of the gauge as shown. (Install clam ps as
shown.)
16E0F1-114
wire as shown.
Fuel pump maximum pressure:

450—630 kPa {5.0—6.5 kgf/cm2, 64— 92 psi}

wire.
F3-123
F3 FUEL SYSTEM
1. Remove the fuel tank.
2. Remove the fuel pump, referring to Removal Note.
Note
• Replace the fuel pump as an assembly.
FUEL PUMP RING

INSTALLATION
STOPPER
FUEL TANK
46U0F3-105

Removal / Installation N o te ................ below
Removal Note
R otate the fuel pum p ring c o u n te rc lo c k w is e and
remove it.
Installation Note
Rotate the fuel pump ring clockw ise until the flange
touches the stopper.
36U0F1-253
F3-124
FUEL SYSTEM F3
FUEL PUMP RELAY
FUEL PUMP
RELAY (GREEN)
Inspection
Operation check
Listen for clicking of the fuel pump relay while turning
the ignition switch from OFF to START.
46U0F3-106
Check continuity between the terminals of the relay.
B+: Battery positive voltage
Terminal A— B Terminal C— D
Apply B+ Yes
B+ not applied No
36U0F1-260
FUEL PUMP Replacement

RELAY (GREEN) 1. Remove the relay from main fuse block No.1.
16E0F1-121
PRESSURE REGULATOR
Inspection
Fuel line pressure
2. Connect a fuel pressure gauge between the fuel filter
and the fuel main hose. (Install clamps as shown.)
INSTALL CLAMPS Fuel line pressure:

36U0F1-261 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}
6. Disconnect the vacuum hose from the pressure regula

tor and measure the fuel line pressure.
Fuel line pressure:

260—320 kPa {2.6—3.3 kgf/cm2, 37—46 psi}
F3-125
F3 FUEL SYSTEM
Hold pressure
Perform this inspection if the fuel pressure hold inspec
tion is not as specified. (Refer to page F 3-118.)
46U0F3-108

2. Connect a fuel pressure gauge between the fuel filter
and the fuel main hose. (Install clamps as shown.)
16E0F1-125
wire as shown.
fuel pump.
wire.
7. Pinch the fuel return hose with a plier.
8. Observe the fuel pressure for 5 min..
Fuel pressure:
Replacement
Warning
• When replacing fuel system components, keep
sparks, cigarettes, and open flames away from
the fuel area.
1. Disconnect the vacuum hose.

2. Disconnect the fuel return hose.
3. Remove the pressure regulator.
4. Install a new O-ring.
Tightening torque:
7.8—10.7 N m {80—110 kgf-cm, 70—95.4 in lbf}
36U0F1-262
F3-126
FUEL SYSTEM F3
INJECTOR
Inspection
Operation check
1. Warm up the engine and run it at idle.
2. Listen for the operational sound of each injector with a
screwdriver or a sound scope.
3. If no sound is heard, measure injector resistance.
4. If the injector resistance is OK, check w iring to the
injector and the voltages of the PCM terminals 35, 39,
58 and 59.
46U0F3-111
Warning
• When removing the fuel system components, keep sparks, cigarettes, and open flames
away from the fuel area.

7.8—10.7 N-m
(80—110 kgf-cm, 70—95.4 in-lbf)
7.8 -1 0 .7 N-m 8 0 -1 1 0 kgf-cm, 70—95.4 in-lbf)
N-m {kgf m, In-lbf)
46U0F3-112
1. Negative battery cable 4. Fuel hose

2. Injector connector 5. Distribution pipe
3. Pressure regulator 6. Injector
Inspection ................................pageF3-131 7. Insulator
F 3 -1 27
F3 FUEL SYSTEM
Fuel leakage test
Caution
• Affix the injectors firmly to the pipe to prevent
any possibility of their movement.
Warning
• Be extrem ely careful when working with fuel.
Always work away from sparks and open flames.

wire as shown.
46U0F3-114
5. Tilt the injectors approx 60 degrees and verify that no
fuel leaks from the injector nozzles.
6. If fuel leaks, replace the injector.
Note
• ONE drop per 2 m inutes’ pressurization is accept
able.
7. Turn the ignition switch OFF and remove the jum per
wire.
Volume test
(Refer to page F3-1 27.)
2. Affix the injectors to the distribution pipe with wire.
Caution
• Affix the injectors firmly to the pipe to prevent
any possibility of their movement.
Warning
• Be extrem ely careful when working with fuel.
16E0F1-134 Always work away from sparks or and open
49 L018 901
flames.
3. Connect the SST to the battery and an injector.

4. Check the injection volume with a graduated container.
Injection volumes:
47—68 ml {47—68 cc, 1.41—2.04 fl-oz}/15 sec.
5. If not as specified, replace the injectors.
46U0F3-115
F3-128
FUEL SYSTEM F3
Installation
Install in the reverse o rder of rem oval, re fe rrin g to
Installation Note.
Tightening torque
Delivery pipe
A: 19—25 N-m {1.9—2.6 kgf m, 14— 18 ft-lbf}
B: 7.8—10.7 N-m {80—110 kgf-cm, 70—95.4 in-lbf}
36U0F1-263
Installation note
O-RING 1. Use new injector O-rings.
INJECTOR
C0H_S 2. Apply a small amount of clean engine oil to the O-rings
before installing them.
WRONG
GROMMET DELIVERY
PIPE
WRONG
16E0F1-137
INSULATOR
4. Install the injectors.
O-RING
DISTRIBUTION PIPE
INTAKE MANIFOLD
16E0F1-138
Inspection
Injector resistance
1. Disconnect the injector harness.
2. Measure resistance of the injector.
Resistance: 12—16Q (at 20°C {68°F})
16E0F1-139
F3-129
F3 PRESSURE REGULATOR CONTROL SYSTEM
DISTRIBUTOR (NE-SIGNAL)
ENGINE COOLANT
TEMPERATURE SENSOR
INTAKE AIR
TEMPERATURE SENSOR
PRC SOLENOID VALVE
THROTTLE
POSITION SENSOR'
A
if MAIN RELAY
FUEL
(FROM DISTRIBUTION
PIPE)
VACUUM
FUEL
(TO FUEL TANK)
Operating condition
Operating time
Coolant temperature Intake air temperature Engine condition
— — While in crank During crank
Above 90°C {194°F} Above 35°C {95°F} Close throttle When the time since
the engine started is
less than 10 seconds.
Above 90°C {194°F} Above 35°C {95°F} Close throttle and engine Engine has been started
speed is less than equal less than 2 minutes.
1,000 rpm.
16E0F1-140
To prevent vapor lock of the fuel during hot restart idle, vacuum to the pressure regulator is momentarily
cut and the fuel injection pressure is increased to slightly more than 284 kPa {2.9 kgf/cm2, 41.2 psi}.
F3-130
PRESSURE REGULATOR CONTROL SOLENOID
VALVE
Inspection
On-vehicle
2. Disconnect the vacuum hose from the pressure regula
tor. Verify that vacuum is felt.
3. Ground the solenoid valve terminal (upper side) with a

jumper wire. Verify that no vacuum is felt.
Solenoid Valve
4. Apply battery positive voltage to solenoid valve termi

nal.
36U0F1-266
F3-131
F3 EXHAUST SYSTEM
EXHAUST SYSTEM
COMPONENTS
1. Main silencer 4. Front pipe assembly

Inspect for deterioration and restriction Inspect for deterioration and restriction
2. Pre-silencer 5. Exhaust manifold
3. Three way catalyst 6. Exhaust manifold insulator
Inspect for deterioration and restriction 7. Heated oxygen sensor
Inspection............................... page F3-164
F3-132
STRUCTURAL VIEW
The following systems are employed to reduce CO, HC, and NOx emissions.
1. EGR control system
2. Positive crankcase ventilation (PCV) system
3. Fuel evaporative system
4. Three way catalyst
xFUEL PUMP
FUEL FILTER
VALVE (TWO-WAY)
FU EL TANK
PURGE SOLENOID VALVE EGR CONTROL VALVE

THREE WAY
PCV VALVE CATALYST
CHARCOAL CANISTER
</ EGR FUNCTION SEN
36U0F1-077
F3-133
F3 EGR FUNCTION CONTROL SYSTEM
EGR FUNCTION CONTROL SYSTEM

DESCRIPTION
This system recirculates a small amount of exhaust gas into the intake manifold to reduce the combus
tion temperature and reduce NOx emissions.
This system consists of the EGR control valve, EGR function sensor, two duty-solenoid valves, PCM,
and input devices.
1: D E T E C T IO N O F E N G IN E R U N N IN G C O N D IT IO N
2: D E T E R M IN A T IO N O F EGR G A S A M O U N T
46U0F3-118
SYSTEM OPERATION
The EGR valve position can be precisely varied depended on engine operating conditions. Spark
advance can be adjusted to compensate for EGR flow.
Cold engine (coolant temperature: below 26°C {78°F})

EGR operation is stopped to improve drivability when the engine is cold.
Function
EGR operates when the follow conditions are met.
__________________________________________ Operating condition
TPS, MAF, ECTS, IAT or EGR function sensor have not failed________
While not in crank
After warm up (warming up)
Engine speed above 1,000 rpm
Except in heavy load
F3-134
EGR FUNCTION CONTROL SYSTEM F3
SYSTEM INSPECTION
1. Connect the SST to the PCM as shown.
3. Drive the vehicle and verify that PCM terminals 12 and
33 voltage is battery positive voltage (B+) while the
engine is still cold.
5. Drive the vehicle and verify that the 12 and 33 voltage
is set to change.
6. Stop the vehicle and run it at idle.
7. Ground the PCM terminal 33 by using a jumper wire.

8. Verify that the engine runs roughly or stalls at idle.
46U0F3-120

Inspection
2. Blow into the solenoid valve and verify that air does not
flow.
4. Apply battery positive voltage and a ground to the
solenoid valve as shown.
5. Blow through the solenoid valve and verify that air
flows.

Inspection
2. Blow into the solenoid valve and verify that air does not
flow.
4. Apply battery positive voltage and a ground to the
solenoid valve as shown.
5. Blow through the solenoid valve and verify that air
flows.
EGR CONTROL VALVE

Inspection
3. Verify that the engine runs roughly or stalls at more
than the specified vacuum.
Specification:
5.4—7.7 kPa (40—60 mmHg, 1.6— 2.3 inHg}

16E0F2-172
F3-135
F3 EGR FUNCTION CONTROL SYSTEM
Replacement
Note
• Plug the water hoses after disconnecting them.

below.
(1) EGR hoses
(2) Vacuum hose
36U0F2-262
Note
• Before installing the EGR control valve, install new
gaskets.
2. Install the EGR control valve in the reverse order of

removal.
EGR FUNCTION SENSOR

Inspection of output voltage
1. Disconnect the PCM connector.
2. Connect the SST to the PCM as shown and connect a
vacuum pump to the EGR control valve.
Vacuum
Terminal PCM OkPa 20.0 kPa
{0 mmHg, 0 inHg} {150 mmHg, 5.90 inHg}
B 26 4.5— 5.5V
A 46 0V
C 27 Approx. 0.8V Approx. 4.9V
5. If not correct at 27 terminals, check the wiring harness

and 26 terminals of the PCM.
Inspection of resistance
1. Disconnect the EGR function sensor connector, and
connector an ohmmeter.
2. Disconnect the vacuum hose from the EGR control
valve, and connect a vacuum pump.
3. Measure the resistance between the term inals as
shown while vacuum is applied.
Vacuum
Terminal OkPa 20.0 kPa
{0 mmHg, 0 inHg} {150 mmHg, 5.90 inHg}
A— B Approx. 2.7 k£2
A— C Approx. 0.5 k£2 Approx. 2.7 k il
B—C Approx. 2.4 k£2 Approx. 0.1 k£2
46U0F3-124
F3-136
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM F3
DESCRIPTION
The Positive Crankcase Ventilation (PCV) System cycles crankcase gases back through the engine
where they one burned. The PCV valve regulates the amount of ventilating air and blow-by gas to
intake manifold and prevents backfire from traveling into the crankcase.
46U0F3-125
PCV VALVE
Inspection
Note
• Perform this inspection while the engine is cold.
1. Run the engine at idle.

2. Disconnect the PCV valve with the ventilation hose
from the cylinder head cover.
3. Block the PCV valve operating.

6. Blow through the valve from port A and verify that air
comes out of port B.
8. Replace the PCV valve if necessary.
16E0F1-155
F3—137

DESCRIPTION
The fuel evaporative system consists of fuel vapor valve, two-way check valve, charcoal canister,
purge solenoid valve, PCM, and input devices. The amount of evaporative fumes introduced into the
engine and burned is controlled by the solenoid valve to correspond to the engine’s operating condi
tions. To obtain the best engine performance, the solenoid valve is controlled by the PCM.
Operation
The purge solenoid valve is controlled by duty signals from the PCM to perform purging of the charcoal
canister. Purging is done when these conditions are met:
(1) After warm-up
(2) Driving in gear
(3) Accelerator pedal depressed
F3-138
FUEL EVAPORATIVE SYSTEM F3
SYSTEM OPERATION
1. Warm up the engine to normal operating temperature
and run it at idle.
2. Disconnect the vacuum hose from the solenoid valve
and plug it as shown in the figure. Verify that no vacu
um is felt at the solenoid valve.
3. If not as specified, check the solenoid valve.
16E0F1-157
Inspection
1. Disconnect the vacuum hoses from the solenoid valve.
2. Verify that no air flows through the valve.
46U0F3-127
3. Disconnect the solenoid valve connector and supply
battery positive voltage as shown in the figure.
4. Verify that air flows through the valve.
26U0F1-267
FUEL VAPOR VALVE
Inspection
1. Verify that air flows through the valve from port A as
16E0F1-160
2. Verify that no air flows through the valve from port A as
3. Replace the fuel vapor valve if necessary.
16E0F1-161
F3-139
Inspection
2. Check the operation of the valve by using a vacuum
pump.
Apply approx. 3.5 kPa {26 mmHg,

1.0 inHg} vacuum at port A Valve opens
Apply approx. 5.9 kPa {44 mmHg,
1.7 inHg} vacuum at port B Valve opens
36U0F1-256
CHARCOAL CANISTER
Inspection
1. Visually check for damage.
2. Replace the charcoal canister if necessary.
16E0F1-163
F3-140
DESCRIPTION
This system is used to improve the fuel economy, to prevent engine bucking during deceleration, and
to protect the engine from overreving.
Deceleration fuel-cut
(x 10J rpm)
16E0F1-164
F3-141
PREPARATION
SST
46U0F3-128
F3-142
SYSTEM OPERATION
Breakout Box
1. Connect a tachometer to the number one spark plug
wire.
2. Connect the SST to the PCM.
and rum it at idle.
Warning
• Confirm that the transaxle is in P range.
4. Measure voltage of the terminal 35, 39, 58 and 59.

5. Increase the engine speed to 4,000 rpm and then sud
denly release the throttle.
6. Verify that the terminals voltage while the engine speed
is above approx. 1,500 rpm on deceleration.
Caution
• Do not hold maximum rpm over 3 sec.
7. Increase the engine speed and verify that the maximum

rpm does not exceed approx. 6,800 rpm.
46U0F3-130
F3 A/C CUTOFF SYSTEM
A/C CUTOFF SYSTEM

DESCRIPTION
The A/C relay is controlled by the PCM with an output signal and is used as circuit cut-off for the
compressor magnetic clutch when the relay activated.
CRANKSHAFT
POSITION
SENSOR
PCM
THROTTLE
POSITION
SENSOR DETERMINATION
OF
AIR CONDITIONING-
A1C CUT OFF
SENSOR
A/C RELAY
IGNITION SWITCH
(START)
IGNITION SWITCH
TRANSMISSION RANGE SENSOR-
CONDENSOR © Q
FAN MOTOR
ENGINE COOLANT ■ MAGNETIC BATTERY
TEMPERATURE CLUTCH
SENSOR
46U0F3-132
Operation
The A/C clutch operation is cancelled under the conditions below.
Engine condition Purpose Cutoff period
After engine starting Improve engine starting Approx. 4 sec.
Throttle valve fully open Approx. 8 sec.
Improve drivability
Acceleration from idle Approx. 2 sec.
Coolant temp, above 117°C {242°F} Prevent engine overheat Until coolant temp, decrease below 107°C {224°F}
SYSTEM OPERATION
2. Turn the blower switch and air conditioning sensor ON.
4. Verify that the condenser fan stops for approx. 4 sec. after the engine starts.
F3-144
COOLANT FAN CONTROL SYSTEM F3
SYSTEM OPERATION
1.Turn the ignition switch to START and verify that the
injector operating sound is heard.
switch to START. Verify that no injector operating
sound is heard.

DESCRIPTION
To improve reliability, the coolant fan is controlled by the PCM. This system consists of the coolant
fan motor, fan relays, PCM and input devices.
PCM
ECTS [ENGINE COOLANT

TEMPERATURE SENSOR]
AIR ____ ^ f
CONDITIONING
SENSOR
CRANKSHAFT-------------------
POSITION
SENSOR
VEHICLE
SPEEDOMETER
SENSOR
IGNITION SWITCH
— •I'M —
BATTERY
46U0F3-133
Coolant fan operation

Fan relay Fan relay Fan relay
Engine condition Fan speed
No.1 No.2 No.3
Coolant temperature above 98°C {208°F} ON OFF OFF LOW
Air conditioning sensor ON ON OFF OFF LOW
Coolant temperature above 109°C {228°F} ON ON ON HIGH
ECTS malfunction ON ON ON HIGH
HEAVY LOAD (engine speed above 2,500 rpm
ON ON ON HIGH
and vehicle speed blow 40 km/h {25 MPH})
F3-145
SYSTEM OPERATION
1. Start the engine, and run it at idle.
2. Verify that the coolant fan operates at low speed when
engine coolant tem perature 98°— 109°C {208°F —
228° F}.
3. Racing the throttle and verify the coolant fan operates
at high speed when engine coolant temperature above
109°C {228°F}.
4. If not as specified, inspect the input signals and fan
relays.
46U0F3-131
CONTROL SYSTEM F3
CONTROL SYSTEM
PREPARATION
SST
F 3-147
F3 CONTROL SYSTEM
STRUCTURAL VIEW
46U0F3-135
1. Powertrain control module (PCM) 6. Throttle position sensor

Removal / Installation ........... page F3-149 Inspection ........................ ..... page F3-163
Inspection .............................. page F3-149 Adjustment....................... ..... page F3-163
2. Mass airflow sensor Replacement.................... ..... page F3-163
Inspection .............................. pageF3-160 7. Heated oxygen sensor
Removal / Installation ........... page F3-160 Inspection ........................ ..... page F3-164
3. Crankshaft position sensor Replacement.................... ..... page F3-164
Inspection .............................. pageF3-161 8. Main relay
4. Engine coolant temperature sensor Inspection ........................ ..... page F3-165
Removal................................. page F3-162 9. Coolant fan relays
Inspection .............................. pageF3-162 Inspection ........................ ..... page F3-165
Installation.............................. page F3-162 10. Steering pressure sensor
5. Intake air temperature sensor Inspection .............................. page F3-166
Inspection .............................. pageF3-162 Replacement.................... ..... page F3-1 66
Replacement..........................page F3-162
F3-148
CONTROL SYSTEM F3
POWERTRAIN CONTROL MODULE (PCM)
Caution
• Powertrain control module is sensitive to static electrical charges. If exposed to these
charges, damage may result.
If service of powertrain control module is required, use the following safeguards to avoid
damage to components.
1. Leave the PCM in their original packaging until ready to install in vehicles.
2. Avoid touching PCM connector pins.
3. Avoid laying modules on nonconductive surfaces.
1. Remove in the order shown in the figure, reffering to Removal Note.

46U0F3-136
1. Negative battery cable 3. PCM connector

2. Console 4. PCM
Removal Note
• The PCM stores information about vehicle operating conditions and uses this information to compen
sate for component tolerance. When an emission related component is replaced, Keep Alive
Memory (KAM) should be cleared to erase the information stored by the PCM from the original com
ponent.
Inspection
Breakout box
1. Disconnect the PCM connectors.
3. Measure the voltage at each terminal.
(Refer to pages F3-150 through F3-159.)
4. If any PCM terminal voltage is incorrect, check the
related input or output devices and wiring. If no prob
lem is found, replace the PCM. (Refer to above.)
46U0F3-137
F3-149
F3 CONTROL SYSTEM
Terminal voltage (reference data)
B+: B attery p ositive vo ltag e
Terminal Input Output C o n nected to T est condition V o lta g e (V) R em ark
Battery Constant B+ For backup
O Stoplight Brake pedal released

switch Brake pedal depressed B+
O Vehicle Idle (AC range) Approx. 0.1
speedometer
48 km/h {30 mph} (AC range) Approx. 8.0
sensor (+)
O Ignition Ignition switch ON B+
control Idle 0.2—0.5
module
O Turbine shaft Idle (AC range) Approx. 0.5

speed (TSS) 48 km/h {30 mph} (AC range) Approx. 0.8
sensor
O Vehicle Constant (AC range) Approx. 0.1
speedometer
sensor
(VSS) (-)
O Engine Engine coolant temperature 20°C {68°F} 2.5 Ignition switch
coolant After warmup 0.5 ON
temprature
sensor
O Fuel pump Ignition switch ON .✓

relay During cranking or at idle B+
O Mass airflow Constant
sensor
10 O Air A/C sensor ON (A/C ON) Ignition switch

conditioning A/C sensor OFF (A/C OFF) B+ ON and blower
sensor switch ON
11 O Purge Ignition switch ON B+

solenoid Driving V o lta g e (V )
Oscilloscope
valve 40
20
VB
0
10 m s
12 O EGR solenoid Idle B+ After warm up

valve (vent) Driving Oscilloscope
[EGRA]
i'l,
f r
13 O Coolant fan Electric fan relay ON
relay
Electric fan relay OFF B+
(LOW)
14 O Daytime ON (Parking brake not applied) Ignition switch ON

running light Canada only
OFF (Parking brake applied) B+
F3-150
CONTROL SYSTEM F3

Always OV • ROOM 15A fuse burnt
• Open circuit in wiring from ROOM 15A fuse to PCM terminal 1
• Refer to Code No.512 Troubleshooting «• page F3-22
Always OV (stoplights OK) • Open circuit in wiring from stoplight switch to PCM terminal 2
• Refer to Code No.536 Troubleshooting cr page F3-22
Always OV or B+ • Refer to Code No.452 Troubleshooting page F3-22
• Open or short circuit in wiring from vehicle speed sensor to PCM terminal 3
Always OV • Short circuit in wiring from ignition control module to PCM terminal 4
• Refer to Code No.211,212, 213 Troubleshooting a-p a g e F 3-22
Always B+ • Open circuit in wiring from Ignition control module to PCM terminal 4
• Open circuit in wiring from Ignition control module to ground PCM
malfunction
Always OV » Section K2
Always OV • Refer to Code No.452 Trouble shooting «■ page F3-22

• Poor connection at ground terminal
• Open circuit in wiring from PCM
Always OV or 5V • Refer to Code No.116, No,117 and No.118 «• page F3-22
Always B+ or below 2.5V • Engine 15A fuse burnt

• Open or short circuit in wiring from fuel pump relay wire to PCM terminal 8
Always OV • Refer to Code No. 157, No.158, and No. 159 Troubleshooting
«• page F3-22
• Open circuit in wiring from mass airflow sensor to PCM terminal 9
Always below 2.5V (blower fan OK) • Air conditioning sensor malfunction «• Refer to 1994 626/MX-6 BETM.
• Short circuit in wiring from air conditioning sensor to PCM terminal 10
• Poor connection at PCM connector
Always B+ (blower fan OK) • Air conditioning sensor malfunction ** Refer to 1994 626/MX-6 BETM.
• Open circuit in wiring from air conditioning sensor to PCM terminal 10
• Open circuit in wiring from air conditioning sensor to blower control switch
Always OV or B+ • Refer to Code No.565 Troubleshooting «■ page F3-22
• Open or short circuit in wiring from purge solenoid valve to PCM terminal 11
Always OV or B+ • Refer to Code No.571 Troubleshooting <&■ page F3-22
Always OV or B+ (Coolant fan OK) • Open or short circuit in wiring from fan relay to PCM terminal 13
• Refer to Code No.564 Troubleshooting «■ page F3-22
Always B+ • Daytime running relay malfunction

• Combination switch malfunction
Always OV • Open circuit in wiring from daytime running relay to PCM terminal 14
F3-151
F3 CONTROL SYSTEM
Termlna Input Output Connected to Test condition Voltage (V) Remark
15 — — — — — —
16 — — Ground Constant 0 —
17 o Data link MILor STO: OFF B+
connector —
(MIL/STO) MILor STO: ON 0
18 — — — — — —
19 — — — — — —
20 — — — — — —
21 o Idle air Ignition switch ON B+ —
control Idle(after warm up)
valve
9.6 - 9.7 —
22 o Fuel pump Ignition switch ON B+

relay During cranking or at idle Below0.5 —
23 o Rear window Rear windowdefroster switch ON Below 1.0 Ignition switch ON

defroster relay Rear windowdefroster switch OFF B+
24 o Distributor Ignition switch ON 0or5
(GSignal) Idle Oscilloscope Voltage (V)
NEW
B+ —
0
20ms
25 O Intakeairtem Engine coolant temperature 20°C {68°F} Approx. 3 Ignition switch ON
perature sensor After warmup Approx. 1.5
26 o Reference Ignition switch ON 4.5—5.5 —
voltage (Vref)
27 O EGRfunction Idle 3.4—5.0
sensor —
28 o Steering Ignition switch ON B+

pressure P/SONat idle Below 1.0
sensor —
P/S OFFat idle B+
29 o Blower switch Blower switch OFF, 1st or 2nd position B+ Ignition switch ON
Blower switch 3rd or 4th position Below 1.0
F3-152 (1994 626/MX-6) Revised 3/94

CONTROL SYSTEM F3

— —
• Open circuit in wiring from PCM to ground
MIL always ON • MIL malfunction
• Short circuit in wiring instrument cluster to PCM terminal 17
MIL never ON always B+ • MIL malfunction
• Open circuit in wiring from instrument cluster to PCM terminal 17
— —
— —
— —
Always OV or B+ • Refer to Code No.411 and No.412 Troubleshooting page F3-22
Always OV or B+ • Engine 15A fuse burnt

• Open or short circuit in wiring from fuel pump relay wire) to PCM
terminal 22
Always OV • Short circuit in wiring from rear window defroster switch to PCM terminal 23
Always B+ • Open circuit in wiring from rear window defroster switch to PCM terminal 23
Always OV or 5V • Refer to Code No.211, No.212 and No.213 Troubleshooting
«■ page F3-22
Always below 1,5V or above 3V • Refer to Code No.112, No.113, and No.114 «• page F3-22
Always OV • Poor connection at PCM connector

• Short circuit in wiring from PCM terminal 26 to throttle sensor
Always OV • Refer to Code No.327, No.332, No.337 Troubleshooting page F3-22
• Open or short circuit in wiring from EGR function sensor to PCM terminal 27
Always OV • Steering pressure sensor malfunction «■ page F3-166

• Short circuit in wiring from steering pressure switch to PCM terminal 28
Always B+ • Steering pressure sensor malfunction «*■ page F3-166
• Short circuit in wiring from steering pressure switch to PCM terminal 28
or ground
Always below 1.OV (blower fan OK) • Short circuit in wiring from blower switch to PCM terminal 29
Always B+ (blower fan OK) • Open circuit in wiring from blower switch to PCM terminal 29
46U0F3-212
F3-153
F3 CONTROL SYSTEM
B+: B attery p ositive vo ltag e
Terminal Input Output C o n nected to T est condition V o lta g e (V) R em ark
30
31 O Coolant fan Ignition switch ON B+

relay (HIGH) Idle Engine coolant temp. Above Approx. 0.6
100°C {212°F}___________
Other B+
32 O PRC Hot condition: Engine coolant temp, above Approx. 0
Solenoid 70°C {158°F} and intake air temp, above
valve 75°C {167°F} for 120 sec. after engine
starting_________________ ______
Other B+
33 O EGR solenoid Idle B+
valve (vacu Driving Oscilloscope
um) [EGRV]
5
< o '7■-"l-
85 “ 5
34 O Hold lamp Idle SWOFF B+
SW ON (HOLD) Below 1.0
35 O Injector Ignition switch ON B+

No.4 Idle Oscilloscope
m
Voltmeter 13.8
36 O SPOUT Connector: connected B+ Ignition switch ON
connector
Connector: disconnected
37 MAIN RELAY Ignition switch ON B+
38 O Electronic Idle Approx. 9.0

pressure
48 km/h {30 mph} Approx. 10.0
control (EPC)
solenoid 88 km/h {55 mph} Approx. 12.0
39 O Injector Ignition switch ON B+
(No.2)
Idle (after warm up) Oscilloscope
d±b:i r± t!
Vb
5 ms
m
Voltmeter 13.8
above 2,000 rpm
on deceleration
(after warmup)
F3-154
CONTROL SYSTEM F3

— —
Always OV or B+ • Refer to Code No.563 Troubleshooting page F3-22
Always OV or B+ • Refer to Code No.554 Troubleshooting w page F3-22
Always OV • Refer to Code No.572 Troubleshooting ra? page F3-22

• Open circuit in wiring from EGR valve (vacuum) solenoid to PCM
terminal 33
Always OV or B+ • Open or short circuit in wiring from hold lamp O/D off lamp to PCM terminal 34
• Hold switch O/D off switch malfunction
Always OV or B+ • Open or short circuit in wiring from injector No.4 PCM terminal 35
Always OV or B+ • Open or short circuit in wiring from SPOUT connector to PCM terminal 36
Always OV • PCM power relay malfunction

• Open or short circuit in wiring from PCM power relay to PCM terminal 37
Always OV or B+ • Open or short circuit in wiring from EPC solenoid to PCM terminal 38
Always OV • Main relay malfunction >®-page F3-165

• Open or short circuit in wiring from injector to PCM terminal 39
Always B+ • Open or short circuit in wiring from injector No.2 to PCM terminal 39
46U0F3-213
F3 CONTROL SYSTEM
40 — — Ground Constant 0 —
41 O Hold HOLD SW Release 9.5

switch
Push Below 1.0
42 O Headlights Headlights ON B+
switch
Headlight OFF 0
43 — — Ground Constant 0
—
44 o Heated oxy Ignition ON Below 1.0
gen sensor Idle Cold engine Approx. 0
(H02S)
After warm up 0.1—0.9
Inceasing engine speed Approx. 0.8

(after warm up)
Deceleration 0
45 — — — — — —
46 — — Ground Constant 0
—
47 o Throttle posi Accelerator pedal released Approx. 0.5 Ignition switch ON
tion sensor Accelerator pedal fully depressed Approx. 4.1
(TPS)
48 o Data link Idle 3.3—4.8

connector
(STI) —
49 o Transmission After warm up (Idle) Approx. 0.7

fluid tempera
ture (TOT) —
sensor
50 o Mass airflow Ignition switch ON 0
sensor
Idle 0.6— 0.7
51 o Shift solenoid ON B+
1 (SS1)
OFF 0
52 o Shift solenoid ON B+
2 (SS2)
OFF 0
53 o Transmission Constant B+
range sensor
—
54 o A/C relay Ignition switch ON B+

A/C sensor ON at idle Below 1.0 —
A/C sensor OFF at idle B+
F3-156
CONTROL SYSTEM F3

Above OV • Poor connector at ground terminal
• Open circuit in wiring from PCM terminal 40
Always below 1.OV or B+ • Open or short circuit in wiring from Hold switch to PCM terminal 41
Always below 1,0V (Headlights OK) • Open or short circuit wiring from headlights switch to PCM terminal 42
Above OV • Poor connector at ground terminal

Always OV or 1.OV after warm up • Refer to Code No.172,173,179,181 Troubleshooting » page F3-22
— —

Always OV or 5V • Refer to Code No.121, No.122 and No.123 Troubleshooting
«• page F3-22
Always below 1.OV • Short circuit in wiring from data link connector teminal STI to PCM
terminal 48
Always B+ • Open circuit in wiring from data link connector terminal STI to PCM
terminal 48
Always OV • Refer to section K2
Always OV or B+ • Refer to Code No.157,158, 159 Troubleshooting «*• page F3-22
Always OV or B+ • Refer to section K2
Always OV or B+ • Refer to section K2
Always below 1.OV or B+ • Refer to Code No.559 Troubleshooting «■ page F3-22
46U0F3-214
F3-157
F3 CONTROL SYSTEM
F3-158 (1994 626/MX-6) Revised 3/94

CONTROL SYSTEM F3
Always OV or 5V • Refer to Code No.211 Troubleshooting «*■ page F3-22
Always OV • Main relay malfunction page F3-165

• Open or short circuit in wiring from main relay to PCM terminal 57
Always OV • Open or short circuit in wiring from injector No.3 to PCM terminal 58
Always B+ • Open or short circuit in wiring from injector No.1 to PCM terminal 59
Always OV • Poor contact at ground terminal

• Open circuit in wiring from PCM to ground
46U0F3-215
F3-159
F3 CONTROL SYSTEM
MASS AIRFLOW SENSOR (MAF) (HOT WIRE TYPE)
Removal
1. Disconnect the MAF connector.
2. Disconnect the Intake air temperature (IAT) sensor con
necter.
3. Loosen the MAF clamp at the air duct.
4. Remove air cleaner housing upper cover.
5. Remove the four MAF mounting bolts.
6. Remove the MAF from air cleaner housing upper cover.
46U0F3-138
Installation
To install, reverse order of removal.
46U0F3-139
Inspection
Caution
• Do not drop or subject the sensor to sharp
shocks.
• Do not put or allow anything in the sensor.
46U0F3-140
1. Check for damage contaminated of the sensor.
.j*v.
I
46U0F3-141
2. Disconnect the PCM connector.
HARNESS 3. Connect the SST. Breakout box and Adapter to the
PCM as shown.
4. Connect voltmeter to the breakout box terminal 50 and 9.
5. Measure the voltage of terminal 50.
Specification
Ign— ON
Condition Idle
(Engine stopped)
49 UN01 Terminal voltage (V) 0 0.6— 0.7
46U0F3-142 6. If not as specified, replace the mass airflow sensor.

F3-160
CONTROL SYSTEM F3
CRANKSHAFT POSITION SENSOR
Inspection
1. Remove the distributor. (Refer to section G.)
Warning
• Before performing following operation, discon
nect the injector connector.
• When checking the crankshaft position sensor,
never connect the distributor connector (6-pin).
2. Connect the distributor connector (4-pin) as shown in

36U0F1-116 figure.
6. Rotate the distributor drive by hand and measure the
output voltage.
46U0F3-143
Specification
Signal Terminal Voltage
NE 56 B+ (4 pulse)
G 24 B + (1 pulse)
SIGNAL
SIGNAL o v _jh ________r u
46U0F3-144
(Refer to section G.)
8. Start the engine and adjust the ignition timing.
Ignition timing: BTDC 9— 11°
Tightening torque:
19—25 N m {1.9—2.6 kgf-m, 14— 18 ft lbf}
Revised 3/94 (1994 626/MX-6) F3-161

F3 CONTROL SYSTEM
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Removal
Note
• The engine coolant temperature sensor is at the rear
of the engine.

nector.
Inspection
1. Place the sensor in water with a thermometer and heat
the water gradually.
Water temperature Resistance (kft)
20°C {68°F} 35.473—39.207
60°C{140°F} 7.171— 7.925
80°C {176°F} 1.131— 1.251
3. If not as specified, replace the engine coolant tempera

ture sensor.
Installation
1. Install a new washer and the engine coolant tempera
ture sensor.
Tightening torque:
25—29 N-m {2.5—3.0 kgf-m, 19—21 ft Ibf}
2. Connect the engine coolant temperature sensor connector.

3. Start the engine and check for coolant leakage.
INTAKE AIR TEMPERATURE (IAT) SENSOR

Inspection
1. Disconnect the intake air thermosensor connector.
2. Check resistance of the sensor.
3. If not as specified, replace the intake air temperature
sensor.
Water temperature Resistance (k£i)
20°C {68°F} 35.473—39.207
60°C{140°F} 7.171— 7.925
80°C{176°F} 1.131— 1.251
46U0F3-149
Replacement
1. Disconnect the intake air thermosensor connector.
2. Remove the sensor.
3. Install the sensor and tighten it to the specified torque.
Tightening torque:
7.9— 11.7 N-m {80— 120 kgf-cm, 70— 104 in lbf}
36U0F1-123
F3-162
CONTROL SYSTEM F3
Inspection
1. Disconnect the connector from the throttle position sen
sor.
2. Connect an ohmmeter between throttle position sensor
terminal B and C.
36U0F1-124
, RESISTANCE 3. Verify that the resistance increases linearly according to

(kfl) the throttle valve opening angle.
5
4 Throttle valve condition Resistance (kft)

Closed throttle position Below 1
3
Wide open throttle Approx. 5
2
1 THROTTLE VALVE 4. If not as specified, adjust the throttle position sensor.

OPENING ANGLE
u
WIDE OPEN THROTTLE
46U0F3-150
Adjustment
2. Connect voltmeter to breakout box terminals 47 and 46.
3. Loosen the sensor screws.
4. Ignition switch ON.
5. Adjust the sensor output voltage by rotating the sensor.
Specification
Condition Terminal voltage (V)
Accelerator pedal released Approx. 0.5
Accelerator pedal fully depressed Approx. 4.1
6. If not as specified, replace the throttle position sensor.
Replacement
2. Remove the screws.
3. Remove the throttle position sensor.
4. Install the throttle position sensor.
5. Adjust the throttle position sensor output voltage.
(Refer to above.)
F3-163
F3 CONTROL SYSTEM
Inspection of Terminal voltage
and run it at idle.
3. Connect a voltmeter between the heated oxygen sen
sor and a ground.
4. Run the engine at 3,000 rpm until the voltmeter indi
cates approx 0.55V.
36U0F1-126
5. Increase and decrease the engine speed suddenly sev
eral. Verify that when the speed is increased, the meter
reads 0.5— 1.0V, and when the speed is decreased it
reads 0V—0.5V.
36U0F1-127
Inspection of Heated Oxygen Sensor Heater
3. Connect an ohmmeter between heated oxygen sensor
terminals as shown.
4. Measure the resistance of the heater.
Specification: Approx 6ft (at 20°C {68°F})
Replacement
Tightening torque:
30—49 N-m {3.0—5.0 kgfm, 22—36 ft lbf}
36U0F1-132
F3-164
CONTROL SYSTEM F3
MAIN RELAY
Inspection
1. Verify that main relay clicks when the ignition switch is
turned ON and OFF.
2. Apply battery positive voltage (B+) to terminal A and
ground terminal B of the relay.
Terminals B+ not applied B+ applied
C— D No continuity Continuity
36U0F1-135
COOLANT FAN RELAYS

Inspection
1. Remove the relays.
2. Apply battery positive voltage (B+) to terminal A and
ground terminal B of the each relays.
Terminals B+ not applied B+ applied
C— D No continuity Continuity

46U0F3-153
F3-165
F3 CONTROL SYSTEM
Inspection
2. Connect an ohmmeter to the sensor.
3. Start the engine and run it at idle. Check continuity of
the sensor while turning the steering wheel.
Turning Yes
Not turning No
Replacement
Replace the steering pressure sensor as shown in the
figure.
Tightening torque:
17— 22 N m {1.7— 2.3 kg fm , 13— 16 ft-lbf)
36U0F1-141
USING THIS SECTION
Introduction
Most of the fuel and emission control systems are electronically controlled, often making it difficult to
diagnose problems, especially intermittent problems. Before undertaking actual checks, take a few
minutes to talk with a customer who approaches with a drivability complaint. The customer is often a
good source of information on such problems, especially the intermittent ones. Through a talk with
the customer, you will usually find out what the symptoms are and under what conditions they occur.
Work flow
CHECK IN
I
REFER TO TROUBLESHOOTING PAGE THAT.........................DIAGNOSTIC INDEX
-► CHECK FOR WHAT IS BAD IN SYSTEM.............................. INSPECTION
CHECK FOR WHAT PART IS BAD. ACTION
I
REPAIR/REPLACE.
-DETERMINE IF TROUBLE HAS BEEN ELIMINATED

No
Yes |
CHECK OUT
46U0F3-220
Diagnostic index
F3-167
ENGINE STALLS •ID L E WITH A /C , P/S, a n d /o r E/L ON
•IO LE WHEN SH IFTED FROM N OR P TO OTHER
RANGES
• Engine s;ops unexpected'/ when A/C, P/S. and/or E /l turned ON at idle

DESCRIP • Engine stops unexpected1/ when shifted from N or P to other ranges at idle
TION • Idle condition is normal when A/C. P/S. and E/L are OFF and in N and P
(TRO UBLESHO O TING HINTS)

• A/C switch © Solenoid valve (ISC)
• Rear w indow defroster
STEPl INSPECTION
Are switches correct when checked by using Self- Go to next step
Diagnosis Checker monitor lam p while ignition
switch ON?
r r page F 2 -4 4
• Blower switch
Check for cause (Reler to specified
• H e a d lig h t s w itc h
check sequence) ro - page F 2 -4 5
• Rear w indow defroster switch
• Selector lever
SYSTEM SELECTOR
SELECT SW: A
is "OCT displayed on Self-Diagnosis Checker with

ignition switch ON?
z r page F 2 -1 8
Service C ode No. d is p la y e d

Check for cause (Reler to specified
check sequence)
16E0F1-256
DESCRIPTION:
Further describes the system. Confirm that the chart addresses the actual symptom before begin
ning troubleshooting.
STEP:
INSPECTION:
This describes and inspection to quickly determine the malfunction of parts. If a detailed procedure is
necessary to perform the INSPECTION, refer to the page specified by the “ra*" mark.
ACTION:
This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to
perform the action is described on the reference page specified by the “«*■” mark.
16E0F1-257
F3-168
DIAGNOSTIC INDEX
TROUBLESHOOTING ITEM n P « r R ID T ID K I PAGE
No. TROUBLE
1 Main fuse — F3-171
2 Will not crank Starter does not work F3-172
3 Hard start/long crank/erratic start/ Starter cranks engine at normal speed but engine F3-173
erratic crank requires excessive cranking time before starting
4 Engine stalls After start Engine stops unexpectedly at idle and/or after start F3-175
At idle
5 Cranks normally but will not start Starter cranks engine at normal speed but engine F3-178
will not run
6 Slow return to idle Engine takes more time than normal to return to idle F3-180
speed
7 Engine runs At idle Engine speed fluctuates between specified idle speed F3-181
rough/rolling and lower speed and excessive engine shake
idle Idle speed too slow and excessive engine shake
8 Fast idle/runs on Engine speed continues at fast idle after warm-up F3-183
Engine runs after ignition switch is turned off
9 Low idle/stalls during deceleration Engine stops unexpectedly at beginning of deceleration F3-184
or recovery from deceleration
10 Engine stalls/ Acceleration/cruise Engine stops unexpectedly at beginning of acceleration F3-185
quits or during acceleration
Engine stops unexpectedly while cruising
Engine runs Acceleration/cruise Engine speed fluctuates during acceleration or cruising F3-185
rough
Misses Acceleration/cruise Engine misses during acceleration or cruising F3-185
Buck/jerk Acceleration/cruise Vehicle bucks/jerks during acceleration, cruising, or F3-185
deceleration deceleration
Hesitation/ Acceleration Momentary pause at beginning of acceleration, or during F3-185
stumble acceleration
11 Surges Acceleration/cruise Momentary minor irregularity in engine output F3-188
12 Backfires Idle/acceleration/ Sound produced from exhaust system F3-190
deceleration
13 Lack/lose of Acceleration/cruise Performance poor under load F3-191
power (i.e., power down when climbing hills)
14 Knocking/ Acceleration/cruise Sound produced when air/fuel mixture is ignition by F3-193
pinging something other than spark plug
(i.e., hot spot in combustion chamber)
15 Poor fuel economy Fuel economy unsatisfactory F3-194
16 Emission compliance fails emission test F3-196
17 MIL never on Malfunction indicator light never on F3-198
18 Automatic Upshift/downshift/ Automatic transmission concerns not related to engine section K2
transmission engagement performance
concerns
19 High oil consumption/leaks Oil consumption excessive F3-199
20 Cooling system Overheating Engine runs at higher than normal temperature/ F3-199
concerns overheats
21 Cooling system Runs cold Engine does not reach normal operating temperature F3-200
concerns
22 Exhaust smoke Blue, black, or white smoke from exhaust system F3-201
23 Fuel odor (in engine compartment) Gasoline fuel smell or visible leaks F3-203
24 Engine noise Engine noise from under hood F3-204
25 Vibration concerns (engine) Vibration from under hood or driveline F3-205
26 A/C does not work A/C compressor magnetic clutch does not engage when F3-205
A/C is turned on
27 A/C always on/ A/C compressor magnetic clutch does not disengage F3-206
A/C compressor runs continuously
28 A/C does not cut off under wide open A/C compressor magnetic clutch does not disengage F3-206
throttle conditions under wide open throttle
29 Exhaust sulphur smell Rotten egq smell (sulphur) from exhaust F3-207
30 Intermittent concerns Symptom occurs randomly and is difficult to diagnose F3-208
46U0F3-155
F3-169
Description of Drivability Problems
46U0F1-158
Warning
Fuel in the fuel system is under high pressure when the

engine is not running.
Warning
• Fuel line spills and leaks are dangerous. Fuel
can ignite and cause serious injuries or death
and damage. Fuel can also irritate skin and eyes.
To prevent this, always complete the following
“Fuel Line Safety Procedures”.
3. After the engine stalls, turn OFF the ignition switch to OFF.
B. Avoid leakage.
1.W hen disconnecting a fuel line hose, w rap a rag
around it to protect against fuel leakage.
C.Install hose clamps to secure the fuel pressure gauge
to the fuel filter and the main hose.
F3-170
1 MELTS MAIN OR OTHER FUSE

MAIN (100A)
BTN (60A) b I IN Tuse nUUM TUS6
ROOM (15A) ......... “ rOM Terminal
1 I • 1 1 _
EGI INJ (30A)
PCM terminal
------------------- Distributor
PRC solenoid valve
EGR solenoid valve
------------------- Mass airflow sensor
ENGINE (15A) ENGINE fuse Main relay

Fuel pump relay
METER (15A) METER fuse Data link connector terminal B+

Transmission range sensor
WIPER (20A) WIPER fuse Heated oxygen sensor
46U0F3-156
F3-171
2 WILL NOT CRANK

DESCRIP • Starter does not work
TION
1 Is a clicking sound heard from the starter relay Yes Go to next Step
when the ignition switch is turned to START?
No Go to Step 3
2 Check the starting system Yes Check for seized/hydrolocked engine, flywheel
«■ section G (Refer to section B1)
Is the starting system OK?
No Service as required
(Refer to section G)
3 Do any other electrical accessories work? Yes Go to next Step
No Check the charging system

4 Is the pass diagnostic trouble code displayed dur Yes Pass diagnostic trouble code displayed
ing Key On Engine Off inspection? Go to next Step
«■ page F3-16
No Diagnostic trouble code no. displayed or
no diagnostic trouble codes displayed
Check for cause
5 Verify test results. If OK, return to diagnostic index to service any additional symptoms
46U0F3-157
F3-172
3 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIP • Starter cranks engine at normal speed but engine requires excessive cranking time before start
ing Key On Engine Off inspection and Key On Go to next Step
Engine Running inspection?
«■ page F3-15
Check for cause (Refer to related chart)
2 Connect a jumper wire between FP terminal of Yes Go to next Step
data link connector and a ground
Is fuel line pressure correct with ignition switch
No Zero or low:
ON?
• Check fuel pump circuit **■ page F3-122
a- page F3-125
• Check pressure regulator diaphragm w page F3-125
Fuel line pressure:
High:
260—320 kPa {2.6— 3.3 kgf/cm2, 37—46 psi}
• Check pressure regulator for high
pressure cause **■ page F3-125
• Check for clogged fuel return line
3 Is fuel line pressure held after ignition switch is Yes Go to next Step
turned off?
cr page F3-118
No Check pressure regulator diaphragm
Fuel line pressure:
condition page F3-125
More than 150 kPa {1.5kg f/cm2, 21 psi}
If condition is OK, check injector **■ pageF3-127
for 5 min.
If condition is not OK, replace pressure
regulator
4 Disconnect the vacuum hose from the pressure Yes Go to next Step
regulator and plug hose. Start the engine
Does the fuel line pressure remain within ±20 kPa
No Check for clogged fuel filter
{0.21 kgf/cm2, 3 psi} while driving vehicle?
w page F3-121
5 Connect the vacuum hose to the pressure regula Yes Go to next Step
tor. Install a vacuum gauge to the intake mani
fold. Start the engine.
Does fuel pressure gauge reading increase as the No Connect vacuum pump to pressure
regulator. Start the engine.
vacuum gauge reading decreases and/or does
Check that fuel pressure reading changed
fuel pressure gauge reading decrease as the vac
as vacuum changes
uum gauge reading increases?
• If changes, check vacuum line
• If no change, replace pressure regulator
6 Is idle speed correct? Yes Go to next Step
■a- page F3-14
No Adjust idle speed
MF1401-B1
F3-173

7 Is there a restriction in the exhaust system? Yes Check exhaust system
«■ page F3-132 «*• page F3-132
No Go to next Step
8 Remove PCV valve and shake PCV valve Yes Go to next Step
Does PCV valve rattle?
No Replace PCV valve
9 Check for contaminated mass airflow sensor. Yes Replace the mass airflow sensor
Is there any contamination?
No Go to next Step
10 Disconnect vacuum hose from EGR control valve Yes Check as follows:
and plug it. • EGR solenoid valve [vacuum] for sticking
Does condition improve? • Condition of EGR solenoid valve [vacuum]
connector female terminal(s)
No Check if EGR control valve moves smoothly
• If yes, Go to next Step
• If no, replace EGR control valve
11 Check starting system Yes Verify test results
«• section G If OK, return to diagnostic index to service
Is starting system normal? any additional symptoms
No Repair or replace components as required
MF1401-B2 46U0F3-158
F3-174
• AFTER START
4 ENGINE STALLS • AT IDLE
DESCRIP • Engine stops unexpectedly at idle and/or after start
TION
1 Does the vehicle stall at idle in park/neutral with Yes Go to Step 3
all accessories off?
No Go to next Step
ing Key On Engine Off inspection and/or Key On Go to Step 4
is- page F3-15
Check for cause
ing Key On Engine Off inspection? Go to Step 11
us- page F3-15
no diagnostic trouble code displayed
Check for cause
4 Disconnect in-line SPOUT connector and start Yes Go to next Step

engine
NOTE:
• If engine stalls, reconnect SPOUT connector
and go to next step
No Adjust timing
• If engine is now a No Start, reconnect SPOUT
If not adjustable, check as follows:
connector and check ignition system
• Distributor
Is base timing correct?
Base timing: BTDC 9— 11° (10±1°)
5 Attempt to start engine at part throttle Yes Check idle air control solenoid and
Will engine run smooth at part throttle? wiring harness
■a- page F2-114
No Go to next Step
6 Disconnect vacuum hose from EGR control valve Yes Check EGR vent on vacuum hose to EGR control
and plug it valve for obstruction or leak
Is drive symptom eliminated? • If OK, replace EGR solenoid (vacuum)
• If not OK, repair or replace vacuum line
No Go to next Step
7 Does EGR control valve seat properly (fully Yes Go to next Step
closed)?
• EGR control valve malfunction
• EGR flange gasket leaking
• EGR control valve attaching nuts or bolts loose
or missing
• EGR control valve contamination
• EGR solenoid (vacuum) malfunction
MF1402-B1
F3-175

8 Connect jumper wire between FP terminal of Yes Go to next Step
Is fuel line pressure correct when the ignition
No Zero or low:
switch is cycled ON and OFF?
• Check fuel pump circuit «■ page F3-116
page F3-125
• Check pressure regulator diaphragm **• page F3-125
Fuel line pressure:
High:
260—320 kPa {2.6— 3.3 kgf/cm2, 37—46 psi}
pressure cause «• page F3-125
9 Visually look for fuel leakage at injector O-ring, Yes Go to next Step
pressure regulator, and fuel line. Service as nec
essary. Connect jumper wire between FP termi
nal of data link connector and a ground
condition
Does fuel pressure remain at specification for 60
«■ page F3-125
seconds?
• If condition is OK, check injector «■ page F3-127
«• page F3-125
• If condition is not OK, replace pressure
regulator
10 Is strong blue spark visible at each disconnected Yes • If symptom occurs during parking
high-tension lead while cranking engine? maneuvers, Go to next Step
• If symptom occurs during A/C ON, go to
Step 13
No Check as follows: »*■ section G

• Ignition control module
11 Disconnect the steering pressure sensor (if Yes Replace steering pressure sensor
equipped)
Does rpm increase?
No Check for short circuit in wiring harness from
steering pressure sensor to PCM
12 Is there correct voltage at terminal 10 of PCM Yes Replace PCM «■ page F3-149
when the A/C is ON?
No Check for open circuit in wiring harness from
Specification:
A/C pressure switch to PCM
More than 10.5V
13 Is there a restriction in the exhaust system? Yes Check exhaust system <&■ page F3-132
«*■ page F3-132
No Go to next Step
MF1402-B2
F3-176
14 Is air leakage felt or heard at intake air system Yes Repair or replace
components while racing engine to higher speed?
No Go to next Step
15 Are spark plugs OK? Yes Go to next Step

«■ section G
v\ 'EAR /W D CARBON
, — BURNT
PLUG.
GAP
No Clean or replace **• section G

^—-D A M A G E AND
^ DETERIORATION
16
□
3— ‘ f
7 __ __DAMAGE
Is engine compression correct? Yes Go to next Step

«■ section B1
No Check for cause «■ section B1
17 Verify test result. If OK, return to diagnostic index to service any additional symptoms
MF1402-A3 46U0F3-159
F3-177
5 CRANKS NORMALLY BUT WILL NOT START

• Starter cranks engine at normal speed but engine will not run
DESCRIP • Refer to “ENGINE STALLS” if this symptom appears after engine stall
TION • Fuel in tank
• Battery in normal condition
ing Key On Engine Off inspection? Go to next Step
**■ page F3-15
Check for cause
2 Disconnect the throttle position sensor connector Yes Go to next Step

Is there correct voltage at terminal of the throttle
position sensor connector with the ignition switch
ON?
No Check voltage at PCM terminals 1, 26, 37, and 57
Specification: 4.5—5.5 V
3 Is a strong blue spark visible at each disconnect Yes Go to Step 5

ed high-tension lead while cranking engine?
ft \ No Go to next Step
( / / Y ®
(n'($<2/ n
4 Is a strong blue spark visible at disconnected Yes Check as follows:
high-tension lead from coil while cranking engine? • Ignition control module cr section G
• Distributor cap
• Rotor
• High-tension leads
No Check the spark output signal and crankshaft

position sensor signal at PCM
page F3-161
• If OK, go to Step 12
5
f ^
Install SST (breakout box) between wiring har Yes
• If not OK, check wiring harness
Go to next Step
ness and PCM. Set the timing switch to the
“COMPUTED" mode on the SST.
Is there correct voltage at pin 36 on the SST while
cranking engine?
No Check the spark output signal and crankshaft
Specification: 3.0— 6.0V
position sensor signal at PCM page F3-161
6 Connect the jumper wire between FP terminal of Yes Go to next Step

Is fuel line pressure correct when the ignition
switch is cycled ON and OFF 5 times?
No Check fuel pump
«• page F3-122
Fuel line pressure:
260—320 kPa {2.6—3.3 kgf/cm2, 37—46 psi}
'
MF1403-B1
F3-178
7 Visually look for fuel leakage at injector O-ring, Yes Go to next Step
nal of data link connector and a ground
condition «■ page F3-125
Does fuel pressure remain at specification for 60
• If condition is OK, check injector «■ page F3-127
seconds?
regulator
8 Disconnect the inertia fuel shutoff switch connec Yes Go to next Step
tor. Crank engine for 5 sec.
Does pressure drop more than 34 kPa {0.35
No Check resistance of injector(s) at PCM
kgf/cm2, 5 psi} by the end of five second crank
connector w page F3-127
cycle?
• If resistance is OK, check as follows:
• Injector drive signal
• Injection flow rate
• PCM
• If resistance is not OK, check as follows:
• Open circuit in injector circuit
9 Does engine start when throttle valve held quarter Yes Check idle air control solenoid and wiring harness
open? «*■ page F3-114
No Go to next Step
10 Disconnect vacuum hose from EGR control valve Yes Check EGR vent or vacuum hose to EGR control valve
and plug it for obstruction or leak
is drive symptom eliminated? • If OK, replace EGR solenoid valve (vacuum)
If not OK, repair or replace vacuum line
No Go to next Step
closed)?
• EGR control valve attaching nuts or bolts loose or missing
• EGR solenoid valve (vacuum) malfunction
12 Is there a restriction in exhaust system? Yes Check exhaust system

«■ page F3-132 «3T page F3-132
No Go to next Step
13 Is engine compression correct? Yes Go to next Step

■a- section B1
No Check for causes
■a- section B1
MF1403-B2 46U0F3-160
F3-179
6 SLOW RETURN TO IDLE

DESCRIP • Engine takes more time than normal to return to idle speed
TION
w pageF3-15
Check for cause
2 Is the throttle body free of contamination? Yes Go to next Step

«■ page F3-112
No Clean or replace the throttle body
3 Is air leakage felt or heard at intake air system Yes Repair or replace
No Go to next Step
MF1404-B 46U0F3-161
F3-180
7 ENGINE RUNS ROUGH/ROLLING IDLE • AT IDLE
DESCRIP • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake
TION • Idle speed too slow and excessive engine shake
<s- page F3-16
No Diagnostic trouble code no. displayed or no diagnostic
trouble codes displayed
Check for cause
2 Disconnect the in-line SPOUT connector. Yes If symptom is rough idle:

Start the engine Go to next Step
Is base timing within specification at idle? If symptom is other:
Go to Step 4
Base timing: BTDC 9— 11 °(10 ± 1°)
No Adjust base timing
• Distributor
3 Start the engine and disconnect the idle air control Yes Go to next Step
solenoid connector
Does the rpm drop or does the engine stall?
No Check the idle air control solenoid and
wiring harness page F3-114
4 Disconnect the vacuum hose from the EGR con Yes Check EGR vent or vacuum hose to EGR control
trol valve and plug it valve for obstruction or leak
Is the drive symptom eliminated? • If OK, replace EGR solenoid (vacuum)
No Go to next Step
5 Does EGR control valve seat properly? Yes Go to next Step
• EGR control valve attaching nuts or bolts loose or
missing
• EGR solenoid (vacuum) malfunction
6 Start engine and run it at idle. Measure fuel line Yes Go to next Step
pressure at idle
Is fuel line pressure correct at idle?
No Low:
page F3-125
• Check pressure regulator diaphragm «■ page F3-125
Fuel line pressure:
• Check fuel pump maximum pressure «■ page F3-122
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}
High:
• Check for clogged fuel return line <&■ page F3-116

data link connector and a ground.
Does fuel line pressure remain at specification for
60 seconds when ignition switch is turned ON?
«• page F3-125
»*■ page F3-125
MF1405-B1
F3-181

8 Perform Cylinder Balance Test Yes Check resistance of injector(s) at PCM
Are there any diagnostic trouble codes? connector
**• page F3-15 is- page F3-149
• If resistance is OK, check as follows:
• injector drive signal
• open/short circuit in injector circuit
No Go to next Step
9 Run engine at 2000 rpm for two minutes Yes Check heated oxygen sensor harness
Are there any diagnostic trouble codes? ef page F3-164
page F3-15
No Check heated oxygen sensor heater harness
Go to next Step
us- page F3-164
10 Are spark plugs OK? Yes Go to next Step
■s- section G
WEAR AND CARBON
p^ | | r BURNT
f f i B i~ - D A M A G E AND No Clean or replace
Jte.... DETERIORATION ■s- section G
N = = = |f^ -D A M A G E
12 Start the engine and bring to normal operating Yes Go to next Step
temperature. Disconnect hose from remote air
cleaner. Place a stiff piece of paper over the hose No Check fuel evaporative system as follows:
end Disconnect evaporative hose and place a stiff piece of
Does vacuum hold the paper? paper over hose
Does vacuum hold paper?
■s- page F3-138
• If yes, malfunction of fuel evaporative system
• If no, check for vacuum leak in PCV system, oil cap,
PCV valve, rocker cover for bolt torque/gasket leak
13 Remove a plug line to charcoal canister. Remove Yes Repair or replace

gas cap and install a vacuum pump/gauge gas
cap. Apply air pressure
Air pressure: No Go to next Step

20—27 kPa {0.21—0.28 kgf/cm2, 3—4 psi}
Is either a vacuum or fuel leak detected?
14 Check for blockage/restrictions or opens (hoses) Yes R eplace vacuum hose

between engine vacuum port and charcoal canis
ter. Check for blockage in fuel tank vent system
Is a fault detected?
No Go to next Step
MF-1405-B2
F3-182
15 Check canister purge solenoid Yes Go to next Step
Is the solenoid operating properly?
<*■ page F3-139
No Go to next Step
16 Is there a restriction in the exhaust system? Yes check exhaust system

«• page F3-132
«■ page F3-132
No Go to next Step
17 Is there air leakage at intake air system Yes Repair or replace

No Go to next Step

■a* section B1
No Check for cause

■a- section B1
MF1405-A3 46U0F3-162
8 FAST IDLE/RUNS ON
DESCRIP • Engine speed continues at fast idle after warm-up
TION • Engine runs after ignition switch is turned off
page F3-15
No Diagnostic trouble code no. displayed or no diagnostic
Check for cause
2 Disconnect the in-line SPOUT connector. Start Yes Go to next Step

the engine
Is base timing within specification at idle?
Base timing: BTDC 9-11 °(10 ± 1°)

• Distributor
3 Is there air leakage felt or heard at intake air sys Yes Repair or replace parts as necessary
tem components while racing engine to higher
speed?
No Go to next Step
MF1406-B 46U0F3-163
F3-183
9 LOW IDLE/STALLS DURING DECELERATION

DESCRIP • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration
TION
® pageF3-15 No Diagnostic trouble code no. displayed or no diagnostic
Check for cause
2 Disconnect in-line SPOUT connector. Start the Yes Go to next Step

engine.
Is base timing within specification?
Base timing:
BTDC 9— 11°(10 ± 1°)
• Distributor
3 Does idle speed drop in the following conditions? Yes Check as follows:
• Circuit from idle air control solenoid to
Condition PCM for open and short
• Air conditioner ON **■ page F3-149
• Idle air control solenoid for sticking
is- page F3-114
No Adjust idle speed

**■ page F3-14
4 Check the following: Yes Repair or replace

• EGR control valve
• EGR vacuum regulator solenoid
Are any of the components faulty?

No Go to next Step
5 Are the following terminals and connections Yes Verify test results. If OK, return to diagnostic index to ser
good? vice any additional symptoms
• Ignition control module connector
• Main relay
• PCM connector
MF1407-B 46U0F3-164
F3-184
ENGINE STALLS/QUITS • ACCELERATION/CRUISE
ENGINE RUNS ROUGH • ACCELERATION/CRUISE
10 MISSES • ACCELERATION/CRUISE
BUCK/JERK • ACCELERATION/CRUISE/DECELERATION
HESITATION/STUMBLE • ACCELERATION
• Engine stops unexpectedly at beginning of acceleration or during acceleration
• Engine stops unexpectedly while cruising
DESCRIP • Engine speed fluctuates during acceleration or cruising
TION • Engine misses during acceleration or cruising
• Vehicle bucks/jerks during acceleration, cruising, or deceleration
• Momentary pause at beginning of acceleration or during acceleration
**• page F3-15 No Diagnostic trouble code no. displayed or no diagnostic trou
ble codes displayed
Check for cause
2 Disconnect the in-line SPOUT connector Yes Go to next Step
Base timing:
BTDC 9— 11 °(10 ± 1°)
• Distributor
3 Disconnect vacuum line at EGR control valve and Yes Check as follows:
plug it • EGR vacuum regulator solenoid for sticking
Is drive symptom eliminated?
No Go to next Step
closed)?
• EGR control valve operation
• EGR contorl valve contamination
• EGR solenoid (vacuum)
• Pressure/vacuum signal hose leak
at idle
Is fuel line pressure correct at idle? No Low:
a- page F3-125
Fuel line pressure:
• Check fuel pump maximum pressure page F3-125
210— 260 kPa {2.1—2.7 kgf/cms, 30—38 psi} High:
pressure cause «■ page F3-125
6 Does fuel pressure remain at specification for 60 Yes Go to next Step
seconds?
No Check pressure regulator diaphragm «*■ page F3-125
• If condition is OK, check injector s ’ page F3-127
• If condition is not OK, replace
pressure regulator
MF1408-B1
F3-185

7 Perform the Cylinder Balance Test. Yes Check injector resistance
a- page F3-17 • If OK, check injector drive signal
If no drive signal, replace PCM
• If not OK, check continuity between
injector and PCM
«■ page F3-149
No Go to next Step
8 Run engine at 2000 rpm for two minutes Yes Check heated oxygen sensor wiring harness
Are diagnostic trouble codes present? « ' page F3-164
No Check heated oxygen sensor heater

«*■ page F3-164
If OK, go to next Step
9 Is a strong blue spark visible at each disconnect Yes Check spark plugs «■ section G
ed high-tension lead while cranking engine? • If OK, go to next Step
• If not OK, clean or replace spark plug
No Check as follows: «■ section G

• Distributor
• Condition of distributor connector female terminals
10 Check that throttle lever is resting on throttle valve Yes Adjust as necessary
stop screw and/or throttle valve orifice plug
Are any faults present?
No Go to next Step
11 Is there air leakage felt or heard at intake air sys Yes Repair or replace parts as necessary
speed?
No Go to next Step
13 Start the engine and bring to normal operating Yes Go to next Step
cleaner. Place a stiff piece of paper over the hose
end
No Check fuel evaporative system as follows:
Does vacuum hold the paper?
Disconnect evaporative hose and place a stiff piece of
paper over hose
Does vacuum hold paper?
• If yes, malfunction of fuel evaporative system
«■ page F3-138
• If no, check for vacuum leak in PCV system, oil cap,
PCV valve, rocker cover for bolt torque/gasket leak
MF148-B2
F3-186
i®- page F3-132 «• page F3-132
No Go to next Step
15 Remove a plug line to canister. Remove gas cap Yes Repair or replace
and install vacuum pump/gauge gas cap.
Apply air pressure
Air pressure:
No Go to next Step
20—27 kPa {0.21—0.28 kgf/cm’, 3—4 psi}
Is either a vacuum or fuel leak detected?
16 Check for blockage/restrictions or opens (hoses) Yes Replace vacuum hose

No Go to next Step
17 Check canister purge solenoid. Yes Go to next Step

«■ page F3-138
No Replace the canister purge solenoid
18 Measure resistance of the heated oxygen sensor Yes Go to next Step

heater
Is the resistance within specification?
Resistance:
Approx 6 0 (at 20°C {68°F})
19 Measure voltage of heated oxygen sensor heater Yes Go to section B1

Is voltage more than 10.5V? If engine OK, go to next Step
No Check heated oxygen sensor heater circuit

«■ page F3-164
MF1408-B3 46U0F3-165
F3-187
11 SURGES • ACCELERATION/CRUISE
DESCRIP • Momentary minor irregularity in engine output
TION
«■ pageF3-15 No Diagnostic trouble code no. displayed or no diagnostic trou
ble codes displayed
Check for cause
Base timing:
BTDC 9— 11° (10 ± 1 °)
• Distributor
3 Disconnect the vacuum hose from the EGR con Yes Check EGR vent on vacuum hose to EGR control valve for
trol valve and plug it obstruction or leak
Is the drive symptom eliminated? • If OK, replace EGR solenoid (vacuum)
No Go to next Step
missing
pressure at idle
«• page F3-125 • Check pressure regulator diaphragm a- page F3-125
Fuel line pressure:
• Check fuel pump maximum pressure <&■page F3-125
High:
210—260 kPa {2.1—2.7 kgf/cm!, 30—38 psi} • Check pressure regulator for high
pressure cause a- page F3-125
60 seconds when ignition switch is turned ON? Check pressure regulator diaphragm
No
«• page F3-125 a- page F3-125
7 Perform Cylinder Balance Test Yes Check resistance of injector(s) at PCM connector
Are there any diagnostic trouble codes? a- page F3-149
«■ page F3-15 • If resistance is OK, check as follows:
• Open/short circuit in injector circuit
No Go to next Step
MF1409-B1
F3-188
8 Run engine at 2000 rpmfor two minutes Yes Check heated oxygen sensor harness
Are there any diagnostic trouble codes? «■ page F3-164
«■ page F3-15
No Check heated oxygen sensor heater harness
Gotonext step
«■ page F3-164
9 Is a strong blue spark visible at each disconnect Yes Check spark plug(s) for damage
ed high-tension lead while cranking engine? • IfOK, go to next Step
• Ifnot OK, replace spark plug(s)
• Distributor cap and rotor for damage
w section G
10 Remove PCVvalve and shake PCVvalve Yes Gotonext Step

Does PCVvalve rattle?
No Replace PCVvalve
11 Check charcoal canister for fuel saturation Yes Replace charcoal canister
Is excess amount of liquid fuel present incanis
ter?
No Check fuel tank vent system
Goto next Step
12 Is there a restriction inthe exhaust system? Yes Check exhaust system « ' page F3-132
No Gotonext Step
13 Measure resistance of heated oxygen sensor Yes Goto next Step

heater
Is resistance within specification?
Resistance:
Approx 6£2 (at 20°C {68°F}
MF1409-A2 46U0F3-166
F3-189
12 BACKFIRES • IDLE/ACCELERATION/DECELERATION
DESCRIP • Sound produced from exhaust system
TION
Engine Running inspection
«■ page F3-15
Check for cause

Base timing: No Adjust base timing

BTDC9— 11° (10 + 1°) • Distributor
3 Is a strong blue spark visible at each disconnect Yes Check spark plugs «*■ section G
No Check as follows: <®- section G
'111 • Distributor
/’ (n\
® " W =±~^\ • High-tension leads
4 Perform Cylinder Balance Test Yes Check resistance of injector(s) at PCM connector
Are there any diagnostic trouble codes? page F3-149
page F3-20 • If resistance is OK, check as follows:
No Go to next Step

«■ section B1
No Check for cause «*■ section B1
6 Is there arestriction in the exhaust system? Yes Check exhaust system page F3-132
page F3-132
No Go to next Step
MF1410-B1 46U0F3-167
13 LACK/LOSS OF POWER • ACCELERATION/CRUISE
DESCRIP • Performance poor under load (i.e., power down when climbing hills)
TION
**• page F3-15
Check for cause

Base timing:
BTDC 9— 11° (10 ± 1 °)
• Distributor
3 Is a strong blue spark visible at each disconnect Yes Check spark plugs <&■ section G
No Check as follows: «■ section G

• Distributor
4 Perform Cylinder Balance Test Yes Check resistance of injector(s) at «■ page F3-149
Are there any diagnostic trouble codes? PCM connector
■a- page F3-20 • If resistance is OK, check as follows:
No Go to next Step
pressure at idle
No Low:
a- page F3-125
• Check pressure regulator diaphragm page F3-125
Fuel line pressure:
• Check fuel pump maximum pressure page F3-125
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}
High:

**■ page F3-125
■a- page F3-125
MF1411-B1
F3-191

» pageF3-132 a- page F3-132
No Go to next Step
8 Is there air leakage felt or heard at intake air sys Yes Repair or replace
speed?
No Go to next Step

a- section B1
No Check for cause

a- section B1
10 Is the brake system functioning properly? Yes Go to next Step

a- section P
No Check for cause

a- section P
11 Disconnect the vacuum hose from the EGR con Yes Check EGR vent on vacuum hose to EGR control valve
trol valve and plug it for obstruction or leak
Is the drive symptom eliminated? • If OK, replace EGR solenoid valve (vacuum)
• If not OK, repair or replace vacuum lines
No Go to next Step
missing
13 Is terminal 10 voltage at PCM correct? Yes Go to next Step
«■ page F3-149
No Refer to 1994 626/MX-6 BETM
MF1411-B2 46U0F3-168
F3-192
14 KNOCKING / PIPING • ACCELERATION/CRUISE
DESCRIP • Sound produced when air/fuel mixture is ignited by something other than spark plug (i.e., hot spot in
TION combustion chamber)
1 Does vehicle overheat when knocking/pinging Yes Inspect cooling system for cause of overheating
occurs? a- section E1
No Go to next Step

Base timing:
BTDC 9— 11° (10 ±1°)
• Distributor
ing Key On Engine Off inspection and Key On Go to next step
«■ page F3-15
Check for causes

a- section B1
No Check for cause

a- section B1
pressure at idle
No Low:
a- page F3-125
Fuel line pressure:
• Check fuel pump maximum pressure a- page F3-125
210—260 kPa {2.1— 2.7 kgf/cm2, 30—38 psi}
High:
pressure cause a- page F3-125

a - page F3-116
a - page F3-125
7 Disconnect the vacuum hose from the EGR con Yes Check EGR vent on vacuum hose to EGR control valve for
trol valve and plug it obstruction or leak
Is the drive symptom eliminated? • If OK, replace EGR solenoid valve (vacuum)
No Go to next Step
MF1412-B1 46U0F3-169
F3-193

DESCRIP • Fuel economy unsatisfactory
TION
»» page F3-15
Check for cause
2 Start the engine and run it at idle. Measure fuel Yes Go to next Step
line pressure at idle
No Low:
page F3-125
Fuel line pressure: • Check pressure regulator diaphragm «*■ page F3-125
210—260 kPa {2.1—2.7 kgf/cm!, 30—38 psi} • Check fuel pump maximum pressure «■ page F3-125
High:
pressure cause «*■ page F3-125

60 seconds when ignition switch is turned ON? No Check pressure regulator diaphragm
ra- page F3-125 **■ page F3-125

Base timing:
BTDC 9— 11° (10 ±1 °)
• Distributor
5 Is a strong blue spark visible at each disconnect Yes Check spark plugs » section G
ed high-tension lead while cranking engine? If OK, go to next Step
If not OK, clean or replace spark plug
\ No Check as follows:
• Distributor
/ /II • High-tension leads
f 'v m 'H i • Condition of distributor connector female terminals
6 Is there a restriction in the exhaust system? Yes Check exhaust system «■ page F3-132
«■ page F3-132
No Go to next Step
MF1413-A1
F3-194
7 Does the engine cooling system function proper Yes Go to next Step
ly?
«- section E1
No Check for cause «■ section E1
closed)?
• EGR control valve operation
• EGR vacuum regulator solenoid
• Pressure/vacuum signal hose leak
9 Remove the PCV vale and shake PCV valve Yes Go to next Step
No Replace PCV vale
10 Is the brake system functioning properly? Yes Go to next Step

section P
No Check for cause

section P

«■ section B1
No Check for cause

«■ section B1
12 Check for contaminated mass airflow sensor Yes Replace the mass airflow sensor
Is there any contamination?
No Go to next Step
MF1413-B2 46U0F3-17Q
F3-195
16 EMISSIONS COMPLIANCE
DESCRIP • Fails emissions test
TION
«■ page F3-15
Check for cause

Base timing: No Adjust base timing

BTDC 9— 11° (10 ± 1 °) If not adjustable, check as follows:
• Distributor
3 Is a strong blue spark visible at each disconnect Yes Check spark plugs «■ section G
ed high-tension lead while cranking engine? • If OK, Go to next Step
No Check as follows: section G

✓cSS® f \ )i • Distributor
i n \ • Condition of distributor connector female terminals
pressure at idle
No Low:
«*■ page F3-125
• Check pressure regulator diaphragm **■ page F3-125
Fuel line pressure:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} • Check fuel pump maximum pressure «■ page F3-125
High:

«• page F3-125
No Replace PCV vale
MF1414-B1
F3-196
7 Check charcoal canister for fuel saturation Yes Replace charcoal canister
Is excess amount of liquid fuel present in canis
ter?
Go to next Step

«• pageF3-132 page F3-132
No Go to next Step
9 Does EGR control valve set properly? Yes Go to next Step
missing
10 Is the engine running at the proper operating tem Yes Go to next Step
perature?
No Check cooling system or cause

■s- section El

«■ section B1
No Check for cause

■a* section B1
MF1414-B2 46U0F3-171
F3-197
17 MIL NEVER ON
DESCRIP • Malfunction indicator lamp never on
TION
1 Is number 7 fuse burnt? Yes Repair wiring harness and replace fuse
No Go to next Step
2 Is there correct voltage at the MIL fuse? Yes Go to next Step
Specification:
More than 10.5V
No Repair open in wiring harness between fuse
block and ignition switch
3 Remove the malfunction indicator lamp bulb Yes Go to next Step

Is the voltage correct on the positive side of the
malfunction indicator lamp bulb socket?
No Repair open in wiring harness between fuse
Specification:
block and malfunction indicator lamp bulb socket
More than 10.5V
4 Apply 12 volts and a ground to the malfunction Yes Go to next Step

indicator lamp bulb
Does the malfunction indicator lamp bulb illumi
nate?
No Replace malfunction indicator lamp bulb
5 Disconnect the PCM. Install SST (breakout box) Yes Replace PCM
to the PCM connector ■a- page F3-149
Does continuity exist between malfunction indica
tor lamp socket and test pin 17?
No Repair open circuit in wiring harness between
PCM and malfunction indicator lamp socket
MF1415-B 46U0F3-172
F3-198
19 HIGH OIL CONSUMPTION / LEAKS
DESCRIP • Oil consumption excessive
TION
1 Remove PCV valve and shake PCV valve Yes Go to next step
2 Is blue smoke coming from exhaust? Yes Check for cause

«■ section P
No Go to next step
MF1417-A 46U0F3-173
20 COOLING SYSTEM CONCERNS • OVERHEATING

DESCRIP • Engine runs at higher than normal temperature/overheats
TION
1 Is drive belt OK? Yes Go to next step
**• section G
No Replace drive belt
«• section G
2 Is cooling system operating properly? Yes Go to next step

■s- section E1
No Check for cause
«■ section E2
3 Inspect engine block for leaks or blockage Yes Repair or replace

Is fault present?
■s’ section E1
No Go to next step
MF1418-A 46U0F3-174
F3-199
21 COOLING SYSTEM CONCERNS • RUNS COLD

DESCRIP • Engine does not reach normal operating temperature
TION
1 Is coolant system operating properly? Yes Go to next step
«• section E1
No Check for cause
**• section E1
2 Is complaint “Lack of passenger compartment Yes Refer to 1994 626/MX-6 BETM

heat” and the engine is operating at normal tem
perature?
No Go to next step
3 Is temperature gauge working properly? Yes Go to next step
No Refer to 1994 626/MX-6 BETM
MF1419-A 46U0F3-175
F3-200
22 EXHAUST SMOKE
DESCRIP • Blue, black, or white smoke from exhaust system

TION
1 What is the color of smoke coming from exhaust Blue Go to next step
system?
White Go to step 4
Black Go to step 5
2 Remove PCV valve and shake PCV valve Yes Go to next step
3 Is engine compression correct? Yes Verify test results. If OK, return to diagnostic
section B1 index to service any additional symptoms
No Check for cause

«*■ section B1
4 Does cooling system hold pressure? Yes Verify test results. If OK, return to diagnostic
er section E1 index to service any additional symptoms
No Check for cause

«■ section E1
«• page F3-15
Check for cause
6 Start engine and run it at idle. Measure fuel line Yes Go to next step
pressure at idle
No Low:
«• pageF3-125
• Check pressure regulator diaphragm page F3-125
Fuel line pressure:
• Check fuel pump maximum pressure «■ page F3-125
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}
High:
pressure cause «- page F3-125
7 Connect a jumper wire between FP terminal of Yes Go to next step

No Check pressure regulator diaphragm «■ page F3-125
pageF3-125
• If OK, check injector «■ page F3-127
• If not OK, replace pressure regulator
MF1420-B1
F3-201

8 Disconnect in-line SPOUT connector. Start the Yes Go to next step
engine
Is base timing within specification at idle? No Adjust base timing
Base timing: • Distributor
BTDC 9— 11° (10 ± 1°)
9 Is a strong blue spark visible at each disconnect Yes Check spark plugs Section G
ed high-tension lead while cranking engine? • If OK, go to next step
• Distributor
• High-tension lead
46U0F3-176
/'"N
F3-202
23 FUEL ODOR (IN ENGINE COMPARTMENT)
DESCRIP • Gasoline fuel smell or visible leaks

TION
1 Visually look for fuel leakage at injector O-ring, Yes Go to next step
nal of data link connector and a ground Check pressure regulator diaphragm
No
Does fuel line pressure remain at specification for condition «*■ page F3-125
60 seconds? • If condition id OK, check injector «*• page F3-127
«■ page F3-125
Fuel line pressure: regulator
260— 320 kPa {2.6—3.3 kgf/cm2, 37—46 psi}
2 Start the engine and bring to normal operating Yes Go to next step
cleaner. Place a stiff piece of paper over the hose
No Check fuel evaporative system as follows:
end.
Disconnect evaporative hose and place a
stiff piece of paper over hose
• If yes, malfunction of fuel evaporative
system «• page F3-138
• If no, check for vacuum leak in PCV
system, oil cap, PCV valve, rocker cover
for bolt torque/gasket leak
3 Remove a plug line to charcoal canister. Remove Yes Repair or replace
gas cap and install a vacuum pump/gauge gas
cap. Apply air pressure
Air pressure:
No Go to next step
20—27 kPa {0.21—0.28 kgf/cm2, 3—4 psi}
Is either vacuum or fuel leak detected?
4 Check for blockage/restrictions or open (hoses) Yes Replace vacuum hose

No Go to next step
5 Check canister purge solenoid Yes Go to next step

ra- page F3-139
No Replace the canister purge solenoid
6 Is the pass diagnostic trouble code displayed dur Yes Pass diagnostic trouble displayed
page F3-15
No Diagnostic trouble code no. displayed
or no diagnostic trouble code displayed
Check for cause
MF1421-B 46U0F3-177
F3-203
24 ENGINE NOISE
DESCRIP • Engine noise from under hood
TION
1 Is a squeal, click or chirp sound present? Yes Check as follows:
• Engine oil level
• Drive belts
• Tappets and push rods
No Go to next step
2 Is a rumble or grind sound present? Yes Check drive belt
No Go to next step
3 Is a rattle sound present? Yes Check location of rattle for loose parts
No Go to next step
4 Is a hiss sound present? Yes Check as follows:

• Engine cooling system for leaks
• Vacuum leaks
• Spark plug loose
• Intake air system leaks
• Fuel evaporative system leaks
No Go to next step
5 Is a snap sound present? Yes Check secondary ignition system for shorts
No Go to next step
6 Is a rap or roar sound present? Yes Check exhaust system for loose parts
No Go to next step
7 Is a knock sound present? Yes Go to the “KNOCKING/PINGING”

diagnostic chart
No Go to next step
MF1422-A 46U0F3-178
F3-204
25 VIBRATION CONCERNS (ENGINE)
DESCRIP • Vibration from under hood or driveline

TION
1 Check the following components for loose attach Yes Repair or replace
ing bolts or worn parts:
• Coolant fan
• Drive belt and pulleys
• Engine mounts No Go to next step
• Vibration damper
Is a fault present?
2 Check the following system for malfunctioning Yes Repair or replace

components:
• Tires
• Wheels
• Transaxle
• Driveline
No Go to next step
• Suspension
Is a fault present?
MF1423-B 46U0F3-179

DESCRIP • A/C compressor magnetic clutch does not engage when A/C is turned on
TION
ing Key On Engine Off inspection? Go to next step
«• page F3-15

Check for cause
2 Disconnect the A/C compressor connector. Start Yes Refer to 1994 626/MX-6 BETM
the engine and turn on the Air Conditioning
Sensor
After 10 seconds, is there correct voltage at termi
nal (PU) of the A/C compressor connector?
No Refer to
Specification:
More than 10.5V
MF1424-A 46U0F3-180
F3-205
27 A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY

DESCRIP • A/C compressor magnetic clutch does not disengage
TION
1 Disconnect the A/C compressor connector Yes Refer to 1994 626/MX-6 BETM
Start the engine and turn OFF the Air Conditioning
Sensor
Is there correct voltage at terminal (PU) of the A/C
compressor connector?
No Go to next Step
Specification:
Less than 2.0V
2 Does the A/C compressor stop when the Air Yes Refer to 1994 626/MX-6 BETM
Conditioning Sensor
No Go to next Step
ing Key On Engine Off inspection? Refer to page F3-22
s ’ page F3-15
Check for cause
MF1425-B 46U0F3-181
28 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS
DESCRIP • A/C compressor magnetic clutch does not disengage under wide open throttle
TION
1 Remove the wide open throttle A/C relay Yes Go to next Step
Is there correct voltage at battery power terminal
of the A/C relay connector with the ignition switch
ON?
No Repair A/C power circuit
Specification:
Less than 10.5V
2 Is the A/C relay OK? Yes Go to next Step

1994 626/MX-6 BETM
No Repair A/C relay
3 Is there correct voltage at terminal 54 of the Yes Check wiring harness between
PCM? A/C relay and PCM for open or short circuit
«• page F3-149
No Replace PCM
MF1426-A 46U0F3-182
F3-206
29 EXHAUST SULPHUR SMELL
• Rotten egg smell (sulphur) from exhaust
NOTE:
DESCRIP
TION • Some slight sulphur smell may be normal. Catalysts with less than 8— 16 thousand kilometers (5— 10 thou
sand miles) are more likely to have a sulphur smell concern due to the highly active state of new catalysts.
Replacing the catalyst if no catalyst if no problem is found may actually make the symptom worse.
1 Start engine andn run it at idle. Measure fuel line Yes Go to next Step
pressure at idle.
» page F3-25 • Check pressure regulator diaphragm «*■ page F3-125
210—260 kPa {2.1— 2.7 kg/cma, 30—38 psi} • Check fuel pump maximum pressure «*■ page F3-125
High:
• Check pressure regulator for high pressure cause
isr page F3-125
data link connector and a ground.
60 seconds when ignition switch is turned on? No Check pressure regulator diaphragm **■ page F3-125
«*■ page F3-25
3 Is the press diagnostic trouble code displayed dur Yes Pass diagnostic trouble code displayed
«■ page F3-16 No Diagnostic trouble code no. displayed or no diagnostic
trouble code S displayed
Check for cause
4 Check charcoal canister for fuel saturation. Yes Replace charcoal canister
Is excess amount of liquid fuel present in canis
ter?
If OK, try different brand of fuel to resolve concern
If not OK, service fuel tank vent system
F3-207
30 INTERMITTENT CONCERNS
DESCRIP • Symptom occurs randomly and is difficult to diagnose

TION
1 Talk to customer. Review the vehicle service Yes Go to next step
history
Does the vehicle have a number of previous No Go to diagnostic chart for symptom
repairs and components replaced for a certain
symptom?
2 Is an engine analyzer available? Yes Follow the instructions supplied with the
engine analyzer to diagnose the concern
No Go to next step
3 Will the engine start? Yes Go to next step
No Go to “CRANKS NORMALLY BUT

WILL NOT START” diagnostic chart
4 Start the engine and run it at idle. Raise the hood, Yes Service wiring harness or connector
shake wiring harness and pull wires at connectors
for ignition components
No Go to next step
Does the engine quit?
5 Run the engine at idle. Close the hood Yes Go to step 9

Turn the A/C on, blower on at medium speed, and
allow engine to run for 15 minutes
No Go to next step
6 Stop the engine. Let the vehicle hot soak for 10 Yes Go to next step
minutes with the hood closed
Will the engine restart?
No Go to “CRANKS NORMALLY BUT
WILL NOT START” diagnostic chart
7 Start the engine and run it at idle. Raise the hood, Yes Service wiring harness or connector
shake wiring harness and pull wires at connectors
No Go to next step
8 Road test the vehicle Yes Go to next step

No Symptom not duplicated. Return to diagnostic
index to service any additional concerns
9 Raise the hood. Shake wiring harness, pull wires Yes Service wiring harness or connector
at connectors, separate and reconnect connectors
No Go to diagnostic chart No.2, No.3
Does the engine start?
MF1428-A 46U0F3-183
F3-208
SERVICE POINTS F3
SERVICE POINTS
OUTLINE
[Power and ground]
PCM Power Relay (Battery Power)
EEC PWR Fuse (PCM Memory Power)

• If the EEC PWR fuse circuit has an open or short, Diagnostic Trouble Code No.512 is output.
• If the circuit is open, the PCM memory function will not operate and Diagnostic Trouble Codes for
intermittent malfunctions will not be indicated. Also, the learning control will be canceled, but will not
produce any particular symptom.
Ground
• If there is a poor ground, the engine may not start.
STI Terminal (Data Link Connector)

• If the circuit is open, the Super STAR II Tester cannot perform Diagnostic Trouble Code checks.
• If the circuit is shorted, the opening amount of the idle air control solenoid will not change, causing
hard starting and rough idle.
STO Terminal (Data Link Connector)

• If the circuit is open, the Super STAR II Tester cannot perform Diagnostic Trouble Code checks.
• If the circuit is shorted, STO LO will be indicated on the Super STAR II Tester, preventing a
Diagnostic Trouble Code check.

• If the circuit is open, the MIL will not illuminate with the ignition switch ON.
• If the circuit is shorted, the MIL will not go off after the engine is started.
[Input Device]
Mass Airflow Sensor
• If the mass airflow sensor or circuit has an open or short, Diagnostic Trouble Code No.157, 158 or
159 is output.
• A malfunction in the mass airflow sensor circuit may cause lack of power, poor acceleration, hesitate
at driveaway or vehicle shake on deceleration.

• If the intake air temperature sensor or circuit has an open or short, Diagnostic Trouble Code No.112
or 113 is output.
• If the intake air temperature sensor circuit fails, no particular symptom will be noticed.

• If the throttle position sensor or circuit has an open or short, Diagnostic Trouble Code No. 121,122 or
123 is output.
• If the throttle position sensor circuit fails, rough idle, poor acceleration or shift shock may occur.

• If the heated oxygen sensor or circuit has an open or short, Diagnostic Trouble Code No.172 or 173
is output
• If the heated oxygen sensor circuit fails, poor fuel economy may occur.
Crankshaft Position Sensor (In Distributor)

• If the crankshaft position sensor or circuit has an open or short, Diagnostic Trouble Code No.211 is
output.
• If the crankshaft position sensor circuit fails, the engine will stall and will not restart.
46U0F3-184
F3-209
SERVICE POINTS F3
Fuel Pump Relay

• If the purge solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.565 is output.
• If the circuit is shorted, the engine may stall at low speed.
• A short circuit may cause an improper air/fuel ratio, causing rough idle and hard starting.
A/C Relay
• If the circuit is open, A/C cutout will not occur.
• If the circuit is shorted, A/C will not operate.
Pressure Regulator Control (PRC) Solenoid Valve

• If the PRC solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.554 is output.
• If the circuit is open, the engine will be hard to start after heat socked.
EGR Solenoid Valve (Vent) [EGRA]

EGR Solenoid Valve (Vacuum) [EGRV]

• If the circuit is shorted, the EGR control valve will remain open, causing engine stalling and hard
starting.
46U0F3-186
F3-211
F3 SERVICE POINTS
Condition
Circuit
PCM (37, 57)— Main relay Engine stalls and will not EGI INJ fuse (30A) burns
restart NA
36U0F3-187

Condition
Circuit
PCM (1)— Room fuse No symptom Room fuse (15A) burns out NA
36U0F3-188

Condition
Circuit
PCM— Ground (Injector) Engine stall and will not Engine may not start
PCM— Ground (Power) restart
PCM— Ground (System) NA
PCM— Ground (Analogue) DTC No.112,113,117

and/or 118 output
46U0F3-189
[Input Device]
Mass Airflow Sensor
Condition
Circuit
PCM (9)— Mass airflow sensor Code Nos. 158 or 159 Code Nos. 158 or 159
output output
Vehicle shake on Vehicle shake on
PCM (50)— Mass airflow sensor Code Nos.157 or 159 Code Nos. 157 or 159
output output NA
Vehicle shake on Vehicle shake on
PCM power relay— Mass airflow Engine stalls and will not
sensor restart
Melts EGI INJ fuse (30A)
Mass airflow sensor—Ground NA —
36U0F3-190
intake Air Temperature Sensor

Condition
Circuit
PCM (25)— Intake air temperature Code Nos.113 or 114 Code Nos.112 or 114 NA
sensor output output
PCM (46)— Intake air temperature NA ---
NA: Not Applicable 46U0F3-191
F3-212
SERVICE POINTS F3
Vehicle Speedometer Sensor
Condition
Circuit
PCM (3) Vehicle speedometer sensor Code No.452 output Code No.452 output NA
PCM (6) Vehicle speedometer sensor NA Code No.452 output
46U0F3-192
Transmission Range Sensor

Condition
Circuit
PCM (30)—Transmission range Code No.522 output Code No.522 output
NA
sensor
46U0F3-193
Fuel Pump Relay (Fuel Pump Monitor Signal)

Condition
Circuit
PCM (8)— Fuel pump relay Code Nos.542 or 543 Code No.542 output
output Engine stalls and will not
Main fuse panel— Fuel pump relay Code Nos.542 or 543 restart
NA
output Melts EGI INJ fuse (30A)
restart
46U0F3-194
Ignition Control Module (Ignition Diagnostic Monitor)

Condition
Circuit
PCM (4)— Ignition control module Code No.212 output Code No.212 output
Ignition control— Ignition coil Engine stalls and will not Engine stalls and will not
module restart restart NA
Ignition switch— Ignition control Code No.212 output Engine stalls and will not
Module No symptom restart
Melts IG KEY fuse (40A)
Ignition control module— Distributor NA —
46U0F3-195
EGR Function Sensor

Condition
Circuit
PCM (27)— EGR function sensor Code No.327, 332, or 337 Code No.327, 332 or 337
No symptom No symptom NA
F3-213
SERVICE POINTS F3
[Output Device]
Injector
Condition
Circuit
PCM (35, 39, 58, 59)— Injector Hard to start Will not start or hard to start
Rough idle Engine rough or stalls
NA
Poor acceleration at low Poor acceleration
speed
46U0F3-203
Spark Output Signal (Ignition Control Module)

Condition
Circuit
PCM (36)— Ignition control module Code No.213 output — NA
46U0F3-204
Idle Air Control Solenoid

Condition
Circuit
PCM (21)— Idle air control solenoid Code Nos.411 or 412 Code Nos.411 or 412
output output
Rough idle High idle speed
Engine stalls after racing
Hard to start after warm up Melts EGI INJ fuse (30A) NA
PCM power relay— Idle air control
Engine rough at driveaway Engine stalls and will not
solenoid
When engine is cold restart
A/C ON
NA: Not Applicable 46UQF3-205
F3-215
F3 SERVICE POINTS
Condition
Circuit
PCM (21)— Purge solenoid valve Code No.565 output Code No.565 output
Engine stalls, Hard starting
Poor acceleration at
driveaway NA
PCM power relay— Purge solenoid Engine stalls and will not
valve restart
46U0F3-206
A/C Signal (A/C Relay)

Condition
Circuit
PCM (54)—Wide open throttle A/C A/C cutout will not operate A/C will not operate NA
cutout relay
46U0F3-207
EGR Solenoid Valve [Vacuum] (EGRV)

Condition
Circuit
PCM (33)— EGR solenoid Code No.572 output Code No.572 output
valve [Vacuum]
PCM power relay— EGR solenoid Engine stalls and will not NA
valve [Vacuum] rBstart
46U0F3-208
Pressure Regulator Control (PRC) Solenoid

Condition
Circuit
PCM— PRC solenoid valve Diagnostic Trouble Code Diagnostic Trouble Code
Hard to start after heat No symptom
Solenoid valve (PRC)— Main relay soaked EGI INJ fuse (30A) burns NA
start
36U0F3-209
EGR Solenoid Valve [Vent] (EGRA)

Condition
Circuit
PCM (12)— EGR solenoid valve Diagnostic Trouble Code Diagnostic Trouble Code
[vent] No.571 output No.571 output
EGR solenoid valve [vent]— Main EGI INJ fuse (30A) burns NA
relay out with ignition switch ON
start
F3—216
SERVICE POINTS F3
Condition
Circuit
PCM (14)— Daytime running light Idle speed may be slightly Idle speed may be slightly
NA
unit low high
36U0F3-261
F3-217
ENGINE ELECTRICAL SYSTEM
INDEX.................................................................G - 2
OUTLINE............................................................ G - 4
SPECIFICATIONS...........................................G - 4
TROUBLESHOOTING GUIDE..........................G - 5
DIAGNOSTIC INDEX...................................... G - 5
SYMPTOM TROUBLESHOOTING................. G - 5
CHARGING SYSTEM....................................... G - 7
PREPARATION...............................................G - 7
CIRCUIT DIAGRAM....................................... G - 7
TROUBLESHOOTING................................... G - 8
BATTERY........................................................ G - 9
ALTERNATOR................................................G-11
DRIVE BELT................................................... G-13
ELECTRONIC IGNITION SYSTEM................. G -15
CIRCUIT DIAGRAM....................................... G -15
TROUBLESHOOTING................................... G -17
IGNITION TIMING..........................................G -18
SPARK PLUGS...............................................G-18
IGNITION COIL...............................................G-19
DISTRIBUTOR................................................G -20
IGNITER (KL, FS [MTX])................................G -26
IGNITION CONTROL MODULE (ICM)
(FS [ATX]).....................................................G -26
HIGH-TENSION LEAD....................................G-27
STARTING SYSTEM........................................ G -28
PREPARATION...............................................G-28
CIRCUIT DIAGRAM....................................... G-28
STARTER........................................................ G-29
STARTER INTERLOCK SWITCH (MTX).........G-33
46U0GX-001
G INDEX
INDEX
FS
46U0GX-002
1 . Battery 6. Distributor
Inspection....................................... page G- 9 Spark test.......................................page G -2 0
Recharging.....................................page G- 9 Electronic spark advance
2. Alternator Inspection...................................... page G -2 4
Removal / Installation................... page G -1 1 Removal / Installation................... page G -2 2
3. Drive belt Disassembly / Assem bly............. page G -2 4
Inspection.......................................page G -1 3 Inspection...................................... page G -2 5
A djustm ent.....................................page G -1 4 7. Igniter (MTX)
R eplacem ent................................. page G -1 4 Ignition control module (ICM) [ATX]
4. Spark plugs Removal / Installation (FS [ATX] only)
Removal / Installation................... page G -1 8 ...................................................... page G -2 6
Spark te st....................................... page G -1 8 Inspection...................................... page G -2 6
Inspection.......................................page G -1 8 Replacement.................................page G -2 7
5. Ignition coil 8. High-tension lead
Removal / Installation Inspection...................................... page G -2 7
(FS [ATX]).....................................page G -1 9 9. Starter
Inspection.......................................page G -1 9 Inspection (on vehicle)................page G -2 9
R eplacem ent................................. page G -1 9 Removal / Installation................... page G -2 9
Performance inspection..............page G -3 2
10. Starter interlock switch (MTX)
Inspection...................................... page G -3 3
G—2
INDEX G
KL
46U0GX-003
1. Battery 6. Distributor
Inspection.......................... ....... page G - 9 Spark test.............................. .... page G-20
Recharging........................ ....... page G - 9 Electronic spark advance
2. Alternator Inspection.............................. .... page G-24
Removal / Installation........ ....... page G-12 Removal / Installation............. .... page G-23
3. Drive belt Disassembly / Assembly........ .... page G-25
Inspection.......................... ....... page G-13 Inspection.............................. .... page G-25
Adjustment........................ ....... page G-14 7. Igniter
Replacement..................... ....... page G-14 Inspection.............................. .... page G-26
4. Spark plugs Replacement......................... .... page G-27
Removal / Installation........ ....... page G-18 8. High-tension lead
Spark test.......................... ....... page G-18 Inspection.............................. .... page G-27
Inspection.......................... ....... page G-18 9. Starter
5. Ignition coil Inspection (on vehicle).......... .... page G-29
Inspection.......................... ....... page G-19 Removal / Installation............. .... page G-30
Replacement.................... ....... page G-20 Performance inspection........ .... page G-32
10. Starter interlock switch (MTX)
Inspection.............................. .... page G-33
G OUTLINE
OUTLINE
SPECIFICATIONS
— Engi ne KL
FS
Item MTX ATX
P o sitive v o lta g e 12
B a tte ry
T y p e a n d c a p a c ity (5 -h o u r ra te ) G R O U P 5 8 R (4 8 A H )
D a rk c u r r e n t* 1 mA 20 o r less
T ype A.C .
O u tp u t V-A 12-80 12-90
R e g u la to r ty p e V o lta g e R e g u la tor, in a lte rn a to r
R e g u la te d v o lta g e V 1 4 .1 -1 4 .7
S ta n d a rd 2 1 .5 ( 0 .8 5 )
B ru s h le n g th m m ( in )
M in im u m 8 .0 (0 .3 1 )
A lte rn a to r
S ta n d a rd fo rc e 3 .1 4 -4 .3 1 (3 2 0 - 4 4 0 , 1 1 .3 -1 5 .5 )
B ru sh s p rin g N (g f, o z )
M in im u m 1 .5 7 -2 .3 5 (1 6 0 - 2 4 0 , 5 .6 5 -8 .4 7 )
6 .5 — 7 .0 6 .0 — 7 .0 5 .5 — 6 .5 * 3
N ew
( 0 .2 6 - 0 .2 7 ) ( 0 .2 4 - 0 .2 7 ) ( 0 .2 2 - 0 .2 5 )
Drive belt deflection
7 .0 — 9 .0 7 .0 — 8 .0 6 .5 — 7 .5 * 3
mm (in)/98 N(10 kgf, 22 Ibf) U se d
( 0 .2 8 - 0 .3 5 ) ( 0 .2 8 - 0 .3 1 ) ( 0 .2 6 - 0 .2 9 )
L im it 10 ( 0 .3 9 ) 9 .0 (0 .3 5 ) 8 .0 (0.3 1 ) * 3
Type C o a xia l re d u c tio n R e d u ctio n
O u tp u t V-kW 12-1.4 12-1.7 1 2-1.6
S ta n d a rd 17.5 ( 0 .6 9 ) 1 7 .0 ( 0 .6 7 )
M in im u m 12 ( 0 .4 7 ) 1 1 .5 ( 0 .4 5 )
1 7 .6 -2 3 .6 1 6 .7 -2 2 .5 1 6 .3 -2 1 .9
S p rin g b a la n c e S ta n d a rd (1 .7 9 - 2 .4 1 , ( 1 .7 0 -2 .3 0 , ( 1 . 6 6 - 2 .2 4 ,
N (k g f, Ib f) 3 .9 4 -5 .3 0 ) 3 .7 4 -5 .0 6 ) 3 .6 6 -4 .9 2 )
S ta rte r M a x im u m 6 .9 (0 .7 , 1 .5 ) 9 .3 2 (0 .9 5 , 2 .0 9 ) 8 .8 (0 .9 , 2 .0 )
Runout Runout 0 .0 5 (0 .0 0 2 )
m m (in )
M a xim u m 0.1 (0 .0 0 4 )
A rm a tu re M in im u m d ia m e te r m m ( in ) 2 8 .8 ( 1 .1 3 ) 3 1 .4 ( 1 .2 4 )
Segment groove D e p th 0 .4 — 0 .6 ( 0 . 0 1 6 - 0 . 0 2 3 )
depth mm ( in ) M in im u m 0 .2 (0 .0 0 8 )
T ype Hall effe ct, P h o to d io d e * 4

D is trib u to r
S p a rk a d v a n c e E le ctro n ic s p a rk a d v a n c e
Ig n itio n tim in g BTD C

• T E N te rm ir lal o f d a ta lin k c o n n e c to r g ro u n d e d
[K L a n d Fi (M TX)] 1 1 - 1 3 ° , 9 — 11 ° * 4 9 -1 1 °
• R e m o v e th e s h o rtin g b a r fro m th e d o u b le w ire S P O U T
c o n n e c to r [FS (ATX)]
P rim a ry coil
0 . 5 8 - 0 . 8 6 , 0 .7 * 4
R e sista n ce w in d in g ( f i)
Ignition coil
(at 2 0 ° ( 6 8 ° F ) ) S e c o n d a ry coil
1 1 . 5 - 1 8 . 5 , 8 .5 3 * 4
w in d in g ( k f i)
B K R 5 E -1 1 *2 Z F R 5 F -1 1 * 2
NGK
B K R 6 E -1 1 Z F R 6 F -1 1
T ype
S p a rk p lu g K 1 6 P R -U 1 1 * 2
N IP P O N D E N S O —
K 2 0 P R -U 1 1
P lu g g a p m m ( in ) 1 .0 — 1.1 ( 0 . 0 3 9 - 0 . 0 4 3 )
F irin g o rd e r 1 -3 -4 -2 1— 2 — 3 — 4 — 5 — 6
*' D a rk c u rre n t is th e c o n s ta n t flo w o f c u rre n t w h ile th e ig n itio n is O FF (i.e., a u d io unit, c lo c k , etc.) 46U0GX-004
*2 S ta n d a rd p lu g
*3 A lte rn a to r + A /C
*4 FS e n g in e [ATX] o n ly
G—4
TROUBLESHOOTING GUIDE G
DIAGNOSTIC INDEX
No. Troubleshooting items Page
1 W ill n o t c ra n k — s ta rte r m o to r d o e s n o t o p e ra te b e lo w
2 W ill n o t c ra n k — sta rte r m o to r s p in s b e lo w
3 C ra n k s slo w ly G- 6
4 A lte rn a to r w a rn in g lig h t illu m in a te s w h ile e n g in e ru n n in g G- 6
5 D is c h a rg e d b a tte ry G - 6
6 M isfire G -1 7
46U0GX-005
1 Will not crank—starter motor does not operate

1 D o e s e n g in e c ra n k w ith fu lly c h a rg e d ba ttery? Y es C h e c k c h a rg in g system cr page G -8
2 S ta rte r in te rlo c k sw itch O K ? (M TX) Yes G o to n e xt ste p
No C h e c k sta rte r in te rlo c k sw itch cr page G -33
3 Is b a tte ry p o sitive v o lta g e p re s e n t a t te rm in a l B? Yes G o to n e xt step
TERMINAL
No C h e c k w irin g h a rn e ss
FS, KL (MTX) KL (ATX)

4 Is b a tte ry p o s itiv e v o lta g e p re s e n t a t te rm in a l S Yes • C h e c k m a g n e tic sw itch
w ith ig n itio n s w itc h in S T A R T p o sitio n ? • C h e c k yo ke
TERMINAL-S • C h e c k a rm a tu re
No • C h e c k p a rk/n e u tra l sw itch cr Section K

• C h e c k ig n itio n sw itch cr Section T
• C h e c k w irin g harness
FS, KL ( M T X ) ^ KL (ATX)
46U0GX-006
G -5
G TROUBLESHOOTING GUIDE
2 Will not crank—starter motor spins

1 Is drive pinion pushed out w hile crar king Yes Remove starter and check ring gear
y
(Is click heard)? teeth and starter drive pinion teeth
No Check magnetic switch

j ,
FS, KL (MTX) 1 L (ATX)
46UCIGX-007
3 Cranks slowly
1 Does engine crank normally with fully charged Yes Check charging system c r page G -8
battery?
No Go to next step
2 Are starter cable connections loose or corroded? Yes Repair connection
No Check starter for binding (brush, arma

ture, etc.)
FS, KL (MTX) KL (ATX)

46U0GX-008
4 Alternator warning light illuminates while engine running

1 Is battery positive voltage correct at idle? Yes Check wiring harness between alternator
L terminal and alternator warning light
Specification: 14.1— 14.7V No Check charging system a- page G -8
46U0GX-009
5 Discharged battery
1 Is charging system OK? Yes Turn ignition switch OFF and measure
cr page G -8 dark current as shown
„ /U
Dark current: Below 20 mA
No Repair or replace parts as necessary
46U0GX-056
G—6
CHARGING SYSTEM G
CHARGING SYSTEM
PREPARATION
SST
49 9200 020 For

inspection of
Tension gauge drive belt tension
V-ribbed belt
T 16E0GX-011
46U0GX-010
The alternator has an on-board diagnosis system to warn of the following problems in the charging system.
If a problem arises, the alternator warning light illuminates.
1. Terminal S circuit open
2. No voltage output
3. Field coil circuit open
4. Terminal B circuit open
5. Voltage output too high (above 16.2V)
CHARGING SYSTEM
TROUBLESHOOTING
Check battery positive voltage; is it correct? Yes Go to next step
Specification: Above 12.4V No Check battery c r page G -9
Does charge warning light illuminate with ignition Yes Go to Step 3

switch ON?
No Check warning light bulb and wiring
harness (Charge light—Terminal L)
Does charge warning light go out after engine Yes Go to Step 5

started?
No Go to next step
Is voltage at alternator terminals correct? Yes Check wiring harness

(Battery—Terminal B)
Terminal Ign: ON (V) Idle (V)

B B+ 14.1—14.7
L Approx. 1 13.2—13.8
S B+ 14.1-14.7
TERMINAL-B RMINAL-L TERMINAL-B

No • Check wiring harness
• Replace alternator c r page G-11
TERMINAL-S
TERMINAL-L
1. Connect an ammeter (90A min.) between ter Yes Charging system normal
minal B and harness
2. Start engine
3. Turn all electrical loads ON and depress
brake pedal
4. Is output current 80A (FS) 90A (KL) or more
at 2,500—3,000 rpm?
Caution
• Do not ground terminal B t e r m i n a l -b
No Go to next step
ENGINE
Is drive belt tension OK? page G -1 3 Yes Replace alternator c r page G -1 1

No • Adjust drive belt tension
• Replace drive belt
46U0GX-011
G -8
CHARGING SYSTEM G
BATTERY
Inspection
Battery discharge test
Measure voltage of battery (with digital voltmeter capable of reading 0.01V)
Below 12.4V Above 12.4V

I
Quick charge for 30 minutes
and recheck voltage
Below 12.4V Above 12.4V

______ I______
Replace battery Apply test load (see test load chart at right) to
battery using a battery load tester
Record battery positive voltage at end of 15 sec Test load
onds; is voltage more than specification?
Battery Load (A)
GROUP 58R 174
YES NO Battery positive voltage with load

Approximate Minimum
Measure voltage of battery Replace battery battery temp. voltage (V)
21°C (70°F) 9.6
15°C (60°F) 9.5
10°C (50°F) 9.4
Below 12.4V Above 12.4V 4°C (40°F) 9.3
______ I______ -1 °C (30°F) 9.1
Charge battery Battery OK -7 °C (20°F) 8.9
-12 °C ( 10°F) 8.7
-18 °C ( 0°F) 8.5
36U0GX-009
Terminal and cable

Removing the label on the top of the battery or removing
the vent caps will void the battery’s warranty.
Note

Recharging
Caution
• Do not quick charge for over 30 minutes. It will dam
age the battery.
Place the battery in a pan of water to prevent it from over

heating. The water level should come up about 3/4 way on
the battery. Keep water off the top of the battery.
46U0GX-013
G -9
G CHARGING SYSTEM
Caution
• To prevent damage to electrical components or the
battery, turn all accessories off and stop the engine
before performing maintenance or recharging the
battery.
• When disconnecting the battery, remove the nega
tive cable first and install it last to prevent damage
to electrical components or the battery.
Slow charging
Perform a slow charge, referring to the following table.
Type Voltage (V) Hour(H) Amperage (A)
12.2-12.3 5
GROUP 58R 12.1—12.2 7 4.8
12.0-12.1 8
Quick charging
Remove the battery from the vehicle to perform a quick
charge.
Type Minutes (M) Amperage (A)
GROUP 58R 30 30
46U0GX-014
CHARGING SYSTEM
ALTERNATOR
Caution
• Reversing the battery connections or using high-voltage testers will damage the rectifier.
Caution
• Do not start the engine while the connector is disconnected from terminals L and S. It can
damage the alternator.
Note
• Positive voltage is always present at alternator terminal B.

FS
GASKET, REPLACE
46U0GX-015
1. Negative battery cable 6. Drive belt

2. Connector Inspection...................................page G -13
3. Terminal B wire Adjustment................................ page G -14
Inspect for damage and corrosion Replacement............................. page G -14
4. Transverse member 7. Alternator
5. Front pipe assembly
G -11
CHARGING SYSTEM
Caution
• Reversing the battery connections or using high-voltage testers will damage the rectifier.
Caution
• Do not start the engine while the connector is disconnected from terminals L and S. It can
damage the alternator.
Note
• Positive voltage is always present at alternator terminal B.
46U0GX-016
1. Negative battery cable 7. Locknut

2. Fresh air duct 8. Drive belt
3. Alternator terminal B wire Inspection...................................page G-13
Inspect for damage and corrosion Adjustment................................ page G-14
4. Connector Replacement............................. page G-14
5. Undercover 9. Compressor
6. Belt tensioner 10. Alternator
G—12
CHARGING SYSTEM G
DRIVE BELT
Inspection
1. Check the drive belts and pulleys for wear, cracks, and dam
age. Replace if necessary.
2. Measure the drive belt tension by using a tension gauge.
3. Measure the deflection by applying moderate pressure 98
N {10 kgf, 22 Ibf) midway between the pulleys.
4. Adjust the belt if necessary.
36U0GX-013
Tension
FS N (kgf, Ibf)
740-830 500-680 390
Alternator
(75-85, 170-180) (50-70,110-150) (40, 88)
590-780 500-680 390
P/S, P/S + A/C
(60-80,140-170) (50-70,110-150) (40, 88)
KL N (kgf, Ibf)
690-880 500-680 440
Alternator
(70-90, 160-190) (50-70,110-150) (45, 99)
690-880 500-680 440
Alternator + A/C
(70-90, 160-190) (50-70,110-150) (45, 99)
540-680 400-530 340
P/S
(55-70, 130-150) (40-55, 88-120) (35, 77)
Deflection
FS mm (in)
6.5—7.0 7.0—9.0 10
Alternator
(0.2 6-0 .27 ) (0.28-0.35) (0.39)
7 .5 -9 .0 8.0—9.5 11
P/S, P/S+ A/C
(0.30-0.35) (0.32-0.37) (0.43)
KL mm (in)
6.0—7.0 7.0—8.0 9.0
Alternator
(0.24-0.27) (0.2 8-0 .31 ) (0.35)
5.5—6.5 6.5—7.5 8.0
Alternator+ A/C
(0.22-0.25) (0.26-0.29) (0.31)
6.0—7.0 7.0—8.0 9.0
P/S
(0.24-0.27) (0.2 8-0 .31 ) (0.35)
G -1 3
G CHARGING SYSTEM
Adjustment
FS
1. Loosen the alternator mounting bolt and adjusting bolt.
2. Move the alternator to set the specified deflection.
3. Tighten all bolts and recheck the tension.
Tightening torque
Mounting bolt:
32—46 N m {3.2—4.7 kgf m, 24—33 ft-lbf)
Adjusting bolt:
16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf)
46U0GX-058
K L W IT H A/C KL
TENSIONER
ALTERNATOR
1. Loosen the tensioner locknut A.
2. Tighten adjuster bolt B.
3. Tighten tensioner locknut A.
Tightening torque
Locknut:
32—46 Nm {3.2—4.7 kgf m, 24—33 ft-lbf)
DRIVE PULLEY A/C

16E0GX-040
Replacement
1. Remove the A/C and P/S drive belt, if equipped. Refer to
Section B1.
2. Loosen the alternator mounting bolt and adjusting bolt.
3. Remove the alternator belt.
4. Install the new alternator belt and adjust it to specifications.
5. Tighten all bolts to the specified torque.
Tightening torque
Mounting bolt:
32—46 N m (3.2—4.7 kgf-m, 24—33 ft-lbf)
46UCK3X-019 Adjusting bolt:
16—22 N-m (1.6—2.3 kgf-m, 12—16 ft-lbf)
6. Install the A/C and P/S drive belt if equipped, and adjust
to specifications. Refer to Section B1.
ELECTRONIC IGNITION SYSTEM G
ELECTRONIC IGNITION SYSTEM
CIRCUIT DIAGRAM
FS (MTX)
46U0GX-020
G ELECTRONIC IGNITION SYSTEM
KL
16E0GX-044
TROUBLESHOOTING
Misfire
Disconnect high-tension lead from spark plug; is Yes Electronic ignition system normal
there a strong blue spark while cranking engine?
cr page G -20
No Go to next step
Is resistance of high-tension lead OK? Yes Go to next step

cr page G -27
No Replace high-tension lead
S p e c ific a tio n : 1 6 0 p e r 1 m (3 .2 8 ft)
Is there corrosion, damage or cracks on the dis Yes Replace cap and rotor
tributor cap and rotor? c r page G -25
No Go to next step
Is ignition coil OK? cr page G -1 9 Yes Go to next step
No Replace ignition coil
Are distributor and PCME connectors con Yes Go to next step (KL, FS [MTX])
nected? Go to step 8 (FS [ATX])
No Connect connectors
• Is igniter (KL, FS [MTX]) OK? Yes Check wiring

• Is ignition control module (ICM) (FS [ATX]) OK?
cr page G -26 If OK, go to next step
No • Replace igniter (KL, FS [MTX])
• Replace ignition control module (ICM)
(FS [ATX])
Is voltage at C terminal of distributor connector Yes Go to step 9
correct?
Voltage: B +
No Check main fuse, ignition switch, wiring

harness, and PCME
Is voltage at A terminal of ignition coil connector Yes Go to step 9

correct?
No Check main fuse, ignition switch, wiring

harness, and ECC-IV (FS ATX)
Try known-good PCME, EEC-IV (FS ATX); does Yes Replace PCME, EEC-IV (FS ATX)
condition improve?
No Replace distributor
46U0GX-022
G -1 7
IGNITION TIMING
Adjustment
Adjust the ignition timing. (Refer to F1, F2, or F3 Section.)
46U0GX-057
SPARK PLUGS
1. Remove and install the high-tension leads carefully.
Caution
• Pulling on the wire part of the spark plug lead may
break it. To remove the lead, pull only on the boot.
2. Remove and install the spark plug with a plug socket.
Caution
• To avoid breaking the spark plug, be sure to fit the
socket squarely over it.
3. Apply anti-seize compound or molybdenum-based lubricant

to the spark plug threads.
4. Tighten the spark plug to the specified torque.
Tighten torque:
15—22 N m (1.5—2.3 kgf m, 11—16 ft-lbf}
Spark test
1. Remove the spark plug.
2. Connect the spark plug to a high-tension lead.
3. Hold the high-tension lead and spark plug with insulated
pliers 5— 10mm (0.20—0.39 in) from a ground.
4. Crank the engine and verify that there is a strong blue spark.
If not, replace the spark plug or high-tension lead as
necessary.
Inspection
Check the following points. If a problem is found, replace
the spark plug.
• Damaged insulation
• Worn electrodes
• Carbon deposits
If cleaning is necessary, use a plug cleaner or a wire
brush. Clean the upper insulator, also.
• Damaged gasket
• Burnt
Plug gap: 1.0— 1.1mm (0.040—0.043 In)
G -1 8
IGNITION COIL
Removal / Installation (FS [ATX])
2. Disconnect the ignition coil connector and high-tension lead
from the ignition coil.
3. Disconnect the condensor connector from the condensor.
4. Remove the ignition coil.
46UOGX-035
Inspection
FS [MTX], KL
Primary coil winding
1. Disconnect the 3-pin connector from the ignition coil.
2. Use an ohmmeter to measure resistance of the primary coil
winding.
Specifications: 0.58—0.860
3. If not within specifications replace the distributor.

(Refer to page G -2 2.)
46U0GX-036
FS [ATX]
1. Disconnect the ignition coil connector from the ignition coil.
2. Use an ohmmeter to measure resistance of the primary coil
winding.
Specifications: Approx. 0.7Q
3. If not within specifications replace the ignition coil.

46U0GX-037
Secondary coil winding
FS [MTX], KL
1. Remove distributor cap.
2. Use an ohmmeter to measure resistance of the secondary
coil.
Specifications: 11.5— 18.5 kfi
3. If not within specifications replace the distributor.
46U0GX-038
G -1 9
FS [ATX]
1. Disconnect the high-tension lead from the ignition coil.
2. Use an ohmmeter to measure resistance of the secondary
coil.
Specifications: Approx. 8.53 kfl
3. If not within specifications replace the ignition coil.

Replacement
1. Remove and replace the distributor (FS [MTX], KL).
(Refer to page G -22.)
2. Remove and replace the ignition coil. (FS [ATX])
3. Adjust the ignition timing. (Refer to Section F1, F2 or F3.)
46U0GX-040
DISTRIBUTOR
Spark test
1. Disconnect the high-tension lead from a spark plug.
2. Hold the lead and spark plug with insulated pliers 5— 10mm
{0.20—0.39 in) from a ground.
3. Crank the engine and verify that a strong blue spark is
visible.
4. If no spark, refer to page G -1 7 “ No.6 MISFIRE” .
46U0GX-041
Electronic Spark Advance Inspection
Verify that the ignition timing advances with engine ac
celeration.
Note
• The amount of advance depends on various factors and
is not specified.
16E0GX-063
2. Install in the reverse order of removal (KL), referring to Installation Note (FS). (Refer to page G -2 3.)
FS (MTX)
POSITION
46U0GX-042
FS (ATX)
Nm (kgf-m, ft lbf)
46U0GX-Q43
1. Negative battery cable 4. Connector

2. Fresh air duct 5. Distributor
3. High-tension lead Disassembly / Assem bly..............page G -2 4
Inspection....................................... page G -2 7 Inspection.......................................page G -2 5
G -2 2
KL
1. Negative battery cable 5. Connector

2. Fresh air duct 6. Distributor
3. Air cleaner housing Disassembly / Assem bly..............page G -2 5
4. High-tension lead Inspection.......................................page G -2 5
Inspection.................. G -2 7
Installation Note (FS)
• After installing the distributor, adjust the ignition

timing. (Refer to Section F1, F2 or F3.)
Verify that the No.1 cylinder is at top dead center
and align the distributor matching marks.
1. Install the distributor and connect the high-tension leads and

distributor connector.
2. Tighten the locknut or bolts to the specified torque.
Torque specification:
19—25 N m (1.9—2.6 kgf m, 14— 18 ft-lbf)
Disassembly / Assembly
2. Assemble in the reverse order of disassembly.
FS (MTX)
O-RING, REPLACE
-1 .0 — 1.9 N-m (10—20 cm-kg, 8.7— 17 in-lb)
46U0GX-046
FS (ATX)
1. Cap 6. Ignition coil (MTX)

Inspection. page G -2 5 Inspection.......................................page G -1 9
2. Rotor Replacem ent.................................page G -2 0
Inspection. page G -2 5 7. Igniter (in distributor) (MTX)
3. Packing Inspection...................................... page G -2 6
4. Cover 8. Shield cover
5. Insulator 9. Distributor assembly
G -2 4
KL
46U0GX-048
1. Cap 4. Igniter (in distributor)

2. Rotor 5. Ignition coil
3. Packing
FS [ATX] Inspection
Cap and rotor
ROTOR 1. Check for corrosion, damage, and cracks.
2. Replace if necessary.
CAP
16E0GX-068
KL
CAP ROTOR
IGNITER (KL, FS [MTX])/IGNITION CONTROL MODULE (ICM) (FS [ATX])
Removal I Installation (FS [ATX])
1. Negative battery cable 4. Ignition control module (ICM)

2. Resonance chamber Inspection.................................page G-26
3. Ignition control module (ICM) connector
Inspection
1. Mesure the voltage of the PCME terminal as follows.
(Refer to Sections F1, F2 or F3.)
FS [MTX]
• 2E (Crankshaft position sensor)
• 2F (Igniter)
• 2 0 (Mass airflow sensor)
FS [ATX]
• 4 (Ignition control module) [ICM]
• 50 (Mass airflow sensor)
• 24 (Crankshaft position sensor)
KL
• 1G (Igniter)
• 2B (Volume airflow sensor)
• 3E (Crankshaft position sensor)
• 3H (Crankshaft position sensor 2)
2. Check the condition of the connector, distributor, ignition

coil, and high-tension leads.
3. If all are normal, but misfire still occurs, replace the igniter
(KL, FS [MTX]) or ignition control module (ICM) (FS [ATX]).
46U0GX-050
G -2 6
Replacement
1. Replace the distributor. (FS [MTX], KL) (Refer to page G-22.), the ignition control module (ICM) (FS [ATX])
(Refer to page G-26.)
2. Adjust the ignition timing. (Refer to Sections F1, F2 or F3.)
46UQGX-052
HIGH-TENSION LEAD
Inspection
1. Measure resistance of the high-tension leads.
Specification: 16 kfi per 1 m (3.28 ft)
2. If not as specified, replace the high-tension lead set.
16E0GX-070
G STARTING SYSTEM
STARTING SYSTEM
PREPARATION
SST
16E0GX-071
CIRCUIT DIAGRAM
PULL-IN COIL HOLD-IN COIL
IGNITION PARK/NEUTRAL
SWITCH SWITCH (ATX)
<Tnnn^-j
ARMATURE
® © ' ' brush MAGNET
BATTERY
TERMINAL-B
TERMINAL-B
TERMINAL-S
TERMINAL-M
KL (MTX) KL (ATX)
16E0GX-072
Note
• KL engines use a reduction starter.
G—28
STARTING SYSTEM G
STARTER
Inspection (on vehicle)
1. Measure the battery positive voltage.
Specification: Above 12.4V
2. Crank the engine, and verify that the starter turns smoothly.
3. If the starter does not turn, check the voltage at terminal S.
4. If the voltage is more than 8V, remove and inspect the start
er. If the voltage is less than 8V, check the wiring harness,
ignition switch, interlock switch (MTX), and park/neutral
switch (ATX).
FS
1. Negative battery cable 5. Intake manifold bracket

2. Fresh air duct 6. Terminal S wire
3. Resonance chamber 7. Terminal B wire
4. Air cleaner housing 8. Starter
G—29
G STARTING SYSTEM
KL (MTX)
46U0GX-055
1. Negative battery cable 4. Terminal S wire

2. Fresh air duct 5. Terminal B wire
3. Air cleaner housing 6. Starter
G—30
STARTING SYSTEM G
KL (ATX)
Warning
• Before performing the following operation, drain the engine coolant.
(Refer to Section E.)
• When removing the fuel hose, keep sparks, cigarettes, and open flames away from it.
• Before disconnecting fuel line, loosen the filler cap to release the fuel pressure from the fuel
system to reduce the possibility of injuly of fire.

46U0GX-Q56
1. Negative battery cable 7. Fuel line

2. Fresh air duct 8. Selector cable
3. Air cleaner housing 9. Cable bracket
4. Accelerator cable 10. Starter bracket
5. Throttle body 11. Terminal S and B wire
6. Coolant hose 12. Starter
G—31
G STARTING SYSTEM
Performance Inspection
Magnetic switch
Disconnect terminal S wire, and perform the following tests.
Pull-in test
Connect battery positive voltage as shown and verify that
the pinion is ejected.
Caution
• Applying power continuously for more than 10 sec
46U0GX-057 onds will damage the starter.
Hold-in test
After completing the pull-in test, disconnect the wire from
terminal M (with pinion ejected) and verify that the pinion
does not return.
16E0GX-Q78
Adjustment of pinion gap
1. Disconnect the wire from the terminal M.
2. Apply battery positive voltage between terminal S and the
starter body.
3. Measure the clearance (pinion gap) between the pinion and
the stopper.
Caution
• Applying power continuously for more than 10 sec
onds will damage the starter.
Pinion gap: 0.5—2.0mm (0.020—0.078 in)
4. If the pinion gap is not within the specification, increase or

decrease the number of washers between the magnetic
switch and the drive housing.
Note
• The gap becomes smaller as the number of washers is
increased.
No load test
1. Connect a circuit as shown.
2. Measure voltage, current, and speed as shown below.
KL
E n g in e FS
M TX ATX
V o lta g e (V) 11 11 11
C u rre n t (A) 90 90 70
Speed (rp m ) 3 ,0 0 0 2 ,9 0 0 2 ,2 0 0
16E0GX-080
G—32
_________________________STARTING SYSTEM G
STARTER INTERLOCK SWITCH (MTX)
IGNITION SWITCH
IG2
46U0GX-059
This system is similar to that of the park/neutral switch on an ATX vehicle.

If the clutch pedal is not depressed during starting, battery power will not be supplied to the starter and
it will not operate.
Inspection
1. Disconnect the interlock switch connector.
2. Connect a circuit tester to the switch.
3. Check the continuity.
Pedal Continuity
Depressed Yes
Released No
4. Replace the switch, if necessary.
36UOGX-O41
G—33
Q
GENERAL INFORMATION
SAFETY INFORMATION................................. G l- 2
LUBRICANTS................................................G l- 2
JACKING POSITIONS.................................. G l- 2
SAFETY STAND POSITIONS....................... G l- 2
VEHICLE LIFT POSITIONS........................... G l- 3
DYNAMOMETER...........................................G l- 3
COMPRESSED A IR ...................................... G l- 3
HOW TO USE THIS MANUAL....................... G l- 4
ADVISORY MESSAGES................................G l- 4
PREPARATION............................................. G l- 4
REPAIR PROCEDURE.................................. G l- 4
SYMBOLS...................................................... G l- 5
IDENTIFICATION NUMBER LOCATIONS..... G l- 6
UNITS................................................................G l- 6
ABBREVIATIONS............................................ G l- 7
SAE STANDARDS...........................................G l- 8
FUNDAMENTAL PROCEDURES....................GI-11
PROTECTION OF THE VEHICLE................ GI-11
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT................................................ GI-11
SPECIAL TOOLS........................................... GI-11
REMOVAL OF PARTS.................................. GI-11
DISASSEMBLY............................................. GI-11
REASSEMBLY...............................................GI-12
ADJUSTMENTS............................................ GI-13
RUBBER PARTS AND TUBING.................. GI-13
HOSE CLAMPS............................................ GI-13
TORQUE FORMULAS.................................. GI-13
VISE...............................................................GI-13
ELECTRICAL TROUBLESHOOTING TOOLS GI-14
TEST LIGHT.................................................. GI-14
JUMPER WIRE............................................. GI-14
VOLTMETER................................................. GI-14
OHMMETER.................................................. GI-14
ELECTRICAL PARTS...................................... GI-15
BATTERY CABLE..........................................GI-15
CONNECTORS............................................. GI-15
TERMINALS.................................................. GI-16
SENSORS, SWITCHES, AND RELAYS.........GI-17
WIRING HARNESS....................................... GI-17
FUSE............................................................. GI-17
INSTALLATION OF MOBILE TWO-WAY RADIO
SYSTEM..........................................................GI-18
AUDIO ANTITHEFT SYSTEM.........................GI-18
's~ TOWING............................................................ GI-19
46UGIX-001
Gl SAFETY INFORMATION
SAFETY INFORMATION
LUBRICANTS
Avoid prolonged and repeated contact with petroleum-based oils. Used oil may irritate the skin, and can
cause skin cancer and other skin disorders.
Wash thoroughly after working with oil. We recommend water soluble hand cleaners. Do not use kero
sene, gasoline, or any other solvent, to remove oil from your skin.
If repeated or prolonged contact with oil is necessary, wear protective clothing. Soiled clothing, particular
ly those soiled with used oils and greases containing lead, should be cleaned at regular intervals.
46UGIX-002
JACKING POSITIONS
Warning
• Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious
injury. Use only the correct front and rear jacking positions and block the wheels.
Use safety stands to support the vehicle after it has been lifted.
46UGIX-003
Front Rear
At the center of the crossmember At the center of the crossmember
SAFETY STAND POSITIONS

Front Rear
Both sides of the vehicle Both sides of the vehicle
Gl—2
SAFETY INFORMATION Gl
VEHICLE LIFT POSITIONS
Front Rear
DYNAMOMETER
When test-running a vehicle on a dynamometer;
• Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
• Connect an exhaust gas ventilation unit.
• Cool the exhaust pipes with a fan.
• Keep the area around the vehicle uncluttered.
• Watch the water temperature gauge.
46UGIX-010
COMPRESSED AIR
When using compressed air to clean or remove parts;
• Wear protective eyewear.
• Hold a rag over the opening to prevent parts from shooting out.
• Take precautions so that people around you are not struck by flying debris.
46UGIX-011
Gl HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

ADVISORY MESSAGES
You’ll find several Warnings, Cautions, and Notes in this manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning
is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle could result if the caution is
ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
46UGIX-012
PREPARATION
This points out the needed SSTs for the service operation. It is best to gather all necessary SSTs before
beginning work.
Example:
REPAIR PROCEDURE
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the
parts fit together, and describes visual part inspection. If a damaged or worn part is found, repair or re
place it as necessary.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration.
3. Pages related to service procedures are shown under the illustration. Refer to this information when ser
vicing the related part.
46UGIX-014
HOW TO USE THIS MANUAL Gl
Example:
SHOWS SHOWS TIGHTENING

EXPENDABLE TORQUE
PARTS
SPECIFICATIONS *2
SHOWS
APPLICATION
POINT OF OIL,
ETC. SHOWS TIGHTENING
|k» luST' TORQUE UNITS
1. Bolt 16 Bearing inner race
2. Lock plate Removal
Hempva:__________ pagt
page M—22
3. Bearing cup in s p e c t fo r d a m a g e o r r o u g h ro ta to ri > SHOWS VISUAL
4. Adjusting screw Installation page M—24
SHOWS 5. Bearing outer race
INSPECTION
17 Spacer
RELATED 6. Locknut 18 Drive pinion INFORMATION
PAGE FOR 7. Washer Removal ............... page M—21
8 . Companion flange Inspect splines and teeth for wear or damage
SERVICE
Adjustment o* height page M—22
_ _ A d i ----- -— —gage M
*1: The numbers (©, etc.) refer to part identification and servicing procedures.
"2: Units are in N-m {kgf-m, ft-lbf) unless otherwise specified.
46UGIX-015
SYMBOLS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such
materials during service.
Symbol Meaning Kind
T Apply oil Ne.1. engine oil or gear oil as appropriate
§8 Apply brake fluid FMVSS116: DOT-3
Q Apply automatic transmission fluid Dexron®n, M-in or Mercon
i Apply grease Appropriate grease
Apply sealant Appropriate sealant
© Apply petroleum jelly Appropriate petroleum jelly
46UGIX-016
Gl—5
Gl IDENTIFICATION NUMBER LOCATIONS/UNITS
IDENTIFICATION NUMBER LOCATIONS
VEHICLE IDENTIFICATIONNUMBER (VIN) AUTOMATIC TRANSAXLE MODEL ANDNUMBER
ENGINEMODEL ANDNUMBER
FS ENGINE KL ENGINE
46UGIX-017
UNITS
Electrical current........... ...... A (ampere)
Electric potential........... ...... V (volt)
Electric power............... ...... W (watt)
Length........................... mm (millimetres)
in (inches)
Negative pressure........ kPa (kilo Pascal)
mmHg (milimetres of mercury)
inHg (inches of mercury)
Positive pressure.......... kPa (kilo Pascal)
kgf/cm2 (kilogram force per square
centimetre)
psi (pounds per square inch)
Resistance..................... ...... Q (ohm)
T c rq je ........................... N-m (Newton metre)
kgf-m (kilogram force per metre)
kgf-cm (kilogram force per centimetre)
ft-lb (foot pounds)
in-lb (inch pounds)
Volume........................... L (litre)
US qt (U.S. quart)
Imp qt (Imperial quart)
46UGIX-018
Gl—6
ABBREVIATIONS Gl
ABBREVIATIONS
ABDC.........................After bottom dead center
ABS............................ Antilock brake system
A C C ...........................Accessory
ATDC.........................After top dead center
ATF............................ Automatic transaxle fluid
ATX............................ Automatic transaxle
BAC............................ Bypass air control
BBDC.........................Before bottom dead center
BTDC.........................Before top dead center
CID............................. Cylinder identification display
C P U ........................... Central processing unit
CU.............................. Control unit
DRL............................ Daytime running light
DTM ........................... Diagnostic test mode
EC-AT......................... Electronically controlled automatic transaxle
EGRA......................... EGR air solenoid valve
EGRV......................... EGR vacuum solenoid valve
EPC............................ Electronic pressure control
ESPS.......................... Engine speed sensing power steering
E X .............................. Exhaust
FMEM ........................Failure mode effects management
HFC............................ High fan control
HLA............................ Hydraulic lash adjuster
HU.............................. Hydraulic unit
1C............................... Integrated circuit
IC M ............................ Ignition control module
ID M ............................ Ignition diagnostic monitor
IG ............................... Ignition
IN ............................... Intake
IN T............................. Intermittent
KAM ........................... Keep alive memory
KOEO.........................Key on engine off
KOER.........................Key on engine running
LFC............................ Low fan control
L H .............................. Left hand
M ................................ Motor
MAF RTN...................Mass airflow return
MTX............................ Manual transaxle
PCV............................ Positive crankcase ventilation
PIP ............................. Profile ignition pickup
PRC............................ Pressure regulator control
P/S.............................. Power steering
P/W ............................ Power window
PWR GND..................Power ground
RH.............................. Right hand
RPM........................... Revolutions per minute
SIG RTN.....................Signal return
SPOUT....................... Spark output
55 1 Shift solenoid No.1
55 2 Shift solenoid No.2
SST............................. Special service too
ST............................... Start
STI.............................. Self-test input
STO............................ Self-test output
SW.............................. Switch
TDC............................ Top dead center
TFT............................. Transaxle fluid temperature
TNS............................ Tail number side (taillights, license plate lights,
and side marker lights)
TRS............................ Transmission range sensor
TSS............................. Turbine shaft speed sensor
VPWR.........................Vehicle power
3-2T/CCS....................3-2 timing/coasting clutch solenoid
46UGIX-019
Gl—7
Gl SAE STANDARDS
SAE STANDARDS
In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbrevi
ations are now used in this manual. The table below lists the names and abbreviations that have been
used in Mazda manuals up to now and their SAE equivalents.
46UGIX-047
Engine and Emission Systems

Previous Standard SAE Standard
Abbreviation Name Abbreviation Name Remark
— Accelerator Pedal AP Accelerator Pedal
— Air Cleaner ACH Air Cleaner Housing
— Air/Fuel (A/F) Solenoid Valve MCS Mixture Control Solenoid F2 Carburetor
— Airflow Meter VAF Volume Airflow Sensor
— Airflow Senaor MAF Mass Airflow Sensor
— Alternator ALT Alternator
Atmospheric Pressure Sensor BARO Barometric Absolute Pressure
— Sensor
— Carburetor CARB Carburetor
Catalytic Converter OC Oxidation Catalyst
— TWC Three Way Catalyst
WU-TWC Warm Up Three Way Catalyst #1
— Circuit Opening Relay FPR Fuel Pump Relay #2
— Cooling Fan Control CFC Coolant Fan Control
— Crank Angle Position CPS Crankshaft Position Sensor
— Diagnosis Connector DLC Data Link Connector
— Direct Ignition DLI Distributorless Ignition
Electronic Gasoline Injection Continuous Fuel Injection System
EGI CIS
System
— Electronic Spark Ignition El Electronic Ignition #3
— EGR Modulator Solenoid EGRC EGR Function Control
EGR Gas Sensor
— EGR Position Sensor EGRS EGR Function Sensor #4
EGR Position Switch
PCM Powertrain Control Module #5
ECU Engine Control Unit
PCME Powertrain Control Module (Engine)
— Engine Modification EM Engine Modification
— Engine Speed RPM Engine Speed
Evaporative Emission Control
— EVAP Fuel Evaporative System
System
— Exhaust Gas Recirculation System EGR Exhaust Gas Recirculation System name
— Feedback System CLS Closed Loop System
— Flexible Fuel FF Flexible Fuel
— Fuel Pump FP Fuel Pump
— IC Regulator VR Voltage Regulator
— Intake Air Thermosensor IATS Intake Air Temperature Sensor
— Intercooler CAC Charge Air Cooler
— ISC Solenoid Valve IACV Idle Air Control Valve
— Knock Sensor KS Knock Sensor
— Malfunction Indicator Light MIL Malfunction Indicator Light
— Multiport Fuel Injection MFI Multiport Fuel Injection
— Oxidizing Converter OC Oxidation Catalyst
# 1: Directy connected to exhaust manifold

#2: In some models, there is a “ Fuel Pump Relay” that controls pump speed. That relay is now called the “ Fuel Pump Relay (Speed)” .
# 3: Controlled by the PCME (PCM)
# 4: EGR valve controller device name
# 5: Device that controls engine and powertrain
Gl—8
SAE STANDARDS Gl
Engine and Emission Systems (cont’d)
O x y g e n S e n so r H 02S H e a te d O x y g e n S ensor W ith h e a te r
—
02S O x y g e n S e n so r
— O pen Loop OL O pen Loop
P o sitive T e m p e ra tu re C o e fficie n t E arly Fuel E va p o ra tio n
PTC EFE
H e a te r
P re ssu re S e n so r M AP M a n ifo ld A b s o lu te Pressure S ensor
— M VS M a n ifo ld V a cu u m S ensor C h e c k s va c u u m
o n ly
— R e e d V alve SAPV S e c o n d a ry A ir Pulse Valve
— R elief 1 S o le n o id V alve SA B V S e co n d a ry A ir B yp a ss va lve
S e c o n d a ry A ir In je ctio n S ystem PAIR P ulsed S e c o n d a ry A ir Injection P u lse d in je ctio n
—
AIR S e c o n d a ry A ir Injection #6
— S e q u e n tia l Fuel In je ctio n SM FI S e q u e n tia l M u ltip o in t Fuel In je ctio n
— S e rv ic e C o d e (s) DTC D ia g n o stic T ro u b le C ode(s)
— S p a rk Ig n itio n Dl D istrib u to r Ig n itio n
— S u p e rc h a rg e r SC S u p e rc h a rg e r
— S w itc h in g S o le n o id V a lve SASV S e c o n d a ry A ir S w itch in g V alve
— T est M ode(s) DTM D ia g n o stic T est M ode(s) #7
— T h re e W a y C a ta lyst TW C T h re e W a y C a ta lyst
— T h ro ttle B o d y TB T h ro ttle B o d y
— T h ro ttle S ensor TPS T h ro ttle P osition S ensor
— T u rb o c h a rg e r TC T u rb o c h a rg e r
— VAC MDP Maifold Differential Pressure
— V a c u u m S w itch M VZS Manifold Vacuum Z o n e Switch
-- W a te r T h e rm o s e n s o r ECTS Engine Coolant Temperature U s e d By CIS
Sensor a n d FAN
46UGIX-048
#6: S u p p lie s a ir to th re e w a y ca ta ly tic

#7: D ia g n o s tic tro u b le c o d e s d e p e n d o n th e te st m o d e
Transmission (Transaxle) and Steering System

— C lu tc h P osition CPP C lu tch Pedal P osition
E C -A T C o n tro l U n it PCM T P o w e rtra in C o n tro l M o d u le FF
(Transaxle)
P o w e rtra in C o n tro l M o d u le FR
(Transm ission)
— F ully C lo se d C TP C lo se d T hro ttle Position
— F ully O p e n WOT W id e O p e n T hro ttle
— In h ib ito r S w itch PNS P a rk/N e u tra l S w itch
— L o c k -u p P o sitio n TC C T o rq u e C o n v e rte r C lutch
— O u tp u t Signal(s) PTCS P o w e rtra in C o n tro l Signal(s)
— O v e rd riv e 4G R F ourth G ear
— P o w e r S te e rin g P re ssu re S w itch SPS S te e rin g P re ssu re S ensor
- P ulse G e n e ra to r VSPG V e h icle S p e e d Pulse G e n e ra to r
— V e h ic le S p e e d S e n so r VSS V e h icle S p e e d S e n so r
— 3 rd G e a r 3G R T h ird G ear
46UGIX-049
>
Gl—9
Gl SAE STANDARDS
B ody E le ctric al S y stem and H e a te r and A ir C o n d itio n er S ystem s
— A /C S w itch ACS A ir C o n d itio n in g S e n so r
— A ir C o n d itio n e r A /C A ir C o n d itio n e r
Vb B a tte ry V o lta g e B+ B a tte ry P ositive V o lta g e
— C o o la n t L e ve l S ensor CO LS C o o la n t Level S e n so r
G ro u n d GND G ro u n d
S e lf-D ia g n o sis S ystem OBD O n -B o a rd D ia g n o sis S ystem #8
46UGIX-050
#8: S ystem n am e. O th e r relate d n a m e s a re u n c h a n g e d .
FUNDAMENTAL PROCEDURES Gl
FUNDAMENTAL PROCEDURES
P R O T E C T IO N OF TH E V E H IC LE
Always be sure to cover fenders, seats, and floor areas be
fore starting work.
46UGIX-020
P R E P A R A TIO N OF TO O L S AN D M EA SU R IN G
E Q U IP M E N T
Be sure that all necessary tools and measuring equipment
are available before starting any work.
16EGIX-009
S P E C IA L TO O LS
Use special tools when they are required.
16EGIX-010
R E M O V A L OF PARTS
While correcting a problem, try also to determine its cause.
Begin work only after first learning which parts and subas
semblies must be removed and disassembled for replace
ment or repair. After removing the part, plug all holes and
ports to prevent foreign material from entering.
46UGIX-021
D IS A S S E M B LY
If the disassembly procedure is complex, requiring many
parts to be disassembled, all parts should be disassembled
in a way that will not affect their performance or external
appearance and identified so that reassembly can be per
formed easily and efficiently.
16EGIX-012
GI-11
Gl FUNDAMENTAL PROCEDURES
1. In sp ectio n of parts
When removed, each part should be carefully inspected for
malfunctioning, deformation, damage, and other problems.
16EGIX-013
2. A rran g em en t of parts
All disassembled parts should be carefully arranged for reas
sembly.
Be sure to separate or otherwise identify the parts to be
replaced from those that will be reused.
16EGIX-014
3. C leaning parts fo r reuse
All parts to be reused should be carefully and thoroughly
cleaned in the appropriate method.
W arning
• Using com pressed air can cause dirt and o th er par
ticles to fly out, causing injury to the eyes. W ear pro
te c tiv e e y e w e a r w h e n e v e r using co m p ressed air.
46UGIX-022
R EA SSEM B LY
Standard values, such as torques and certain adjustments,
mus: be strictly observed in the reassembly of all parts.
Refer to STANDARD BOLT AND NUT TIGHTENING
TORQUE in Section TD for tightening torques not mentioned
in the main text.
If removed, these parts should be replaced with new ones:

1. Oil seals 2. Gaskets
3. O-rings 4. Lock washers
5. Cotter pins 6. Nylon nuts
16EGIX-016
Depending on location:
1. Sealant should be applied to gaskets.
2. Oil should be applied to the moving components of parts.
3. Specified oil or grease should be applied at the prescribed
locations (such as oil seals) before reassembly.
16EGIX-017
Gl—12
FUNDAMENTAL PROCEDURES Gl
ADJUSTMENTS
Use suitable gauges and testers when making adjustments.
46UGIX-023
RUBBER PARTS AND TUBING
Prevent gasoline or oil from getting on rubber parts or
tubing.
9MUGIX-005
HOSE CLAMPS
When reinstalling, position the hose clamp in the original
location on the hose, and squeeze the clamp lightly with
large pliers to ensure a good fit.
46UGIX-024
TORQUE FORMULAS
When using a torque wrench-SST combination, the writ
ten torque must be recalculated due to the extra length that
the SST adds to the torque wrench. Recalculate the torque
by using the following formulas. Choose the formula that
applies to you.
T o rq u e U nits F orm ulas L & A U nits

N-m N m x [ L / ( L + A)] ce n tim e tre
K gf-m K g fm x [L /(L + A)] ce n tim e tre
kg f-cm K g fcm x [L /(L + A)] c e n tim e tre
46UGIX-025
ft-lb ft lb x [L /(L + A)] inch
in-lb in lb x [L /(L + A)] in ch
A = T h e le n g th of th e SST p a st th e to rq u e w re n c h drive.
L = T he le n g th o f th e to rq u e w re n ch .
VISE
When using a vise, put protective plates in the jaws of the
vise to prevent damage to parts.
46UGIX-026
Gl—13
Gl ELECTRICAL TROUBLESHOOTING TOOLS
ELECTRICAL TROUBLESHOOTING TOOLS
TEST LIGHT
The test light, as shown in the figure, uses a 12V bulb. The
two lead wires should be connected to probes.
The test light is used for simple voltage checks and for
checking for short circuits.
Caution
• Using a bulb over 3.4W when checking the control
unit may damage the control unit.
JUMPER WIRE
A jumper wire is used to create a temporary circuit. Con
nect the jumper wire between the terminals of a circuit to
bypass a switch.
Caution
• Do not connect a jumper wire from the power source
line to a body ground; this may cause burning or
other damage to harnesses or electronic com
ponents.
VOLTMETER
The DC voltmeter is used to measure circuit voltage. A volt
meter with a range of 15V or more is used by connecting
the positive (+ ) probe (red lead wire) to the point where
voltage is to be measured and the negative (-) probe
(black lead wire) to a body ground.
OHMMETER
The ohmmeter is used to measure the resistance between
two points in a circuit, and to check for continuity and short
circuits.
Caution
• Do not connect the ohmmeter to any circuit to which
voltage is applied; this will damage the ohmmeter.
46UGIX-030
ELECTRICAL PARTS Gl
ELECTRICAL PARTS
BATTERY CABLE
Before disconnecting connectors or removing electrical
parts, disconnect the negative battery cable.
CONNECTORS
Data Link Connector
Insert the probe into the service hole when connecting a
jumper wire to the data link connector.
Caution
• Inserting a jumper wire probe into the data link con
nector terminal may damage the terminal.
Disconnecting Connectors
When disconnecting two connectors, grasp the connectors,
not the wires.
46UGIX-033
Connectors can be disconnected by pressing or pulling the
lock lever as shown.
Locking connector
When locking connectors, listen for a click that will indicate
they are securely locked.
46UGIX-035
G I-1 5
Gl ELECTRICAL PARTS
Inspection
1. When a tester is used to check for continuity or to measure
voltage, insert the tester probe from the wiring harness side.
46UGIX-036
2. Check the terminals of waterproof connectors from the con
nector side, as they cannot be accessed from the wiring
harness side.
Caution
• To prevent damage to the terminal, wrap a thin wire
around the lead before inserting it into the terminal.
46UGIX-037
TERMINALS
Inspection
Pull lightly on individual wires to check that they are secured
in the terminal.
46UGIX-038
Replacement
Use the appropriate tools to remove a terminal as shown.
When installing a terminal, be sure to insert it until it locks
securely.
Insert a thin piece of metal from the terminal side of the con
nector, and then, with the terminal locking tab pressed
down, pull the terminal out from the connector.
46UGIX-039
Gl—16
ELECTRICAL PARTS Gl
SENSORS, SWITCHES, AND RELAYS
Handle sensors, switches, and relays carefully. Do not drop
them or strike them against other objects.
WIRING HARNESS
Wiring color codes
Two-color wires are indicated by a two-color code symbol.
The first letter indicates the base color of the wire and the
second the color of the stripe.
CODE COLOR CODE COLOR
B B la ck 0 O ra n g e
BR B ro w n P P ink
G G ree n R R ed
GY G ray V V iolet
L B lue W W hite
LB L ig h t B lue Y Y e llo w
LG L ig h t G ree n — —
FUSE
Replacement
1. When replacing a fuse, be sure to replace it with one of the
specified capacity.
If a fuse again fails after it has been replaced, the circuit
probably has a short and the wiring should be checked.
2. Be sure the negative battery terminal is disconnected be
fore replacing a main fuse (80A).
46UGIX-042
3. When replacing a pullout fuse, use the fuse puller supplied
PULLER
in the fuse box cover.
t
9MUGIX-032
G I-1 7
Gl INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEM/AUDIO ANTITHEFT SYSTEM
INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEM
If a mobile two-way radio system is installed improperly or if a high-powered type is used, the CIS and other
systems may be affected.
When the vehicle is to be equipped with a mobile two-way radio, observe the following precautions:
1. Install the antenna at the farthest point from control units.
2. Install the antenna feeder as far as possible from the control unit harnesses (at least 30 cm {11.8 in}).
3. Ensure that the antenna and feeder are properly adjusted.
4. Do not install a high-powered mobile two-way radio system.
46UGIX-043
AUDIO ANTITHEFT SYSTEM

An audio with an antitheft function is optionally available.
Before removing the negative battery terminal or discon
necting the audio power source, obtain the code number
and deactivate the audio antitheft system.
(Refer to 1994 626/MX-6 Body Electrical Troubleshooting
Manual.)
46UGIX-044
Gl—18
TOWING Gl
TOWING
Proper towing equipment is necessary to prevent damage
to the vehicle.
Laws and regulations applicable to vehicles in tow must al
WHEEL DOLLIES
ways be observed.
As a general rule, towed vehicles should be pulled with the
driving wheels off the ground. If excessive damage or oth
er conditions prevent towing the vehicle with the driving
wheels off the ground, use wheel dollies.
16EGIX-027 With either automatic or manual transaxle:

1. Set the ignition switch in the ACC position;
2. Place the selector lever or shift lever in N (Neutral);
3. Release the parking brake.
Caution
• Do not tow the vehicle backward with driving wheels
on the ground. This may cause internal damage to
the transaxle.
46UGIX-045
Caution
• Don’t use the hook loops under the front and rear
for towing. They are designed ONLY for tying down
the vehicle when it’s being transported. Using them
for towing will damage the bumper.
c
Gl—19
warnings and section J for audio antitheft system alarm conditions.________
CLUTCH
INDEX................................................................. H - 2
OUTLINE............................................................ H - 3
SPECIFICATIONS........................................... H - 3
TROUBLESHOOTING GUIDE..........................H - 3
CLUTCH FLUID................................................. H - 4
PREPARATION...............................................H - 4
INSPECTION.................................................. H - 4
REPLACEMENT............................................. H - 4
CLUTCH PED AL...............................................H - 5
ADJUSTMENT................................................H - 5
REMOVAL / INSTALLATION..........................H - 6
OVERHAUL.....................................................H - 7
CLUTCH MASTER CYLINDER........................ H - 8
PREPARATION...............................................H - 8
REMOVAL / INSTALLATION..........................H - 8
AIR BLEEDING...............................................H-10
OVERHAUL.....................................................H-11
CLUTCH RELEASE CYLINDER...................... H-13
PREPARATION...............................................H-13
REMOVAL / INSTALLATION..........................H-13
AIR BLEEDING (REFER TO PAGE H-10)
OVERHAUL.....................................................H -14
CLUTCH U N IT .................................................. H-15
PREPARATION...............................................H-15
REMOVAL / INSTALLATION..................... . H -16
CLUTCH COVER...............................................H-18
INSPECTION.................................................. H-18
CLUTCH DISC.................................................. H-19
INSPECTION.................................................. H-19
CLUTCH RELEASE COLLAR..........................H-20
INSPECTION.................................................. H-20
PILOT BEARING...............................................H-20
INSPECTION.................................................. H-20
FLYWHEEL........................................................ H-20
INSPECTION.................................................. H-20
36U0HX-0Q1
H INDEX
INDEX
FL U ID S P E C IF IC A T IO N
F M V S S 1 1 6 D O T-3
T R A N S A X L E S E R V IC E ,
S E C T IO N J
C L U T C H S W IT C H
S E R V IC E , S E C T IO N F
36U0HX-002
1. Clutch pedal 5. Clutch release fork

Adjustment................................. page H - 5 Removal / Installation................ page H -1 6
Removal / Installation................ page H - 6 6. Clutch cover
O v e r h a u l.................................... p a g e H - 7 R e m o v a l / In s ta lla tio n ................ p a g e H - 1 6
2. Clutch master cylinder Inspection.................................. page H -1 8
Removal / Installation................ page H- 8 7. Clutch disc
Air bleeding............................... page H-10 Removal / Installation................ page H -1 6
Overhaul.................................... page H -1 1 Inspection.................................. page H -1 9
3. Clutch release cylinder 8. Pilot bearing
Removal / Installation................ page H -13 Inspection.................................. page H-20
Overhaul.................................... page H -14 Removal / Installation................ page H -16
4. Clutch release collar 9. Flywheel
Removal / Installation................ page H -1 6 Removal / Installation................ page H -1 6
Inspection.................................. page H-20 Inspection.................................. page H-20
H—2
OUTLINE, TROUBLESHOOTING GUIDE H
OUTLINE
SPECIFICATIONS
Engine/Transaxle FS KL
Item G25 M-R
C lu tc h C o n tro l H y d ra u lic
Type S u sp e n d e d
P e d a l ratio 6 .5 5
C lu tc h p e d a l
Full stroke m m ( in ) 1 35 (5 .3 1 )
H e ig h t m m ( in ) 1 86— 211 ( 7 .3 2 — B .3 1 ) (w ith ca rp e t)
O u te r d ia m e te r m m ( in ) 2 2 5 ( 8 .8 6 )
In n e r d ia m e te r m m ( in ) 150 (5 .9 1 )
F lyw h ee l sid e
C lu tc h d is c 3 .5 ( 0 .1 4 )
m m ( in )
T h ic k n e s s
P re ssu re p la te sid e
3 .8 (0 .1 5 )
m m ( in )
Type D ia p h ra g m s p rin g
C lu tc h c o v e r
S et lo a d N (k g f, Ib f) 4 ,6 1 0 (4 7 0 , 1 ,0 3 0 ) 5 ,2 0 0 (5 3 0 , 1 ,1 7 0 )
C lu tc h m a s te r
In n e r d ia m e te r m m ( in ) 15 .87 (0 .6 2 4 8 )
c y lin d e r
C lu tc h relea se
In n e r d ia m e te r m m ( in ) 1 9 .0 5 (0 .7 5 0 0 )
c y lin d e r
C lu tc h flu id F M V S S 1 16 DO T-3
46U0HX-001
Problem Possible cause Action Page
Slipping C lu tc h d is c fa c in g w o rn R e p la ce H -1 6
C lu tc h d is c fa c in g su rfa c e h a rd e n e d o r o ile d R e p a ir o r re p la ce H - 1 6 , 19
P re ssu re p la te d a m a g e d R e p la ce H -1 6
D ia p h ra g m s p rin g d a m a g e d or w e a k e n e d R e p la ce H -1 6
In su fficie n t c lu tc h p e d a l p la y A d ju s t H - 5
C lu tc h p e d a l stickin g R e p a ir o r re p la ce S ee b e lo w
F lyw h e e l d a m a g e d R e p a ir o r re p la ce H -1 6 , 20
Poor E xce ssive ru n o u t o r d a m a g e d c lu tc h d isc R e p la ce H -1 6

disengagement C lu tc h d is c s p lin e s ru ste d o r w o rn R e m o ve rust o r re p la ce H -1 6
O il on fa c in g R e p a ir o r re p la ce H - 1 6 , 19
D ia p h ra g m s p rin g w e a k e n e d R e p la ce H -1 6
E xce ssive c lu tc h p e d a l p la y A d ju s t H- 5
In su fficie n t c lu tc h flu id A d d flu id H- 4
L e a k a g e o f c lu tc h flu id L o c a te a n d re p a ir o r
re p la c e
Vibration of clutch Oil on fa c in g R e p a ir o r re p la ce H - 1 6 , 19

when accelerating T o rsio n ru b b e rs w e a k e n e d R e p la ce H -1 6
C lu tc h d is c fa c in g h a rd e n e d o r d a m a g e d R e p a ir o r re p la ce H - 1 6 , 19
C lu tch d is c fa c in g rivets lo o se R e p la ce H -1 6
P re ssu re p la te d a m a g e d o r has e xce ssive ru n o u t R e p la ce H -1 6
F lyw h e e l su rfa c e h a rd e n e d o r d a m a g e d R e p a ir o r re p la ce H - 1 6 , 20
L o o se o r w o rn e n g in e m o u n t T ig h te n o r re p la ce
Clutch pedal P edal sh a ft n o t p ro p e rly lu b ric a te d L u b ric a te o r re p la ce H -6

sticking
Abnormal noise C lu tc h relea se c o lla r d a m a g e d R e p la ce H -1 6
P o o r lu b ric a tio n of release c o lla r sleeve L u b ric a te o r re p la ce H -1 6
T o rsio n ru b b e rs w e a k e n e d R e p la ce H -1 6
E xce ssive c ra n k s h a ft e n d p la y R e p a ir R efer to
S e ctio n B
P ilot b e a rin g w o rn o r d a m a g e d R e p la ce H - 1 6 , 20
W o rn p iv o t p o in ts o r relea se fo rk R e p la ce H -1 6
36U0HX-004
H CLUTCH FLUID
CLUTCH FLUID
PREPARATION
SST
49 0259 770B For

air bleeding
Wrench, flare nut system
16E0HX-006
INSPECTION
Note
• A common reservoir is used for the clutch and brake sys
tem fluids.
1. Verify that the fluid level in the reservoir is between the MAX
and MIN marks.
2. If the fluid level is extremely low check the clutch and brake
systems for leakage.
46UOHX-002
REPLACEMENT
Caution
• Clutch fluid will damage painted surfaces. If clutch
fluid does get on a painted surface, wipe it off im
mediately.
46U0HX-003

tion pump, and fill the reservoir with new fluid of the speci
fied type.
2. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder plug.
3. Insert the other end of the vinyl hose into a clear container.
4. Working with another person, have the person depress the
clutch pedal several times, then hold it down.
5. With the clutch pedal depressed, loosen the bleeder screw
by using the SST to let the fluid escape. Close the bleeder
screw.
6. Repeat steps 4 and 5 until only clean fluid is seen. Make
sure the reservoir is always 3/4 full or more during this
procedure.
7. Modify the bleeder screw tightening torque to allow for a
torque wrench-SST combination. (Refer to section Gl
“ Torque Formulas” .)
8. Tighten the bleeder screw by using the SST.
Tightening torque:
5.9—8.8 N-m (60—90 kgf-cm, 53—78 in-lbf)
9. Fill the reservoir to MAX with new fluid of the specified type.
10. Slowly pump the clutch pedal several times. Verify that there
is no fluid leakage.
11. Check operation of the clutch system.
12. Check operation of the brake system.
H -4
CLUTCH PEDAL H
CLUTCH PEDAL
13.8—17.6
® [ 140-180, 122-156
ADJUSTMENT
Height
Inspection
1. Measure the distance from the upper surface of the pedal
pad to the carpet.
Pedal height: 186—211 mm {7.32—8.31 in}

(with carpet)
2. If necessary, adjust the pedal height
Adjustment
1. Loosen locknut A and turn adjusting bolt B until the height
is correct.
2. Tighten locknut A.
Tightening torque:
13.8—17.6 N m (140—180 kgf cm, 122—156 inlbf}
3. After adjustment, measure the pedal free play.
Free Play
Inspection
1. Depress the clutch pedal by hand until clutch resistance
is felt.
N-m [ kgf-cm, in-lbf)

Free play: 1—3 mm (0.04—0.12 in}
36U0HX-005
Total free play: 5—14 mm (0.20—0.55 in)
2. If necessary, adjust the pedal free play.
Adjustment
1. Loosen locknut C and turn push rod D until the pedal free
play is correct.
2. Verify that the disengagement height (from the upper sur
face of the pedal pad to the carpet) is correct when the pedal
is fully depressed.
Minimum disengagement height:

67 mm (2.64 in} (with carpet)
3. Tighten locknut C.
Tightening torque:
11.8—16.6 N m (120—170 kgf cm, 105—147 in Ibf}
4. After adjustment, measure the pedal height.
H -5
H CLUTCH PEDAL
1. Remove the brake pedal. (Refer to section P.)
4. After installation, adjust the clutch pedal. (Refer to page H-5.)
(1 .9—2.6,
1 4 -1 8 )
Nm {kgf m, ft-lbfj
36U0HX-006
1. Nut 4. Nuts
2. Clutch switch connector 5. Clutch pedal assembly
3. Clutch switch Adjustment...................................page H -5
Removal Note............ below Overhaul.......................................page H -7
Removal Note
Clutch switch
Turn the clutch switch 90-df- in either direction and remove
from the bracket.
36U0HX-007
H -6
CLUTCH PEDAL H
OVERHAUL
3. Apply lithium-based grease to all bushings and pins.
46U0HX-0Q5
1. Clip 6. Clevis
2. Pin 7. Pedal pad
3. Bushing Inspect for wear
4. Nut 8. Clutch pedal
5. Push rod
Inspect for damage and bending
H -7
H CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER
PREPARATION
SST
49 0259 770B For

disconnecting/
Wrench, flare nut connecting
clutch pipe
16E0HX-016
Caution
• Clutch fluid will damage painted surfaces. If clutch fluid does get on a painted surface, wipe
it off immediately.

3. After installation, bleed the clutch system. (Refer to page H-10.)
4. Inspect and adjust the clutch pedal height and free play. (Refer to page H-5.)
11.9—2.6, 14— 18}
Nm | kgf m, ft-lbf)
46U0HX-006
1. Charcoal canister 4. Nuts

2. Clamp 5. Clutch master cylinder
Removal Note........................ page H -9 Inspect for fluid leakage from cylinder bore
Installation Note............................page H -9 Overhaul...................................page H—11
3. Clutch pipe Air bleeding............................. page H-10
Removal Note..............................page H -9 6. Gasket
Installation Note............................page H-9
H—8
CLUTCH MASTER CYLINDER H
Removal Note
Clamp
1. Disconnect the hose from the reservoir.
2. Plug the outlet of the reservoir.
46U0HX-031
Clutch pipe
Loosen the clutch pipe by using the SST.
Installation Note
Clutch pipe
1. Modify the clutch pipe tightening torque to allow for a torque
wrench-SST combination. (Refer to section Gl “ Torque
Formulas” .)
2. Tighten the clutch pipe by using the SST.
Tightening torque:
12.8—21.5 N m (130—220 kgf cm, 113—190 in lbf)
46U0HX-032
Clamp
Connect the hose and install the clamp as shown in the
figure.
46U0HX-Q33
AIR BLEEDING
The clutch hydraulic system must be bled to remove air that
enters whenever a hydraulic line is disconnected.
Caution
• Clutch fluid will damage painted surfaces. If clutch
mediately.
46U0HX-007
1. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder plug.
2. Insert the other end of the vinyl hose into a clear container.
3. Working with another person, have the person depress the
clutch pedal several times, then hold it down.
4. With the clutch pedal depressed, loosen the bleeder screw
by using the SST to let fluid and air escape.
Close the bleeder screw by using the SST.
5. Repeat steps 3 and 4 until no air bubbles are seen. Make
49 0 2 5 9 770B
sure the reservoir is always 3/4 full or more during this
procedure.
46U0HX-008 6. Modify the bleeder screw tightening torque to allow for a
torque wrench-SST combination. (Refer to section Gl
“ Torque Formulas’’.)
7. Tighten the bleeder screw by using the SST.
Tightening torque:
5.9—8.8 N m (60—90 kgf cm, 53—78 in lbf)
8. Fill the reservoir to MAX with new fluid of the specified type.
9. Slowly pump the clutch pedal several times. Verify that there
49 0 2 5 9 7 7 0B
is no fluid leakage.
10. Check operation of the clutch system.
11. Check operation of the brake system.
CLUTCH MASTER CYLINDER H
OVERHAUL
Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eyewear whenever using compressed air.
3. Wipe all parts, and clean all ports, passages, and inner parts with compressed air.
REPLACE
46U0HX-009
1. Clip 7. Spacer
2. Hose 8. Primary cup
3. Joint Inspect for wear and cracks
4. Bushing 9. Return spring
5. Snap ring 10. Master cylinder body
Disassembly Note...............................below Inspect cylinder bore for scoring and
Assembly Note.......................... page H -12 corrosion
6. Piston and secondary cup assembly Replace clutch master cylinder assembly if
Disassembly Note..................... page H -12 necessary
Assembly Note.......................... page H -12
Inspect for wear, scoring and cracks
Disassembly Note
Snap ring
While holding the piston down with a cloth-wrapped pin
punch, remove the snap ring.
46U0HX-010
H—11
Piston and secondary cup assembly
Warning
• Applying compressed air to the cylinder assembly
can make the contents suddenly pop out, possibly
causing injury. Hold a rag over the cylinder open
ing when using compressed air.
Remove the piston-and-secondary-cup assembly, spacer,

and primary cup by applying compressed air through the
clutch pipe installation hole.
Assembly Note
Piston and secondary cup assembly
1. Apply new fluid of the specified type to the cylinder bore
and all internal parts.
2. Verify that all parts are completely free of dirt, dust, and other
small particles.
3. Install the spring, primary cup, spacer, and piston-and-
secondary-cup assembly into the master cylinder body.
Snap ring
While holding the piston down with a cloth-wrapped pin
punch, install the snap ring.
46U0HX-013
H -1 2
CLUTCH RELEASE CYLINDER H
CLUTCH RELEASE CYLINDER
PREPARATION
SST
49 0259 770B For

disconnecting/
Wrench, flare nut connecting
clutch pipe
16E0HX-030
Caution
• Clutch fluid will damage painted surfaces. If clutch fluid does get on a painted surface, wipe
it off immediately.

3. After installation, bleed the clutch system. (Refer to page H-10.)
N-m (kgf m, ft-lbf |

46U0HX-014
1. Clutch pipe 3. Clutch release cylinder

Removal Note.....................................below Remove boot and inspect for fluid leakage
Installation Note......................... page H-14 Overhaul.................................... page H-14
2. Bolt
R em oval N ote
Clutch pipe
Disconnect the clutch pipe by using the SST, and plug the
clutch pipe immediately.
46U0HX-015
H -1 3
H CLUTCH RELEASE CYLINDER
Installation Note
Clutch pipe
1. Modify the clutch pipe tightening torque to allow for a torque
wrench-SST combination. (Refer to section Gl “ Torque
Formulas” .)
2. Tighten the clutch pipe by using the SST.
Tightening torque:
12.8—21.5 N m {130—220 kgf-cm, 113—190 in-lbf)
OVERHAUL
Warning
3. Wipe all parts, and clean all ports passages, and inner parts with compressed air.
46U0HX-016
1. Boot 6. Bleeder screw

2. Push rod 7. Steel ball
3. Piston and cup assembly 8. Release cylinder body
Disassembly Note..................... page H -15 Inspect cylinder bore for scoring and
Inspect for wear, scoring and cracks corrosion
4. Return spring Replace clutch release cylinder assembly if
5. Bleeder cap necessary
H -1 4
CLUTCH RELEASE CYLINDER, CLUTCH UNIT H
Disassembly Note
Piston and cup assembly
Warning
• Applying compressed air to the cylinder assembly
can make the contents suddenly pop out, possibly
causing injury. Hold a rag over the cylinder open
ing when using compressed air.
Remove the piston and cup assembly by applying com

pressed air through the clutch pipe installation hole.
CLUTCH UNIT
PREPARATION
SST
49 SE01 31 OA For 49 1285 071 For

support of removal of
Centering tool, clutch disc Puller, bearina pilot bearing
clutch disc
49 1285 073 For 49 E011 1A0 For

removal of prevention of
pilot bearing Brake, ring gear engine rotation
e=iaLJffl
49 1285 071)
49 E011 103 For 49 E011 105 For

Shaft engine rotation Stopper \ engine rotation
(Part of (Part of \
49 E011 1AO) 49 E011 1A0) \
49 E011 104 For

prevention of
Collar f engine rotation — —
(Part of c /n )
49 E011 1A0)
16E0HX-036
H CLUTCH UNIT
Note
• The clutch release cylinder can be removed from the transaxle with the clutch pipe connected.

JSAXLE ENGIh
SIDE SIC
(LITHIUM-BASED GREASE)
1
(MOLYBDENUM SULFIDE)
N m (kgf m, ft-lbf)
46U0HX-018
1. Clutch release cylinder 7. Clutch disc

2. Transaxle Removal Note........................... page H -1 7
Service........................................... Section J Inspection...................... ............ page H -19
3. Boot Installation Note............. ............ page H -1 8
4. Clutch release collar Pilot bearing
Inspection...................................page H-20 Inspection...................... ............ page H-20
5. Clutch release fork Removal Note........................... page H -1 7
6. Clutch cover Installation Note............. ............ page H -1 8
Removal Note........................... page H -1 7 Flywheel
Inspection...................................page H -1 8 Removal Note............... ............ page H -1 7
Installation Note......................... page H -1 8 Inspection...................... ............ page H-20
Installation Note............. ............ page H -1 7
H -1 6
CLUTCH UNIT H
Removal Note
Clutch cover and clutch disc
1. Install the SST.
2. Loosen each bolt one turn at a time in a crisscross pattern
until the spring tension is released.
3. Remove the clutch cover and disc.
16E0HX-038
Pilot bearing
Note
• The pilot bearing does not need to be removed unless
you are replacing it.
Use the SST to remove the pilot beaing.
46U0HX-019
Flywheel
1. Hold the flywheel by using the SST or equivalent tool.
2. Remove the bolts evenly and gradually in the pattern shown.
4. Inspect for oil leakage from the crankshaft rear oil seal. If
there is any such leakage or if the oil seal is damaged, re
fer to section B and replace the crankshaft oil seal.
46U0HX-020
Installation Note
Flywheel
Flywheel bolts on FS-engine models require sealant. New bolts
have sealant already applied at the factory. However, when
reusing bolts, remove all old sealant and then apply new seal
ant. Remove all old sealant from the bolt holes in the crank
shaft, whether using new or reused bolts. These steps help
to ensure that engine oil does not leak from the crankshaft bolt
holes.
1. Install the flywheel to the crankshaft.
2. Hand tighten the flywheel installation bolts.
46U0HX-021 3. Install the SST or equivalent tool to the flywheel.
4. Tighten the flywheel installation bolts in the pattern shown
in the figure.
Tightening torque
FS: 97—102 N m {9.8—10.5 kgf m, 71—75 ft-lbf J
KL: 61—67 Nm {6.2—6.9 kgf m, 45—49 ft-lbf}
H—17
H CLUTCH UNIT, CLUTCH COVER
Pilot bearing
Install a new pilot bearing by using a suitable pipe.
Pipe outer diameter: 35.0 mm (1.378 in)

Bearing installation depth: 0—0.4 mm (0—0.016 in)
16E0HX-042
Clutch disc
1. Clean the clutch disc splines and main drive gear splines.
2. Apply organic molybdenum sulfide grease to the splines.
3. Hold the clutch disc in position by using the SST.
16E0HX-043
Clutch cover
1. Align the dowel holes with the flywheel dowels and install
the clutch cover.
2. Install the SST or equivalent tool.
3. Tighten the bolts evenly and gradually in the pattern shown.
Tightening torque:
18—26 N m (1.8—2.7 kgf m, 14—19 ft Ibf)
46U0HX-Q35
CLUTCH COVER
INSPECTION
1. Measure the wear of the diaphragm spring fingers.
Depth: 0.5 mm (0.020 in) max.
46U0HX-036
2. Measure the flatness of the pressure plate surface with a
straightedge and a feeler gauge as shown in the figure.
Maximum clearance: 0.50 mm (0.020 in)
46U0HX-022
H -1 8
CLUTCH COVER, CLUTCH DISC H
The KL engine is made of aluminum, so the magnet will not
hold the dial indicator to the engine block as it would for the
FS engine. Therefore, use the SST to hold the dial indicator
when checking the runout of the diaphragm spring fingers on
the KL engine.
3. Rotate the flywheel and check for misaligned diaphragm
spring fingers.
Misalignment: 0.600 mm (0.0236 in) max.
4. Replace the clutch cover if not as specified.
CLUTCH DISC
INSPECTION
1. Inspect the contact surface of the clutch disc for scoring,
cracks, burning, and oil contamination.
2. Remove minor scoring or burning with emery paper. Re
pair if scoring or burning is major. Replace if cracked or
oil soaked.
3. Inspect for loose facing rivets and dampers.
Replace the clutch disc if either is loose.
4. Using vernier calipers, measure the thickness of the lining

at a rivet head on both sides.
Replace the clutch disc if its thickness is less than minimum.
Thickness: 0.3 mm (0.012 in) min.
46U0HX-025
5. Measure the clutch disc runout with a dial indicator.
Replace the clutch disc if runout is excessive.
Runout: 0.700 mm (0.0276 in} max.
46U0HX-026
H -1 9
H_______ CLUTCH RELEASE COLLAR, PILOT BEARING, FLYWHEEL_________
CLUTCH RELEASE COLLAR
INSPECTION
Caution
• Cleaning the clutch release collar with cleaning
fluids or a steam cleaner can wash the grease out
of the sealed bearing.
1. Turn the collar while applying force in the axial direction.

2. If the collar sticks or has excessive resistance, replace it.
46U0HX-027
PILOT BEARING
INSPECTION
Note
• The pilot bearing can be inspected while it is in the
flywheel.
1. Turn the bearing while applying force in the axial direction.

2. If the bearing sticks or has excessive resistance, replace it.
46U0HX-028
FLYWHEEL
INSPECTION
1. Inspect the contact surface for scoring, cracks, and burning.
2. Remove minor scoring or burning with emery paper. Re
pair if scoring or burning is major. Replace if cracked.
46U0HX-029
3. Inspect the ring gear teeth for wear and damage. If neces
sary, replace the ring gear.
4. Measure the flywheel runout with a dial indicator. Replace
the flywheel if runout is excessive.
Runout: 0.200 mm (0.0079 in} max.
46U0HX-030
H -2 0
warnings and section J for audio antitheft system alarm conditions. ____
MANUAL TRANSAXLE
(G25M-R)
IN D E X .....................................................................J - 2
O U TLIN E................................................................J - 3
SPECIFICATIONS............................................. J - 3
STRUCTURAL VIEW......................................... J - 4
POWER FLOW...................................................J - 5
TROUBLESHOOTING G U ID E ........................... J - 6
TRANSAXLE O IL ................................................. J - 7
INSPECTION.......................................................J - 7
REPLACEMENT............................................ J - 7
OIL SEAL (DIFFERENTIAL)............................... J - 8
PREPARATION...................................................J - 8
REPLACEMENT................................................ J - 8
OIL SEAL (CHANGE ROD ASSEMBLY)......... J - 9
REPLACEMENT................................................ J - 9
TRANSAXLE......................................................... J -1 0
PREPARATION...................................................J -1 0
REMOVAL.......................................................... J—12
DISASSEMBLY...................................................J -1 8
INSPECTION.......................................................J -2 9
ASSEMBLY......................................................... J -3 2
INSTALLATION................................................. J -4 8
DIFFERENTIAL..................................................... J -5 4
PREPARATION...................................................J -5 4
DISASSEMBLY / INSPECTION / ASSEMBLY.. J -5 5
SHIFT MECHANISM............................................ J -5 8
OVERHAUL........................................................J -5 8
36U0JX-03Q
J INDEX
INDEX
GRADE: API SERVICE GL-4 or GL-5

VISCOSITY: ALL-SEASON SAE 75W-90
ABOVE 10°C (5 0 °F ) SAE80W -90
CAPACITY: 2.7 L (2.9 US qt, 2.4 Imp qt)
16E0JX-002
1. Transaxle 3. Shift mechanism

Removal..................................... page J—12 Overhaul..................................... page J-58
Disassembly............................... page J—18 4. Transaxle oil
Inspection................................... page J-29 Inspection................................... page J- 7
Assembly.................................... page J-32 Replacement..............................page J- 7
Installation.................................. page J-48 5. Oil seal (differential)
2. Differential Replacement..............................page J- 8
Disassembly / Inspection / 6. Oil seal (change rod assembly)
Assembly.................................. page J-55 Replacement..............................page J- 9
J—2
OUTLINE J
OUTLINE
SPECIFICATIONS
____ _______________ Engine/T ransaxle FS KL
Item ------------------ _____ G2S M-R
T ra n s a x le c o n tro l Floo shift
F o rw a rd : S yn ch ro m e sh
S y n c h ro m e s h system
R everse: S e le ctive s lid in g a n d s y n ch ro m e s h
1st 3 .3 0 7
2nd 1.833
3 rd 1.233 1.310
G e a r ratio
4 th 0 .9 1 4 1.0 30
5th 0 .7 1 7 0 .7 9 5
R e ve rse 3 .1 6 6
F inal g e a r ratio 4 .1 0 5
G ra d e API S e rvice G L -4 o r G L-5
A ll-se a so n SA E 75 W -9 0
Oil V isco sity
A b o ve 1 0 °C (5 0 °F ) SAE 8 0 W -9 0
C a p a c ity L { US qt, Im p q t ) 2 .7 (2 .9 , 2 .4 )
J_______ OUTLINE
STRUCTURAL VIEW
16E0JX-0Q4
1.1 st gear 8. 2nd gear

2. 2nd gear 9. Secondary 3rd gear
3.3rd gear 10. Secondary 4th gear
4. 4th gear 11. Secondary 5th gear
5. 5th gear 12. Clutch hub sleeve (Reverse gear)
6. Reverse gear 13. Reverse idler gear
7.1st gear 14. Ring gear
J -4
OUTLINE J
J TROUBLESHOOTING GUIDE
Shift lever won’t shift S e ize d sh ift le ve r b all seat R e p la ce J -5 8
smoothly or is hard to S e ize d c h a n g e c o n tro l rod jo in t R e p la ce J -5 8
shift B e n t c h a n g e c o n tro l rod R e p la ce J -5 8
Too much play in shift W o rn c h a n g e c o n tro l ro d b u s h in g R e p la ce J -5 8

lever W o rn s h ift le ve r ball seat R e p la ce J -5 8
Difficult to shift B e n t c h a n g e c o n tro l rod R e p la ce J -5 8

N o g re a s e in tra n s a x le co n tro l L u b ric a te w ith g re a se J -5 8
In s u ffic ie n t oil A d d oil J- 7
D e te rio ra tio n o f oil q u a lity R e p la ce w ith oil of J- 7
s p e c ifie d q u a lity
W e a r o r p la y o f sh ift fo rk o r sh ift rod R e p la ce J —18
W o rn s y n c h ro n iz e r rin g R e p la ce J —24, 26
W o rn s y n c h ro n iz e r c o n e o f g e a r R e p la ce J —2 4 , 2 6
B a d c o n ta c t o f s y n c h ro n iz e r rin g a n d c o n e o f g e a r R e p la ce J —24, 2 6
E xce ssive lo n g itu d in a l p la y of g e a rs R e p la ce J —24, 2 6
W o rn b e a rin g R e p la ce J - 2 4 , 26
W o rn s y n c h ro n iz e r ke y s p rin g R e p la ce J —24, 26
E x ce ssive p rim a ry s h a ft g e a r b e a rin g p re lo a d A d ju s t J —3 8
Im p ro p e rly a d ju s te d c h a n g e g u id e plate A d ju s t J -2 1
Won’t stay in gear B e n t c h a n g e c o n tro l ro d R e p la ce J -5 8

W o rn c h a n g e c o n tro l ro d b u s h in g R e p la ce J -5 8
Im p ro p e rly in sta lle d e x te n s io n b a r T ig h te n J -5 8
W o rn sh ift fo rk R e p la ce J —18
W o rn c lu tc h h u b R e p la ce J -2 4 , 26
W o rn c lu tc h h u b sle e ve R e p la ce J - 2 4 , 26
W o rn g e a r s lid in g su rfa c e o f sh a ft g e a rs R e p la ce J - 2 4 , 26
W o rn g e a r s lid in g su rfa c e o f g e a r R e p la ce J - 2 4 , 26
W o rn steel s lid in g g ro o v e o f c o n tro l e n d R e p la ce J —18
W e a k s p rin g p re s s in g a g a in s t steel ball R e p la ce J —18
E x c e s s iv e th ru s t c le a ra n c e R e p la ce J—18, 24, 26
W o rn b e a rin g R e p la ce J -2 4 , 26
Im p ro p e rly in sta lle d o r lo o se e n g in e m o u n t T ig h te n J -4 8 , 50
Abnormal noise In s u ffic ie n t oil A d d oil J- 7

D e te rio ra tio n o f oil q u a lity R e p la ce w ith oil of J- 7
sp e c ifie d q u a lity
W o rn b e a rin g A d ju s t o r re p la c e J - 2 4 , 26
W o rn s lid in g s u rfa c e s o f g e a rs o r shafts R e p la ce J - 2 4 , 26
E xc e s s iv e g e a r b a ckla sh R e p la ce J -2 4 , 26
D a m a g e d g e a r teeth R e p la ce J - 2 4 , 26
F o re ig n m ate ria l in g e a rs R e p la ce J -2 4 , 26
D a m a g e d d iffe re n tia l g e a r o r e x c e s s iv e b a ckla sh R e p la ce J —55
16E0JX-006
J—6
TRANSAXLE OIL J
TRANSAXLE OIL
INSPECTION
1. On level ground, jack up the vehicle and support it evenly
on safety stands.
2. Remove the oil level plug and washer.
3. Verify that the oil level is near the lower edge of the plug port.
4. If the oil level is low, add the specified amount and type
of oil through the plug port.
46U0JX-Q01
Specified oil
Above 10°C {50°F} SAE 80W-90
5. Install a new washer and the oil level plug.
Tightening torque:
40—58 N m {4.0—6.0 kgf m, 29—43 ft-lbf}
46U0JX-002
REPLACEMENT
on safety stands.
2. Remove the drain plug and washer.
4. Install a new washer and the drain plug.
Tightening torque:
40—58 N m {4.0—6.0 kgf m, 29—43 ft Ibf}
46U0JX-073
5. Remove the oil level plug and washer. Add the specified
amount and type of oil through the plug port until the level
reaches the lower edge of the port.
Specified oil
Above 10°C {50°F} SAE 80W-90
Capacity: 2.7 liters (2.9 US qt, 2.4 Imp qt}
46U0JX-074 6. Install a new washer and the oil level plug.
Tightening torque:
40—58 N m {4.0—6.0 kgf m, 29—43 ft Ibf}
J -7
J OIL SEAL (DIFFERENTIAL)
OIL SEAL (DIFFERENTIAL)

P R E P A R A T IO N
SST
49 B001 795 For

Installation of
Installer, oil seal oil seal
16E0JX-011
R E P LA C E M E N T
on safety stands.
4. Separate the drive shaft and joint shaft from the transaxle.
(Refer to pages J - 1 2, 14.)
46U0JX-075
5. Remove the oil seal.
46U0JX-076
6. Using the S S T and a hammer, tap the new oil seal in even
ly until the S S T contacts the transaxle case.
7. Coat the lip of the oil seal with transaxle oil.
46U0JX-003
8. Insert the drive shaft and joint shaft to the transaxle.
(Refer to pages J -4 8 , 50.)
9. A dd the specified amount and type of oil.
(Refer to page J -7 .)
46U0JX-004
J -8
OIL SEAL (CHANGE ROD ASSEMBLY) J
OIL SEAL (CHANGE ROD ASSEMBLY)
R E P LA C E M E N T
on safety stands.
(Refer to Replacement, page J -7 .)
4. Remove the transverse member.
5. Disconnect the change control rod from the transaxle.
6. Remove the joint and boot from the change rod assembly.
46U0JX-077
7. Remove the oil seal.
46U0JX-078
8. Install the new oil seal by using a pipe.
O u te r d ia m e te r o f pipe: 2 6 .0 m m {1 .0 2 in }
46UOJX-005
10. Install the boot and joint to the change rod assembly with
the boot draining hole facing downward.
T ig h te n in g to rq u e:
1 3 .8 — 18.6 N m {1 4 0 — 190 kgf cm , 12 2 — 164 in Ib f )
11. Connect the change control rod.
1 9 - 2 5 N m { 1 . 9 - 2 . 6 kg f m , 1 4 - 1 8 ft lb f}
46U0JX-006 12. Add the specified amount and type of oil.

(Refer to page J -7 .)
13. Install the transverse member.
9 4 — 131 N m {9 .5 — 1 3 .4 kgf m , 6 8 .8 — 9 6 .9 ft-lb f}
46U0JX-007
J TRANSAXLE
TRANSAXLE
SST
49 G017 5A0 For 49 0118 850C For

support of engine removal of tie rod
Support, engine Puller, ball joint end
49 0107 680A For 49G019 0A0 For

Engine stand assembly of Hanger, transaxle assembly
transaxle transaxle
49 G030 440 For 49 FT01 361 n r \ For
Holder, primary
holding primary sqYrfi™ removal of
shaft Remover, bearing bearing race
shaft
49 B001 795 For 49 0636145 For

installation of oil removal of
Installer, oil seal seal Puller, fan pulley bearing
m r ......1 1 boss
k lL T
49 G030 370 For 49G017 1A0 For

Removing plate secondary 3rd Remover set, bearings
gear and 2nd bearing
gear
49 F401 366A For 49 B092 373 For

Plate bearing Attachment G bearing
(Part of (Part of
49G017 1A0) 49 G0171A0)
49 B092 374 For 49 0839 425C For

Attachment H bearing Puller set, bearing
(Part of bearing
49G017 1A0)
49 F401 330B For 49 F401 331 For

Installer set, bearing Body bearing
bearing (Part of
49 F401 330B)
J -1 0
TRANSAXLE
49 F401 335A For 49 F401 336B For

Attachment A bearing Attachment B bearing
(Part of (Part of
49 F401 330B) 49 F401 330B)
49 G030 380C For 49 G030 381 For

adjustment of adjustment of
Shim selector set j|j||j| bearing preload Selector <#>68
(Part of
bearing preload
49 G030 380C)
49 G030382A For 49 F401 382A For

Selector <t>58 bearing preload Selector </>52 bearing preload
(Part of (Part of
49 G030 380C) 49 G030 380C)
49 F401 384 For 49 G019 021 For

Collar bearing preload Bolt set bearing preload
(Part of (Part of
49 G030 380C) 49 G030 380C)
49FT01 515A For 49 F401 385 For

Adapter, preload bearing preload Bar bearing preload
(Part of (Part of
49 G030 380C) 49 G030 380C)
49 B017102 For 49 G017 202 For

Adapter, preload bearing preload Adapter, preload bearing preload
49 G030 455 For

holding side
Holder, diff. side gears
gear
16E0JX-021
J—11
J TRANSAXLE
REMOVAL
2. On level ground, jack up the vehicle and support it evenly on safety stands.
3. Drain the transaxle oil into a suitable container.
4. Remove in the order shown in the figure, referring to R em oval Note.
KL ENGINE
^ a
TRANSAXLE J
1. Battery 17. Exhaust pipe
2. Battery carrier 18. Extension bar
3. Fresh air duct 19. Change control rod
4. Air cleaner housing assembly 20. Tie rod ends
5. Starter Removal N o te ................................page J -1 5
6. Park/neutral switch connector 21. Stabilizer control links
7. Back-up light switch connector 22. Drive shafts
8. Vehicle speed sensor (speedometer driven Removal N o te ................................page J -1 5
gear) connector 23. Joint shaft
9. Ground 24. No.5 engine mount
10. Fuel filter mounting nuts 25. No.1 engine mount bracket
11. Harness bracket 26. Engine mount member
12. Clutch release cylinder Removal N o te ................................page J -1 7
Removal N o te ................................ page J—15 27. Under cover
13. Oxygen sensor connecter 28. No.4 engine mount
14. Wheels and tires 29. Transaxle
15. Splash shields Removal N o te ................................page J -1 7
16. Transverse member 30. No.2 engine mount
46U0JX-080
J -1 3
J TRANSAXLE
TRANSAXLE J
1. Battery 16. Extension bar
2. Battery carrier 17. Change control rod
3. Resonance cham ber 18. Tie rod ends
4. Fresh air duct Removal N o te .........................................below
5. Air cleaner housing assembly 19. Stabilizer control links
6. Park/neutral switch connector 20. Drive shafts
7. Back-up light switch connector Removal N o te .........................................below
8. Vehicle speed sensor (speedometer driven 21. Joint shaft
gear) connector 22. Starter
9. Ground 23. No.5 engine mount
10. Fuel filter mounting nuts 24. No.1 engine mount bracket
11. Harness bracket 25. Engine mount member
12. Clutch release cylinder Removal N o te ................................page J - 1 7
Removal N o te ......................................... below 26. No.4 engine mount
13. Wheels and tires 27. Transaxle
14. Splash shields Removal N o te ................................page J - 1 7
15. Transverse member 28. No.2 engine mount
46U0JX-081
R em oval N ote
C lutch release cylin d er
C aution
• B ending th e clutch pipe can cause kinks o r cracks.
1. Remove the bolts and clips shown.

2. Put the clutch release cylinder and the clutch pipe in a place
where they will not interfere with transaxle removal.
T ie rod end
C aution
• T h e sharp edges of the S S T can slice th e tie rod end
d ust boot. Install th e S S T so th a t th e sh arp ed g es
a re b e tw e e n th e dust bo o t and th e kn u ckle.
1. Remove the cotter pin.

2. Loosen the nut until it is flush with the end of the ball stud.
3. Disconnect the tie rod end from the knuckle by using the
SST.
D rive shafts
1. Remove the clips.
2. Remove the ABS wheel speed sensor harness mounting
nuts.
16E0JX-026
J -1 5
J TRANSAXLE
3. Remove the clinch bolt and nut.
46U0JX-010
4. Wrap a rag around the ball joint dust boot.
5. Pry the lower arm out of the knuckle.
46U0JX-011
C aution
• T h e sharp ed g es o f th e d rive sh aft sn ap ring can
slice o r p u n ctu re th e oil seal. Be c a re fu l w h en
rem o vin g th e d rive s h aft fro m th e tra n s a x le .
6. Separate the left- side drive shaft from the transaxle by pry
ing with a bar inserted between the outer ring and the trans
axle, as shown in the illustration.
7. Suspend the drive shaft with a rope.
8. Install the S S T into the transaxle to hold the side gears.
46U0JX-013
9. Separate the drive shaft from the joint shaft by using a cop
per bar and hammer.
46U0JX-014
J -1 6
TRANSAXLE
En g in e m o u n t m em b er
2. Remove the engine mount member.
Tran saxle
1. Loosen the S S T (engine support) and lean the engine to
ward the transaxle.
2. Support the transaxle on a jack.
16E0JX-033
3. Remove the transaxle mounting bolts.
4. Remove the transaxle.
J—17
J TRANSAXLE
D IS A S S E M B L Y
P re c a u tio n
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
W arn in g
• U sing co m p re ss e d a ir can cau se d irt and o th e r p articles to fly o u t, causing injury to th e eyes.
W e a r p ro te c tiv e e y e w e a r w h e n e v e r using co m p ressed air.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry
with com pressed air.
3. Clean out all holes and passages with compressed air, and check that there are no obstructions.
5 th /R e v e rs e G e a r and H o u sin g P arts

1. Measure the 5th gear thrust clearance, referring to P reinspection.
2. Disassemble in the order shown in the figure, referring to D isassem b ly Note.
46U0JX-016
J—18
TRANSAXLE J
1. Rear cover 19. Magnet
2. Locknut (primary shaft) 20. Reverse idler shaft
Disassembly N o te ......................... .........below 21. Reverse idler gear
3. Locknut (secondary shaft) Inspection....................................page J-30
Disassembly N o te ............ ............ below 22. 5th/reverse shift rod
4. Primary reverse synchronizer gear 23. 5th/reverse shift rod end
Inspection........................................ page J -2 9 24. Pin
5. Reverse synchronizer ring 25. Crank lever shaft
Inspection........................................ page J -2 9 26. Crank lever assembly
6. Secondary reverse synchronizer gear 27. Shift fork and shift rod assembly
Inspection........................................ page J -2 9 Disassembly Note...................... page J-20
7. 5th/reverse shift fork 28. Steel ball
8. 5th/reverse clutch hub assembly 29. Spring
Inspection........................................ page J -2 9 30. Primary shaft gear assembly
9. 5th synchronizer ring 31. Secondary shaft gear assembly
Inspection........................................ page J -2 9 32. Differential assembly
10. 5th gear 33. Clutch housing
Inspection........................................ page J -2 9 34. Synchronizer key springs
11. Gear sleeve 35. Clutch hub sleeve
Inspection........................................ page J-31 36. Synchronizer keys
12. Secondary 5th gear 37. Clutch hub
Inspection........................................ page J -2 9 38. 3rd/4th shift fork
13. Lock bolt 39. Interlock sleeve
14. Guide bolt 40. Control lever
15. Lock bolt, ball and spring 4 1 .1st/2nd shift fork
16. Back-up light switch 42. Control rod
17. Park/neutral switch 43. Control end
18. Transaxle case assembly
46U0JX-083
P rein sp ectio n
5th g e a r th ru st clearan ce
1. Measure the 5th gear thrust clearance by using a dial in
dicator.
C learance: 0 .1 0 0 — 0 .2 2 0 m m (0 .0 0 3 9 — 0 .0 0 8 7 in )
M axim um : 0 .2 7 0 mm (0 .0 1 0 6 in )
2. If the clearance exceeds the maximum, check the contact

surfaces of the 5th gear and the clutch hub. Replace worn
or damaged parts.
36U0JX-009
D isassem b ly note
Locknut
1. Mount the transaxle on the SST.
49 G 0 1 9 0 A 0
49 0107 680A
16E0JX-038
J -1 9
J TRANSAXLE
2. Lock the primary shaft with the SST.
3. Shift to 1st gear to lock the rotation of the primary shaft.
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary
shafts.
49 G030 440
46U0JX-017
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the control le
\ \ ver (arrow). Turn the shift rod counterclockwise.
CON' 2. While holding the 1st/2nd shift fork with one hand and the
3rd/4th shift fork with the other, raise them both at the same
time and shift each of the clutch hub sleeves.
46U0JX-084
3. Lift the control end and remove the steel ball, and, at the
same time, remove the control rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from each
of the clutch hub sleeves.
16E0JX-041
J—20
TRANSAXLE
Clutch Housing and Transaxle Case Components
Note
• The oil seals do not need to be removed unless you are replacing them.
46U0JX-018
1. Bearing race (primary shaft) 15. Oil seal (differential)

2. Oil seal (primary shaft) Disassembly Note.................. .... page J -2 2
Disassembly Note..................... ... page J-2 2 16. Bearing race (differential)
3. Bearing race (secondary shaft) Disassembly Note.................. .... page J-2 3
Disassembly N ote..................... ... page J -2 2 17. Reverse lever shaft
4. Funnel Disassembly Note.................. .... page J -2 3
5. Guide plate assembly 18. Reverse lever
6. Change arm Inspection................................ .... page J -3 0
7. Roll pin 19. Drain plug and water
Disassembly N ote.................... page J -2 2 20. Bearing race (transaxle case)
8. Change rod assembly Disassembly Note.................. .... page J -2 3
9. Boot 21. Diaphragm springs
10. Selector 22. Adjustment shim(s)
11. Oil seal (change rod assembly) 23. Bearing race (differential)
Disassembly Note..................... .. page J -2 2 Disassembly Note................... .... page J-2 3
12. Bleeder cover assembly 24. Adjustment shim(s)
13. Bleeder 25. Oil seal (differential)
14. Vehicle speed sensor (speedometer driven Disassembly Note................... , , page J-2 2
gear) 26. Oil passage
Inspection................................... .. page J-31 27. Joint
28. Change rod
J—21
J TRANSAXLE
Disassembly note
Oil seal (primary shaft)
Caution
• The clutch housing is made of aluminum, and is
therefore easily dented and scratched by metal
tools. When removing the oil seal, keep contact with
the clutch housing to a minimum.
Remove the oil seal from the clutch housing as shown in

the figure.
46U0JX-019
Bearing race (secondary shaft)
Remove the bearing race by lifting it and the funnel out to
gether.
16E0JX-044
Roll pin
Align the groove for removal of the clutch housing pin with
the position of the roll pin, then tap the pin out by using a
pin punch.
Oil seal (change rod assembly)

Remove the oil seal.
Oil seal (differential)

Remove the oil seal.
46U0JX-086
J—22
TRANSAXLE J
Bearing race (differential)
1. Install the SST onto the differential bearing race, and sup
port the SST so that it does not fall.
2. Remove the bearing outer race by using the SST.
46U0JX-020
Reverse lever shaft
1. Remove the roll pin by using pliers.
16E0JX-049
2. Protect the reverse lever shaft with a rag and use pliers to
remove the shaft.
16E0JX-050
Bearing race (transaxle case)
Remove the bearing race by using the SST.
46U0JX-021
J TRANSAXLE
Primary Shaft Assembly
1. Measure the thrust clearance of all gears before disassembly, referring to Preinspection.
© r a n REPLACE
46U0JX-087
1. Bearing (4th gear end) 7. 3rd gear

Disassembly Note.................. .... page J -2 5 Preinspection......................... ..... page J -2 5
Inspection................................ .... page J-3 0 Disassembly Note................. .... page J-2 5
2. 4th gear Inspection............................... .... page J-2 9
Preinspection.......................... .... page J -2 5 8. Bearing (primary shaft end)
Inspection................................ .... page J-2 9 Disassembly Note................. .... page J -2 5
3. 4th synchronizer ring Inspection............................... .... page J -3 0
Inspection................................ .... page J -2 9 9. Primary shaft gear
4. Retaining ring Inspection............................... .... page J-3 0
5. 3rd/4th clutch hub assembly 10. Synchronizer key springs
Disassembly Note.................. .... page J-2 5 11. 3rd/4th clutch hub sleeve
Inspection................................ .... page J -2 9 12. Synchronizer keys
6. 3rd synchronizer ring 13. 3rd/4th clutch hub
Disassembly Note.................. .... page J -2 5
Inspection................................ page J-2 9
J-24
TRANSAXLE J
Preinspection
3rd gear thrust clearance
1. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05—0.20 mm {0.002—0.008 in)

Maximum: 0.25 mm (0.010 in)

surfaces of the 3rd gear, 2nd gear and 3rd/4th clutch hub.
Replace worn and damaged parts.
46U0JX-088
4th gear thrust clearance
1. Measure the clearance between the 4th gear and the ball
bearing.
Clearance: 0.17—0.37 mm (0.007—0.015 in)


surfaces of the 4th gear, ball bearing, and 3rd/4th clutch
hub. Replace worn and damaged parts.
Disassembly note
Bearing (4th gear end)
1. Support the primary shaft to keep it from falling.
2. Remove the bearing by using the SST.
46U0JX-022
3rd/4th clutch hub assembly, 3rd synchronizer ring and
3rd gear
1. Support the primary shaft to keep it from falling.
2. Remove the 3rd/4th clutch hub assembly, 3rd synchroniz
er ring, and 3rd gear by using the SST.
46U0JX-023
Bearing (primary shaft end)
Remove the bearing by using the SST.
46U0JX-024
J—25
J TRANSAXLE
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear before disassembly, referring to Preinspection.
46U0JX-090
1. Bearing 8 . 1st/2nd clutch hub assembly

Disassembly Note........................page J-2 7 Disassembly Note........................page J-2 7
Inspection......................................page J -3 0 Inspection......................................page J-2 9
2. Secondary 4th gear 9.1st synchronizer ring
Inspection......................................page J-2 9 Inspection..................................... page J -2 9
3. Retaining ring 10.1 st gear
4. Secondary 3rd gear Preinspection............................... page J-2 7
Inspection......................................page J-2 9 Inspection..................................... page J -2 9
5. 2nd gear 11. Bearing (secondary shaft end)
Preinspection............................... page J-2 7 Disassembly Note........................page J -2 8
Disassembly Note........................page J-2 7 Inspection......................................page J-3 0
Inspection......................................page J-2 9 12. Secondary shaft gear
6. 2nd synchronizer ring Inspection..................................... page J -3 0
Inspection......................................page J-2 9 13. Synchronizer key springs
7. Retaining ring 14. Reverse gear clutch hub sleeve
15. Synchronizer keys
1 6 .1st/2nd clutch hub
J—26
TRANSAXLE J
Preinspection
1st gear thrust clearance
1. Measure the clearance between the 1st gear and the
differential drive gear.
Clearance: 0.05—0.28 mm {0.002—0.011 in)

Maximum: 0.33 mm {0.013 in}

surfaces of the 1st gear, differential drive gear of the secon
dary shaft gear, and 1st/2nd clutch hub assembly. Replace
worn and damaged parts.
2nd gear thrust clearance

1. Measure the clearance between the 2nd gear and secon
dary 3rd gear.
Clearance: 0.18—0.46 mm {0.007—0.018 in}

Maximum: 0.51 mm {0.020 in}

surfaces of the 2nd gear, secondary 3rd gear, and 1st/2nd
clutch hub assembly. Replace worn and damaged parts.
46U0JX-O92
Disassembly note
Bearing and secondary 4th gear
1. Support the secondary shaft to keep it from falling.
2. Remove the bearing and secondary 4th gear by using the
SST.
46U0JX-025
Secondary 3rd gear and 2nd gear
1. Shift the gears to 1st gear.
3. Remove the secondary 3rd gear and 2nd gear by using
the SST.
46U0JX-026
1st/2nd clutch hub assembly, 1st synchronizer ring, and
1st gear
2. Remove the 1st/2nd clutch hub assembly, 1st synchroniz
er ring, and 1st gear by using a press.
J—27
J TRANSAXLE
Bearing (secondary shaft end)
2. Remove the bearing by using the SSTs.
46U0JX-028
TRANSAXLE
INSPECTION
Inspect all parts and repair or replace as necessary.
16E0JX-065
Gears
1. Inspect the synchronizer cones for wear.
2. Inspect the gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer ring matching teeth for damage
and wear.
16E0JX-066
Synchronizer Ring
1. Inspect the synchronizer ring teeth for damage, wear, and
cracks.
2. Inspect the tapered surface for wear and cracks.
16E0JX-067
3. Set the synchronizer ring squarely in the gear.
4. Measure the clearance between the synchronizer ring and
the flank surface of the gear all around the circumference.
Standard clearance: 1.50 mm (0.059 in}

Minimum: 0.80 mm (0.031 in}
46U0JX-029
Clutch Hub Assembly
1. Inspect the clutch hub sleeve and hub operation.
3. Inspect the synchronizer keys for damage, wear, and
cracks.
16E0JX-069
J—29
TRANSAXLE
4. Measure the clearance between the hub sleeve and shift
fork.
Clearance
mm (in)
Standard Maximum
1st/2nd 0 .10-0.45 (0.004-0.018) 0.95 (0.037)
3rd/4th 0 .10-0.40 (0.004-0.016) 0.90 (0.035)
5th/Rev. 0 .10-0.36 (0.004-0.014) 0.86 (0.034)
16E0JX-070
Reverse Idler Gear and Reverse Lever
2. Measure the clearance between the reverse idler gear bush
ing and the reverse lever.
Standard clearance:
0.10—0.35 mm [0.004—0.014 In)
46U0JX-030
Primary Shaft Gear and Secondary Shaft Gear
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
4. Inspect the oil passage for blockage.
5. Measure the shaft gear runout.
Primary shaft gear runout:

0.050 mm (0.0020 in} max.
46U0JX-093
Secondary shaft gear runout:
0.015 mm (0.0006 in} max.
46U0JX-031
J—30
TRANSAXLE
6. Measure the clearance between the shaft and the gears.
Clearance
mm (in)
Shaft Gear Sleeve
(Outer dia.) (Inner dia.) Clearance
(Outer dia.)
39.445—39.470 39.500—39.525
1st —
{1.5529-1.5539) (1.5551-1.5561)
34.945—34.970 35.000-35.025
2nd —
(1.3758-1.3768) (1.3780-1.3789)
35.945-35.970 36.000-36.025 0.030-0.080
3rd —
46U0JX-094 (1.4152-1.4161) (1.4173-1.4183) (0.0012-0.0031)
30.945-30.970 31.000-31.025
4th —
(1.2183-1.2193) (1.2205-1.2215)
34.000-34.025 33.945-33.970
5th —
(1.3386-1.3396) (1.3364-1.3374)
Vehicle Speed Sensor (Speedometer Driven Gear)

1. Inspect the teeth for damage and wear.
2. Inspect the O-ring for damage and wear.
36U0JX-Q15
J-31
J TRANSAXLE
ASSEMBLY
Precaution
1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. Verify that all parts are completely cleaned before assembly.
3. Assemble parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transaxle with transaxle oil.
4. Bearing races and bearings must be replaced as sets.
Secondary Shaft Assembly

Assemble in the order shown in the figure, referring to Assembly Note.
46U0JX-095
1 .1st/2nd clutch hub 9 . 1st/2nd clutch hub assembly

Assembly Note............................page J-33 Assembly Note....................... page J-33
2. Synchronizer keys 10. Retaining ring
3. Reverse gear clutch hub sleeve 11. 2nd synchronizer ring
4. Synchronizer key springs Assembly Note....................... page J-34
5. Secondary shaft gear 12. 2nd gear
6. Bearing (secondary shaft end) Assembly Note....................... page J-34
Assembly Note............................page J-33 13. Secondary 3rd gear
7.1st gear Assembly Note....................... page J-34
Assembly Note............................page J-33 14. Retaining ring
8.1 st synchronizer ring 15. Secondary 4th gear
Assembly Note............................page J-33 Assembly Note....................... page J-34
16. Bearing
Assembly Note....................... page J-34
J—32
TRANSAXLE J
Assembly note
Clutch hub
Synchronizer key dimensions

mm (in)
— — __ ... @ ... .. <D
1st/2nd 19.0 ( 0.748) 4.3 (0.17) 5.0 (0.20)
3rd/4th
17.0 (0.669) 4.3 (0.17) 5.0 (0.20)
5th/Rev.
46U0JX-032
Install the synchronizer keys and springs in the clutch hub.
16E0JX-079
Bearing (secondary shaft end)
Install the new bearing by using the SST.
49 F 4 0 1 3 3 5A
16E0JX-080
1st gear, 1st synchronizer ring and 1st/2nd clutch hub
assembly
The 2nd synchronizer ring has teeth missing at three places
around its outer edge to help distinguish it from the other
synchronizer rings.
46U0JX-033
1. Assemble the 1st gear, 1st synchronizer ring, and 1st/2nd
clutch hub assembly.
2. Align the synchronizer ring grooves and synchronizer keys.
46U0JX-034
J—33
J TRANSAXLE
3. Press the 1st/2nd clutch hub assembly on by using the SST.
46U0JX-096
2nd synchronizer ring, 2nd gear and secondary 3rd gear
1. Install the 2nd synchronizer ring and 2nd gear.
2. Install the secondary 3rd gear by using the SST.
49 F401 331
40 F401 336B
49 F401 335A
46U0JX-097
Secondary 4th gear and bearing
1. Install the secondary 4th gear and the bearing by using the
SST.
4TH GEAR - a
49 F401 331
49 F401 335A
16E0JX-085
2. Measure the clearance between the 1st gear and the
differential drive gear.
Clearance: 0.05—0.28 mm (0.002—0.011 in}

Maximum: 0.33 mm (0.013 in}
16E0JX-086
3. Measure the clearance between the 2nd gear and the
secondary 3rd gear.
Clearance: 0.18—0.46 mm (0.007—0.018 in}

Maximum: 0.51 mm (0.020 in}
4. If not as specified, reassemble the secondary shaft as

sembly.
16E0JX-087
J -3 4
TRANSAXLE
Primary Shaft Assembly
Assemble in the order shown in the figure, referring to Assembly Note
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
C A N BE IN S T A L L E D IN
E ITH E R D IR E C T IO N
46U0JX-098
1. 3rd/4th clutch hub 8. 3rd synchronizer ring

Assembly Note..................... page J-33 Assembly Note...................... ....page J-36
2. Synchronizer keys 9. 3rd/4th clutch hub assembly
3. 3rd/4th clutch hub sleeve Assembly Note...................... .... page J-36
4. Synchronizer key springs 10. Retaining ring
5. Primary shaft gear 11. 4th synchronizer ring
6. Bearing (primary shaft end) Assembly Note...................... page J-36
Assembly Note..................... ............. below 12. 4th gear
7. 3rd gear Assembly Note...................... page J-36
Assembly Note..................... page J-36 13. Bearing
Assembly Note...................... page J-36
Assembly note
Bearing (primary shaft end)
49 F401 335A
16E0JX-089
J—35
J TRANSAXLE
3rd gear, 3rd synchronizer ring and 3rd/4th clutch hub
assembly
Install the 3rd gear, 3rd synchronizer ring, and 3rd/4th clutch
hub assembly by using a press.
4th synchronizer ring, 4th gear and bearing

1. Install the 4th synchronizer ring, 4th gear, and a new bear
ing by using the SSTs.
46U0JX-100
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05—0.20 mm (0.002—0.008 in)

16E0JX-092
3. Measure the clearance between the 4th gear and bearing.
Clearance: 0.17—0.37 mm (0.007—0.015 in)

4. If not as specified, reassemble the primary shaft assembly.
16E0JX-093
TRANSAXLE J
Clutch Housing and Transaxle Case Components
1. Select the adjustment shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the figure, referring to Assembly Note.
3. Verify that the bearing preload is within specification, referring to Bearing Preload.
13.8—18.6 N-m
NEW © 140-190 kgf-cm, 122-164 in-lbf]
SELECTIVE
7.9—10.7 N-m 180—110 kgf-cm, 69—95 In-lbf)
23—32 12.3—3.3, 17—23)
SELECTIVE SELECTIVE
N-m fkgf-m, ft-lbf)

46U0JX-101
1. Change rod 14. Oil seal (differential)

2. Joint Assembly Note...........................
3. Oil passage 15. Vehicle speed sensor (speedomete
4. Oil seal (differential) gear)
Assembly Note........................ page J-41 16. Bleeder
5. Adjustment shim(s) 17. Bleeder cover assembly
Bearing preload adjustment... .... page J-38 18. Oil seal (change rod assembly)
Bearing preload...................... page J-43 Assembly Note...........................
6. Bearing race (differential) 19. Selector
Assembly Note........................ page J-41 20. Boot
7. Adjustment shim(s) Assembly Note...........................
Bearing preload adjustment page J-38 21. Change rod assembly
Bearing preload...................... page J-43 22. Roll pin
8. Diaphragm springs 23. Change arm
Assembly Note......................... page J-42 24. Guide plate assembly
9. Bearing race (transaxle case) 25. Funnel
Assembly Note......................... ... page J-42 26. Bearing race (secondary shaft)
10. Drain plug and washer 27. Oil seal (primary shaft)
11. Reverse lever Assembly Note...........................
12. Reverse lever shaft 28. Bearing race (primary shaft)
13. Bearing race (differential)
Assembly Note......................... ... page J-41
J—37
J TRANSAXLE
Bearing preload adjustment
When replacing any of the parts listed in the table below, adjust the bearing preload by selecting and
installing the proper adjustment shim(s).
Primary shaft assembly Secondary shaft assembly Differential

• Transaxle case • Transaxle case •Transaxle case
•Clutch housing • Clutch housing •Clutch housing
• Primary shaft gear bearing • Secondary shaft gear bearing • Differential side bearing
• Primary shaft gear • Secondary shaft gear •Ring gear and case assembly
• Secondary 4th gear
SST 49 G 03 0 380C
49 F401 3 8 2 A 49 G 0 3 0 381
49 F401 384
49 G 0 1 9 021
49 FT01 5 1 5 A
46U0JX-035
SST USAGE
49
BEARING RACE
16E0JX-096
J—38
TRANSAXLE J
1. Install the primary and secondary shaft bearing races into
BEARING RACE
the transaxle case (diaphragm springs and shims removed).
2. Mount the clutch housing onto the transaxle hanger, and
set the differential bearing race into the clutch housing. Po
sition a piece of pipe against the bearing race and tap it
SELECTOR in until it contacts the clutch housing.
3. Set the bearing races into the SSTs (selector) as shown in
the figure.
4. Turn the selector to eliminate the gap indicated by the arrow.
46U0JX-036
5. Set the differential assembly into the clutch housing, and
set the bearing race and the SST (selector) on the differen
tial. Set the assembled selectors for the primary and secon
dary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the figure.
46U0JX-037
6. Set the SST (collars) in the positions shown in the figure.
46U0JX-038
7. Install the transaxle case and tighten the SST (bolts) to the
specified torque.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf}
46U0JX-039
8. To seat the bearings, mount the SST (bars) on parts A and
B of the selectors, and turn the selectors so the gaps are
widened. Then turn the SST in the reverse direction until
the gaps are eliminated.
46U0JX-040
J—39
J TRANSAXLE
9. Manually expand the selector until it no longer turns by hand.
10. Verify that both the primary and secondary shafts turn
smoothly.
46U0JX-041
SELECTOR 11. Measure the clearance between the two halves of the SST
49 G 030 3 8 2 A (selector) around the circumference by using a feeler gauge.
49 F401 3 8 2 A 12. Take the maximum reading and determine the shim to be
used. Use no more than two shims.
< Primary shaft adjustment shim >

• Subtract the diaphragm spring thickness (0.65 mm,
{0.026 in}) from the gap determined in Step 11 for the
primary shaft.
• Make a shim selection range by subtracting the standard
clearance parameters from the result in the previous step.
46U0JX-042 • Select the thinner shim within the range to obtain the stan
dard clearance.
Thickness (Shaft gears] mm (in)
Standard clearance:
0 -0 .0 5 mm {0 -0 .0 0 2 in)
0.20 (0.008) 0.50 (0.020)
Example:
0.25 (0.010) 0.55 (0.022) 1.22 mm {0.048 in}-0.65 mm {0.026 in}
0.30 (0.012) 0.60 (0.024) = 0.57 mm {0.022 in)
0.35 (0.014) 0.65 (0.026) Shim selection range:
0.40 (0.016) 0.70 (0.028) (0.57 mm {0.022 in}-0.05 mm {0.002 in } ) -
(0.57 mm {0.022 in }-0 mm {0 in}) = 0.52 mm
0.45 (0.018)
{0.020 in} -0 .5 7 mm {0.022 in}
46U0JX-102
Shim: 0.55 mm {0.022 in}
< Secondary shaft adjustment shim >

• Subtract the diaphragm spring thickness (0.65 mm,
{0.026 in}) from the gap determined in Step 11 for the
secondary shaft.
• Make a shim selection range by adding the standard
clearance parameters to the result in the previous step.
• Select the thinner shim within the range to obtain the stan
dard clearance.
Tightening amount:
0 .0 3 -0 .0 8 mm {0.0 01 -0 .0 0 3 in}
Example:
1.22 mm {0.048 in}-0.65 mm {0.026 in} = 0.57
mm {0.022 in}
Shim selection range:
(0.57 mm {0.022 in} + 0.03 mm {0.001 in})
-(0 .5 7 mm {0.022 in} + 0.08 mm {0.003 in}) =
0.60 mm {0.024 in} -0 .6 5 mm{0.026 in}
Shim: 0.60 mm {0.024 in}
13. Install the SST to the differential.
46U0JX-043
J—40
TRANSAXLE J
14. Turn the SST with a torque wrench. Adjust the SST (selec
tor) with the SST (bars) until the specified preload is ob
tained.
Preload: 0.5 N-m (5.0 kgf cm, 4.3 inlbf)
46U0JX-044
15. Measure the gap between A and B around the circumfer
ence of the SST (selector) by using a feeler gauge.
16. Add 0.15 mm (0.006 in) to the measured clearance and
select a combination of two shims closest in value to that
measurement. Use no more than two shims.
46U0JX-Q45
Thickness mm (in) Example: 0.32 mm (0.013 in)

0.32 mm (0.013 in) + 0.15 mm (0.006 in) = 0.47
0.10 (0.004) 0.70 (0.028) mm (0.019 in).
0.20 (0.008) 0.75 (0.030)
0.80 (0.031)
Nearest shim (on thick side) to 0.47 mm
0.25 (0.010)
0.30 (0.012) 0.85 (0.033) (0.019 in) is 0.50 mm (0.020 in).
0.35 (0.014) 0.90 (0.035)
0.40 (0.016) 0.95 (0.037) 17. Remove the transaxle case and the SSTs.
0.45 (0.018) 1.00 (0.039) 18. Remove the selectors, the primary shaft assembly, and the
0.50 (0.020) 1.05 (0.041)
0.55 (0.022) 1.10 (0.043)
differential.
0.60 (0.024) 1.15 (0.045) 19. Remove the bearing races.
0.65 (0.026) 1.20 (0.047)
46UOJX-072
Assembly note
Oil seal (differential)
1. Using the SST and a hammer, tap the new oil seal in even
ly until the SST contacts the transaxle case.
46U0JX-046
Bearing race (differential)
1. Install the adjustment shim(s) to the differential case.
2. Apply transaxle oil to the bearing race, and install it to the
differential case by using a pipe.
46U0JX-047
J—41
J TRANSAXLE
Diaphragm spring
Install the diaphragm spring as shown in the figure.
16E0JX-111
Bearing race (transaxle case)
1. Install the adjustment shim(s) to the primary and secondary
shaft bearing seats in the transaxle case.
2. Apply transaxle oil to each bearing race, and install them
to the transaxle case by using a pipe.
46U0JX-048
Oil seal (change rod assembly)
1. Install the new oil seal by using a pipe.
Outer diameter of pipe: 26.0 mm {1.02 in)
46U0JX-049
Boot
Install the boot so that the drain hole is facing downward
when mounted on the vehicle.
46U0JX-103
Oil seal (primary shaft)
Apply transaxle oil to the outer circumference of the oil seal,
and install it to the transaxle case by using a pipe.
46U0JX-05Q
J -4 2
TRANSAXLE J
Bearing preload
Verify the shaft gears and the differential bearing preloads.
Readjust the bearing preloads if they are not within specifi
cation.
1. Set the primary shaft gear assembly and the differential into
the clutch housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque:
38—51 N m {3.8—5.3 kgf m, 28—38 ft-lbf}
46U0JX-051
3. Install the SST to the differential.
4. Connect a torque wrench to the SST and measure the
preload.
Preload:
1.4—1.9 N-m {14—20 kgf-cm, 13—17 in-lbf)
46U0JX-104
5. Remove the SST.
6. With the transaxle facing in the direction shown in the fig
ure, install the SST to the primary shaft gear assembly.
preload.
Preload:
0.1—0.2 Nm {1.0—2.5 kgf cm, 0.9—2.1 in-lbf}
46U0JX-105
8. Remove the SST, transaxle case, primary shaft gear as
sembly and differential.
9. Install the secondary shaft gear assembly and transaxle
case, and tighten to the specified torque.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf}
10. Install the SST to the secondary shaft gear assembly.

preload.
Preload:
0.2—0.4 N-m {2.0—4.0 kgf-cm, 1.8—3.4 in-lbf}
J—43
TRANSAXLE
5th/Reverse Gear and Housing Parts
Assemble in the order shown in the figure, referring to Assembly Note.
@ 2 0 - 2 9 (2.0—3.0, 1 5 - 2 1 )
WASHER, NEW
ROLL PIN, NEW
11.8—13.7 N-m (120—140 kgf-cm,

105—121 in-lbf)
0—3 . 0 , - ^ 8.9— 13.7 N-m ’

15—2 1 1 (90— 140 kgf-cm,
\ 79— 121 In-lbf)
V \ WASHER, NEW
128— 196 (13—20, 95— 144)
ROLL PIN, NEW
7.9—11.2 N-m
(80—115 kgf-cm,
70—99 in-lbf)
N-m (kgf-m, ft-lbf)
16E0JX-120
J—44
TRANSAXLE
1. Control rod 23. Reverse idler gear
2. Control end Assembly Note........................... page J-46
3.1 st/2nd shift fork 24. Reverse idler shaft
4. Control lever Assembly Note........................... page J-46
5. Interlock sleeve 25. Magnet
6. 3rd/4th shift fork 26. Transaxle case assembly
7. Clutch hub Assembly Note........................... page J-47
8. Synchronizer keys 27. Park/neutral switch
9. Clutch hub sleeve 28. Back-up light switch
10. Synchronizer key springs 29. Lock bolt, ball and spring
11. Clutch housing 30. Guide bolt
12. Differential assembly 31. Lock bolt
13. Secondary shaft gear assembly 32. Secondary 5th gear
Assembly Note....................................below Assembly Note........................... page J-47
14. Primary shaft gear assembly 33. Gear sleeve
Assembly Note....................................below 34. 5th gear
15. Spring 35. 5th synchronizer ring
16. Steel ball 36. 5th/reverse clutch hub assembly
17. Shift fork and shift rod assembly Assembly Note........................... page J-47
Assembly Note....................................below 37. 5th/reverse shift fork
18. Crank lever assembly Assembly Note........................... page J-47
Assembly note........................... page J-46 38. Secondary reverse synchronizer gear
19. Crank lever shaft 39. Reverse synchronizer ring
Assembly Note............................page J-46 40. Primary reverse synchronizer gear
20. Pin 41. Locknut (secondary shaft)
21. 5th/reverse shift rod end Assembly Note........................... page J-47
Assembly Note............................page J-46 42. Locknut (primary shaft)
22. 5th/reverse shift rod Assembly Note........................... page J-47
Assembly Note............................page J-46 43. Rear cover
46U0JX-107
Assembly note
Primary shaft gear assembly and secondary shaft gear
assembly
Install the primary and secondary shaft gear assemblies to
gether.
46U0JX-108
Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod
assembly as shown.
16E0JX-123
J—45
J TRANSAXLE
2. Insert the spring seat and spring into the reverse lever shaft.
Install the steel ball, and place a scraper so that it contacts
the steel ball.
3. With the edge of the control end against the scraper, push
the control end in the direction of the arrow so that the ball
goes into the shaft. This will line up the rod with the shift
rod coupling hole in the clutch housing.
SCRAPER
46U0JX-109
4. Set each clutch hub sleeve to the neutral position, and tap
the shift rod from above so that the steel ball goes into the
center groove (of the three grooves in the control end).
5. Pull up on the ball part of the control end so that the steel
ball goes into the detent in the groove.
46U0JX-110
Crank lever assembly and crank lever shaft
1. Install a new O-ring to the crank lever shaft.
2. Fit the crank lever between the change arm and the con
trol end, and connect the crank lever shaft to the crank lever.
3. Align the pin holes of the crank lever shaft and the clutch
housing, and insert a new pin.
46U0JX-052
5th/reverse shift rod end and 5th/reverse shift rod
1. Install the shift rod (©) into the shift rod end (©).
2. Align the mark on the shift rod with the mounting bolt hole
in the shift rod end as shown in the figure, and tighten the
gate mounting bolt.
Tightening torque:
11.8—13.7 Nm (120—140 kgf cm, 105—121 in-lbf)
46U0JX-053
R everse id ler g e a r and reverse id ler shaft
1. Install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever
(arrow), and, at the same time, face the reverse idler shaft
screw hole in the direction shown in the figure.
16E0JX-128
J—46
TRANSAXLE J
Transaxle case assembly
1. Apply a thin coat of sealant to the contact surfaces of the
clutch housing and transaxle case, and tighten the trans
axle case installation bolts to the specified torque.
Tightening torque:
38—51 N m {3.8—5.3 kgf m, 28—38 ft-lbf}
2. Insert the SSTs through the drive shaft and joint shaft hole.
Secondary 5th gear

Install the secondary 5th gear as shown.
16E0JX-130
5th/reverse clutch hub assembly and 5th/reverse shift
fork
Install the 5th/reverse clutch hub assembly and the 5th/re-
verse shift fork together.
46U0JX-111
Locknut
1. Shift to 1st gear.
2. Lock the primary shaft by using the SST.
3. Tighten new locknuts onto the primary and secondary
shafts.
Tightening torque:
128—196 N m {13—20 kgf m, 95—144 ft-lbf}
49 G 03 0 440 4. Stake the locknuts.
16E0JX-132
5. Measure the 5th gear thrust clearance by using a dial in
dicator.
Clearance: 0.100—0.220 mm {0.0039—0.0087 in}

Maximum: 0.270 mm {0.0106 in}
6. If not as specified, reassemble the transaxle.
16E0JX-133
J -4 7
J TRANSAXLE
INSTALLATION
1. On level ground, jack up the vehicle and support it evenly on safety stands.
2. Install in the order shown in the figure, referring to Installation Note.
3. Add the specified amount and type of transaxle oil. (Refer to page J-7.)
4. Warm up the engine and transaxle, inspect for oil leakage, and check transaxle operation.
KL ENGINE
7.9—10.7 N-m (80—110 kgf-cm,

70—95 In-lbf)
\ CLIP,
^ N E W f ®
COTTER PIN
REPLACE x
I 7.9—10.7 N-m 180—110 kgf-cm, 70—95 In-lbf)
37—53 13.7—5.5, J 8 9 -1 1 7 19.0-

16—22 11.6—2.3, 1 2 -1 6 ) (£}) 27—39) r
10.8—14.7 N-m 1110—150 kgf-cm, \ )— 10.8—14.7 N-m | m - 1 M k g f < m / ^ > v
96—130 In-lbf) ^ 96—130 In-lbf)
(D 43—61 — @ 7.9—10.7 N-m
(80—110 kgf-cm, 70—95 In-lbf)
10.8—14.7 N-m [110—150 kgf-cm,
96—130 In-lbf)
68—99 (6.9—10.1, 50—73)

86—116
(8 .7 -1 1 .9 ,
10.8—14.7 N-m
(110—150 kgf-cm,
96—130 In-ibf'l
67—93 (6.8—9.5, 50—68)
75—104 (7.6—10.7, 55—77)
46U0JX-112
J—48
TRANSAXLE
1. No.2 engine mount 14. Exhaust pipe
Installation Note..........................page J-51 15. Transverse member
2. Transaxle 16. Splash shields
Installation Note..........................page J-51 17. Wheels and tires
3. Under cover 18. Clutch release cylinder
4. No.4 engine mount 19. Oxygen sensor connecter
5. No.1 engine mount bracket 20. Harness bracket
Installation N ote..........................page J-51 Installation Note......................... page J-54
6. Engine mount member 21. Fuel filter mount nuts
Installation Note..........................page J-52 22. Ground
7. No.5 engine mount 23. Vehicle speed sensor (speedometer driven
8. Joint shaft gear) connector
Installation Note..........................page J-52 24. Back-up light switch connector
9. Drive shafts 25. Park/neutral switch connector
Installation Note..........................page J-53 26. Starter
10. Stabilizer control link 27. Air cleaner housing assembly
11. Tire rod end 28. Fresh air duct
Installation Note..........................page J-54 29. Battery carrier
12. Change control rod 30. Battery
13. Extension bar 46U0JX-113
J—49
TRANSAXLE
FS ENGINE
7.9—10.7 Nm (80—110 kgf-cm, 70—95 in-lbf)
C U P 7 N E W x l 1 -9r 2-6’ 14- 18t
32—44
13.2—4.5, 14—18)
35—56 ^
13.5—5.8,
26—41) i
/ 7.9—10.7 N-m
/1 8 0 —110 kgf-cm,
70—95 in-lbf )-a /!
37—53 (3.7—5.5, 27—39)

89—117 (9.0—12.0, 66—86)
10.8—14.7 N-m
10.8—14.7 N-m
[110—150 kgf-cm,
© (110—150 kgf-cm,
_/96—130 in-lbf
96—130 in-lbf)
----- (jj) 7.9—10.7 N-m

(80—110 kgf-cm,
70—95 in-lbf)
10.8—14.7 N-m
A (110—150 kgf-cm,
[ K 96—130 in-lbf)
90—116 (9.1—11.9, 66—86)
10.8—14.7 N-m f
(110—150 kgf-cm,
96—130 in-lbf)ft
67—93 (6.8—9.5, 50—68)
N-m (kgf-m, ft-lbf)
J—50
TRANSAXLE J
1. No.2 engine mount 13. Extension bar
Installation N ote..................................below 14. Transverse member
2. Transaxle 15. Splash shields
Installation N ote..................................below 16. Wheels and tires
3. No.4 engine mount 17. Clutch release cylinder
4. No.1 engine mount bracket 18. Harness bracket
Installation N ote..................................below Installation Note......................... page J-54
5. Engine mount member 19. Fuel filter mount bolts
Installation Note..........................page J-52 20. Ground
6. No.5 engine mount 21. Vehicle speed sensor (speedometer driven
7. Starter gear) connector
8. Joint shaft 22. Back-up light switch connector
Installation Note..........................page J-52 23. Park/neutral switch connector
9. Drive shafts 24. Air cleaner housing assembly
Installation Note..........................page J-53 25. Fresh air duct
10. Stabilizer control link 26. Resonance chamber
11. Tire rod end 27. Battery carrier
Installation Note..........................page J-54 28. Battery
12. Change control rod 46U0JX-114
Installation Note
No.2 engine mount
1. Install the No.2 engine mount bracket to the transaxle.
Tightening torque:
38—51 N m {3.8—5.3 kgfm, 28—38 ftlb f)
2. Loosely tighten the engine mount nut.
Transaxle
1. Set the transaxle on a jack and lift into place.
2. Install the transaxle mounting bolts.
Tightening torque
KL: 68—99 N-m {6.9—10.1 kgf m, 50—73 ft lbf)
FS: 90—116 N m {9.1—11.9 kgf m, 66—86 ft Ibf)
3. Loosely tighten the No.4 engine mount bolts and nuts.
No.1 engine mount
Caution
• Align the transaxle bolt holes and the engine mount
exactly. Any misalignment can result in bolts and
bolt holes becoming damaged or stripped during in
stallation.
1. Use the SST (engine support) to make sure the transaxle

bolt holes and No.1 engine mount meet evenly.
2. Set the 3 bolts in the holes, and tighten them to the speci
fied torque.
Tightening torque:
75—104 N m {7.6—10.7 kgf m, 55—77.3 ft lbf)
J—51
J TRANSAXLE
Engine mounting member
FRONT SIDE
1. Install the engine mount bushings as shown in the figure.
0 2. Install the engine mount member, making sure that the No.1
engine mount stud bolts pass through the mount member
installation hole.
46U0JX-057
3. Install the bolts and nuts as shown.
Tightening torque
A: 67—93 N m {6.8—9.5 kgf m, 50—68 ft-lbf}
B: 75—104 Nm {7.6—10.7 kgf m, 55—77 ft-lbf}
4. Tighten the engine mount rubber No.2 nut.
Tightening torque:
86—116 N m {8.7—11.9 kgf m, 63—86 ft-lbf}
5. Tighten the engine mount No.4 bolts and nuts.
Tightening torque:
67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf}
46U0JX-059
Joint shaft
1. Remove the SST from the transaxle case.
2. Verify that there is no damage to the oil seal.
46UQJX-060
3. Insert the joint shaft into the transaxle.-
4. Install the joint shaft to the cylinder block in the order shown.
Tightening torque:
43—61 Nm {4.3—6.3 kgf m, 32—45 ft-lbf}
46U0JX-061
TRANSAXLE J
Drive shafts
46U0JX-062
Caution
• The sharp edges of the drive shaft snap ring can
slice or puncture the oil seal. Be careful when in
stalling the drive shaft to the transaxle.
3. Install the clip with the gap facing upward.
46U0JX-063
4. Apply transaxle oil to the oil seal lip and install the drive shaft.
5. Verify that the drive shaft is correctly seated by pulling on
the shaft.
6. Connect the lower arm to the knuckle and tighten the clinch
bolt.
Tightening torque:
35—56 N m (3.5—5.8 kgf m, 26—41 ft Ibf)
46U0JX-065 /
7. Install the ABS wheel speed sensor harness mounting nuts.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95 in-lbf)
8. Install the clips.
46U0JX-066
J—53
J TRANSAXLE, DIFFERENTIAL
Tie rod end
1. Install the locknut.
Tightening torque:
32—44 N m (3 .2 -4 .5 kgf m, 24—32 ft Ibf}
2. Secure the locknut by using a new cotter pin.
Harness bracket
Install the harness bracket as shown in the figure.
46U0JX-115
After warming up the engin, do the following.
• Check the amount of oil. (Refer to page J -7 .)
• Conduct a road test and verify the following.
1. There is no abnormal noise in each shift position.
2. Smooth shift change is possible.
3. Transaxle does not jump out of gear.
4. Speedometer operates correctly.
5. Back-up lights operate correctly.
46U0JX-116
DIFFERENTIAL
PREPARATION
SST
49 G017 1AO For 49 F401 366A For

removal of removal of side
Remove set, bearing Plate bearing
bearing (Part of
49 G017 1A0)
49 B092 375 For 49 0839 425C For

removal of side removal of side
Attachment J bearing Puller set, bearing
(Part of bearing
49 G017 1AO)
9
49 G030 338 For

installation of side
Attachment E bearing
16E0JX-151
J -5 4
DIFFERENTIAL J
DISASSEMBLY / INSPECTION / ASSEMBLY
Note
• The bearings do not need to be removed unless you are replacing them.
1. Before disassembly, inspect the backlash of the side gears and pinion .gears, referring to Preinspection.
5. Measure the backlash after assembly, referring to Backlash of Side Gear and Pinion Gear.
REPLACE
46U0JX-067
1 Roll pin 6. Thrust washer

Assembly Note..................... page J-57 7. Bearing (side opposite ring gear)
2. Pinion shaft Disassembly Note...................... page J-56
3. Pinion gear Inspection....................................page J-56
Inspect for wear and cracks Assembly Note........................... page J-57
Preinspection........................ ....... below 8. Speedometer drive gear
Inspection of backlash......... page J-57 9. Bearing (ring gear side)
4. Thrust washer Disassembly Note...................... page J-56
5. Side gear Inspection................................... page J-56
Inspect for wear and cracks Assembly Note........................... page J-56
Preinspection........................ ....... below 10. Ring gear and gear case assembly
Inspection of backlash......... page J-57 Inspection....................................page J-56
Preinspection
Backlash of side gear and pinion gear
Measure the backlash by the following procedure.
1. Install the left and right drive shafts in the differential as
sembly.
2. Support the drive shafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: 0.050—0.150 mm {0.0020—0.059 in)
4. If not as specified, replace parts as necessary.
J—55
J DIFFERENTIAL
Disassembly Note
Bearing (side opposite ring gear)
While supporting the gear case, remove the bearing by us
ing the SST.
46U0JX-068
Bearing (ring gear side)
Remove the bearing by using the SST.
49 08 39 425C
46U0JX-069
Inspection
Ring gear and gear case assembly
Inspect the ring gear for wear and cracks. Refer to page
J-38 for bearing preload adjustment if the ring gear and
gear case assembly is being replaced.
46U0JX-070
Bearing
Inspect for wear and rough rotation. If replacing the bear
ing, replace the bearing and race as an assembly.
46U0JX-071
Assembly Note
Bearing (ring gear side)
16E0JX-158
J—56
DIFFERENTIAL J
Bearing (side opposite ring gear)
1. Install the speedometer drive gear.
2. Install the new bearing by using the SST.
46U0JX-118
Backlash of Side Gear and Pinion Gear
Measure the backlash by the following procedure.
1. Install the left and right drive shafts in the differential as
sembly.
2. Support the drive shafts on V-blocks as shown in the figure.
3. Measure the backlash of both pinion gears.
Backlash: 0.050—0.150 mm [0.0020—0.059 in]
46U0JX-119
J SHIFT MECHANISM
SHIFT MECHANISM
OVERHAUL
16E0JX-162
J -5 8
SHIFT MECHANISM J
1. Shift lever knob 17. Assist boot
2. Front console Inspect for wear and damage
3. Insulator 18. Mounting rubber boot
4. Transverse member 19. Retaining ring
5. Exhaust pipe 20. O-ring
6. Nut 21. Ball seat (upper)
7. Bolt 22. Boot
8. Nut Inspect for wear and damage
9. Bolt 23. Ball seat (lower)
10. Change control rod 24. Gear shift lever
Inspect for bending 25. Pipe
11. Bushing 26. Bushing
12. Bushing 27. Extension bar
13. Nut 28. Nut
14. Washer 29. Bolt
15. Washer 30. Rubber mount
16. Nuts (base plate) 31. Base plate
Assembly Note....................................below 16E0JX-170
Assembly Note
Nuts (base plate)
1. Install the base plate to the floor. Then install the extension
bar onto the transaxle.
Tightening torque:
38—51 N-m {3.8—5.3 kgf m, 28—38 ft-lbf}
2. Tighten the base plate nuts to the specified torque.

{100—150 kgf cm, 86.8—130 in-lbf}
Before beginning any service procedure, refer to section S of the 1994 626/MX-6
Body Electrical Troubleshooting Manual for air bag system service warnings.
AUTOMATIC TRANSAXLE
(GF4A-EL)
INDEX........................................................K1— 2 CONTROL VALVE BODY

OUTLINE................................................... K1— 4 (DISASSEMBLY/INSPECTION)...............K1-107
SPECIFICATIONS.....................................K1- 4 PREMAINCONTROL VALVE BODY..........K1-114
CROSS-SECTIONAL VIEW........................ K1- 5 MAINCONTROL VALVE BODY................K1-118
POWER FLOW DIAGRAM........................ K1- 6 REAR CONTROL VALVE BODY...............K1-122
OPERATION OF COMPONENTS...............K1- 7 CONTROL VALVE BODY
FLUID PASSAGE LOCATIONS..................K1- 8 (ASSEMBLY)....................................... K1-125
MECHANICAL SYSTEM TEST..................... K1- 11 CONTROL VALVE BODY(ON-VEHICLE
PREPARATION........................................K1- 11 REMOVAL/INSTALLATION)..................K1-135
STALL TEST............................................ K1- 11 DIFFERENTIAL..................................... K1-138
TIME LAG TEST......................................K1- 14 BEARINGPRELOAD..............................K1-142
LINE PRESSURE TEST............................ K1- 15 TRANSAXLE UNIT(ASSEMBLY)...............K1-148
SOLENOID REDUCING TRANSAXLE UNIT
PRESSURE TEST...................................K1- 17 (INSTALLATION)................................. K1-165
ROAD TEST............................................... K1- 19 OIL COOLER........................................... K1-172
D RANGE TEST.......................................K1- 19 OILCOOLER....................................... K1-172
S RANGE TEST....................................... K1- 22 DRIVE PLATE......................................... K1-175
L RANGE TEST....................................... K1- 24 PREPARATION.....................................K1-175
P RANGE TEST.......................................K1- 25 DRIVEPLATE....................................... K1-175
AUTOMATIC TRANSAXLE FLUID (ATF)...... K1- 27 SHIFT MECHANISM
ATF........................................................K1- 27 (WITHSHIFT-LOCKSYSTEM)..................K1-177
ELECTRICAL SYSTEM COM PONENTS....... K1- 29 SHIFT-LOCKSYSTEMCOMPONENTS.......K1-177
PREPARATION........................................ K1- 29 TROUBLESHOOTING.............................K1-178
HOLD SWITCH........................................K1- 29 SHIFT-LOCK........................................ K1-180
PARK/NEUTRAL SWITCH......................... K1- 30 EMERGENCYOVERRIDE KEYCYLINDER.. K1-180
ATF THERMOSENSOR............................ K1- 32 KEYINTERLOCK.................................. K1-180
VEHICLE SPEED PULSE GENERATOR..... K1- 33 P RANGESWITCH.................................K1-181
SPEEDOMETER.......................................K1- 33 SHIFT-LOCKACTUATOR........................K1-182
STOPLIGHT SWITCH............................... K1- 35 SELECTOR LEVER................................ K1-183
SOLENOID VALVES.................................K1- 35 TROUBLESHOOTINGGUIDE.....................K1-191
HOLD INDICATOR LIGHT........................ K1- 36 GENERAL NOTES..................................K1-191
POWERTRAIN CONTROL MODULE QUICKDIAGNOSIS CHART.......................K1-192
(TRANSAXLE)........................................K1- 38 OUTLINE............................................. K1-192
SELECTOR INDICATOR LAMP..................K1- 44 QUICKDIAGNOSIS CHART (I).................K1-192
TRANSAXLE.............................................. K1- 45 QUICKDIAGNOSIS CHART (II)................K1-194
TRANSAXLE UNIT (REMOVAL).................K1- 45 SYMPTOMTROUBLESHOOTING................K1-196
TRANSAXLE UNIT (DISASSEMBLY).......... K1- 51 USINGTHIS SECTION............................K1-196
TORQUE CONVERTER............................ K1- 65 DIAGNOSTIC INDEX..............................K1-198
2-3 ACCUMULATOR............................... K1- 66 SYMPTOMTROUBLESHOOTING
OIL PUMP.............................................. K1— 68 CHART.............................................. K1-201
CLUTCH ASSEMBLY............................... K1- 71 SELF-DIAGNOSIS FUNCTION....................K1-232
SMALL SUN GEAR AND DESCRIPTION...................................... K1-232
ONE-WAY CLUTCH 1 ............................ K1- 81 PREPARATION..................................... K1-232
ONE-WAY CLUTCH 2 AND CARRIER DIAGNOSTICTROUBLE CODE NUMBER... K1-233
HUB ASSEMBLY....................................K1- 84 SERVICE POINTS.................................... K1-253
3-4 CLUTCH........................................... K1- 86 OUTLINE............................................. K1-253
LOW AND REVERSE BRAKE....................K1- 90 WIRINGDIAGRAM.................................K1-256
2-4 BRAKE BAND ELECTRICAL DIAGNOSIS
(DISASSEMBLY / INSPECTION / SUPPORT.......................................... K1-257
ASSEMBLY).......................................... K1- 94 SYSTEM INSPECTION...............................K1-262
2-4 BRAKE BAND LINEPRESSURE SOLENOIDVALVE
(ON-VEHICLE ADJUSTMENT)..................K1- 97 OUTPUT DUTY................................... K1-262
IDLER GEAR........................................... K1- 99 LOCKUP SOLENOIDVALVE
OUTPUT GEAR.......................................K1-102 OUTPUT DUTY................................... K1-263
BEARING COVER ASSEMBLY.................. K1-104 MANUAL OPERATIONTEST....................K1-263
OIL SEAL (TRANSAXLE).......................... K1-106 HYDRAULICCIRCUIT................................K1-264
46UOK1-001
K1 INDEX
INDEX
POWERTRAIN CONTROL MODULE (ENGINE)

SERVICE, SECTION F2
ATF SPECIFICATION TYPE Dexron®H or M-ID

CAPACITY 8.8 L (9.3 US qt, 7.7 Imp qt)

AND IDLE SWITCH
SECTION F2
DISTRIBUTOR SERVICE,
SECTION F2
16E0KX-002
K 1 -2
INDEX K1
1. Data link connector 14. 2-4 brake band
Self-diagnosis function... ........ page K1- 234 Disassembly / Inspection /
2. ATF Assembly....................... page K 1- 94
Inspection...................... ........ page K1- 27 On-vehicle Adjustment .... page K 1- 97
3. Hold switch 15. Oil seal
Inspection...................... ........ page K1- 29 On-vehicle Replacement . page K1-106
Replacement................ ........ page K1- 30 16. Control valve body
4. Park/Neutral switch Disassembly / Inspection page K1-107
Inspection...................... ........ page K1- 30 Assembly......................... page K1-125
Replacement................ ........ page K1- 31 On-vehicle removal.......... page K1-135
Adjustment.................... ........ page K1- 32 On-vehicle installation .... page K1-135
5. ATF thermosensor 17. Oil cooler
Inspection...................... ........ page K1- 32 Removal / Inspection /
Replacement................ ........ page K 1- 33 Installation...................... page K1-172
6. Vehicle speed pulse generator 18. Drive plate
Inspection...................... ........ page K 1- 33 Removal / Inspection /
Replacement................ ........ page K1- 33 Installation...................... page K1-175
7. Speedometer 19. Shift-lock
Inspection...................... ........ page K1- 33 Inspection......................... page K1-180
8. Stoplight switch 20. Emergency override key cylinder
Inspection...................... ........ page K1- 35 Inspection......................... ..... page K1-180
9. Solenoid valves 21. Key interlock
Inspection...................... 35 Inspection......................... page K1-180
Replacement................ ........ page K1- 36 22. P range switch
10. Hold indicator light Inspection......................... page K1-181
Inspection...................... 36 23. Shift-lock actuator
11. Powertrain control module (Transaxle) Inspection......................... page K1-182
Inspection...................... ........ page K1- 38 Replacement.................... page K1-182
Replacement................ ........ page K1- 44 24. Selector lever (with shift-lock system)
12. Selector indicator lamp Inspection......................... page K1-183
Inspection...................... ........ page K1- 44 Adjustment....................... page K1-183
13. Transaxle Removal / Inspection /
Removal........................ ........ page K1- 45 Installation....................... page K1-185
Disassembly................. ........ page K1- 51 Disassembly / Inspection /
Assembly....................... ........ page K1- 148 Assembly........................ page K1-188
Installation...................... ........ page K1- 165 46U0K1-002
K 1 -3
K1 OUTLINE
OUTLINE
SPECIFICATIONS
Transaxle/Engine GF4A-EL
Item KL
T ra n s a x le c o n tro l F loo r shift
L o c k u p M e c h a n is m E q u ip p e d
1st g e a r 2 .8 0 0
2 n d gear 1.540
G e a r ratio T h ird g e a r 1 .0 00
F o u rth g e a r 0 .7 0 0
R e ve rse 2 .3 3 3
A u to m a tic tra n s a x le Type M -m o r Dexron® I I

flu id (ATF) C a p a c ity L {U S qt, Im p q t) 8 .8 (9 .3 , 7 .7 )
T o rq u e c o n v e rte r stall to rq u e ratio 2 .0 5
F o rw a rd c lu tc h 3 /3
C o a s tin g c lu tc h 2 /3
N u m b e r o f d riv e /
3 -4 c lu tc h 4 /4
d riv e n pla te s
R e ve rse c lu tc h 2 /2
L o w a n d re ve rse b ra ke 4 /4
B a n d s e rv o (p is to n o u te r d ia ./re ta in e r in n e r d ia .) m m ( in ) 7 8 .0 /4 0 .0 (3 .0 7 /1 .5 7 )
L a rg e sun g e a r 36
S m all sun g e a r 30
N u m b e r o f p la n e ta ry g e a r
L o n g p in io n g e a r 24
te e th
S h o rt p in io n g e a r 22
In te rn a l g e a r 84
N u m b e r o f o u tp u t g e a r te e th 19
N u m b e r o f id le g e a r te e th 42
N u m b e r o f rin g g e a r teeth 79
46UQK1-003
K 1 -4
OUTLINE K1
CROSS-SECTIONAL VIEW
2-4 BRAKE BAND
COASTING CLUTCH OUTPUT GEAR
REVERSE CLUTCH TORQUE CONVERTER
OIL PUMP
DIFFERENTIAL
16E0KX-005
K 1 -5
K1_________________ _________ OUTLINE
POWER FLOW DIAGRAM
36U0KX-321
1. Crankshaft 10. Reverse clutch 17. Long pinion gear

2. Drive plate 11.2-4 brake band 18. Short pinion gear
3. Torque converter 12. Low and reverse brake 19. Internal gear
4. Turbine shaft 13. One-way clutch 1 20. Parking gear
5. Oil pump shaft (Sprag type) 21. Output gear
6. Oil pump 14. One-way clutch 2 22. Idler gear
7. Forward clutch (Roller type) 23. Ring gear
8. Coasting clutch 15. Large sun gear
9. 3-4 clutch 16. Small sun gear
ONE-WAY CLUTCH 2 (ROLLER TYPE)

2-4 BRAKE BAND
__ LOW AND REVERSE BRAKE
REVERSE CLUTCH \ ^ 3-4 CLUTCH
OUTPUT GEAR
INTERNAL GEAR
CLUTCH 1 (SPRAG TYPE)
COASTING CLUTCH
FORWARD CLUTCH
K 1 -6
OUTLINE K1
OPERATION OF COMPONENTS
2-4 brake
One-way clutch 1
Low and reverse
One-way clutch 2
Coasting clutch
Engine braking
Forward clutch
Reverse clutch
(Sprag type)
(Roller type)
3-4 clutch
Range Mode Gear
Released
Applied
effect
brake
P — —
B e lo w a p p ro x . 4 km /h
Yes O O
( 2 .5 m p h )
Reverse
A b o v e a p p ro x . 5 km /h
R — Yes o O
(3 m p h )
A b o v e a p p ro x . 3 0 km /h
—
(1 9 m p h )
No o
B e lo w a p p ro x . 4 km /h
—
( 2 .5 m p h )
N — —
A b o v e a p p ro x . 5 km /h
—
(3 m ph )
1st g e a r No 0 0 0
P ower ☆
N o rm a l 2nd gear No 0 O O
(E x c e p t) T h ird g e a r Yes o O o © O o
I h o ld I F ou rth g e a r Yes o o O ©
D B e lo w a p p ro x .
Yes 0 o o o
2nd 14 km /h (8 .7 m p h )
gear A b o v e a p p ro x .
H o ld 17 km /h (1 0 .5 m p h )
No 0 o o K1
T h ird g e a r Yes 0 o 0 © o o
* F ou rth g e a r Yes 0 0 o ©
1st g e a r No o o O
Pow er 2n d gear No o o o
(E x c e p t)
\ h o ld / T h ird g e a r Yes o o o © o o
S * F ou rth g e a r Yes 0 o o ©
2nd gear Yes o o o o
H o ld * T h ird g e a r Yes o 0 o © o o
* F ou rth g e a r Yes 0 0 o ©
Power 1 st g e a r No 0 o o o
(E x c e p t)
L
\ h o ld / 2n d gear Yes 0 o 0 0
1st g e a r Y es o o 0 o o
H o ld
♦2 n d gear Y es 0 o 0 o
46U0K1-004
O O p e ra tin g .
© O p e ra tin g b u t n o t c o n trib u tin g to th e p o w e r tran sa xle .
© P o w e r is n o t tra n s m itte d .
* E n g in e o v e rs p e e d p ro te c tio n .
☆ T h e P o w e rtra in c o n tro l m o d u le (T ransaxle) a u to m a tic a lly sw itch e s b e tw e e n p o w e r a n d no rm a l m o d e s c o rre s p o n d in g to
th e s p e e d a t w h ic h th e a c c e le ra to r p e d a l is d e p re s s e d .
K 1 -7
K1 OUTLINE
FLUID PASSAGE LOCATIONS
Transaxle Case
INLET AND OUTLET

OUTLET TO OIL PUM P
TRANSAXLE CASE
INLET
CONTROL VALVE BODY

2-3 ACCUMULATOR
COASTING CLUTCH
OIL COOLER
TORQUE CONVERTER FRONT CHAMBER
REVERSE CLUTCH
TORQUE CONVERTER REAR CHAMBER 4 - f h H FORWARD CLUTCH
3-4 CLUTCH
LOW AND REVERSE BRAKE/ \ ^
2-4 BRAKE ENGAGEMENT 2-4 BRAKE RELEASE
TRANSAXLE CASE
OUTLET
- 2-3 ACCUMULATOR
OIL COOLER
TORQUE CONVERTER REAR CHAMBER
3-4 CLUTCH
TRANSAXLE CASE
16E0KX-0Q8
K1—8
OUTLINE K1
Clutch Housing
OIL COOLER

TORQUE CONVERTER REAR CHAMBER
INLET
TRANSAXLE HOUSING
16EOKX-009
Oil Pump
OUTLET TO FORWARD CLUTCH
OUTLET TO COASTING CLUTCH
INLET TO OIL PUMP
OUTLET TO REVERSE CLUTCH
INLET TO FORWARD CLUTCH OUTLET TO OIL PUMP
LUBRICATION
INLET TO COASTING CLUTCH
INLET TO REVERSE CLUTCH
16E0KX-010
K 1 -9
K1
______________________________ OUTLINE
Turbine Shaft
TORQUE CONVERTER
3-4 CLUTCH REAR CHAMBER
LUBRICATION 3-4 CLUTCH TORQUE CONVERTER

REAR CHAMBER
16E0KX-011
K 1-10
MECHANICAL SYSTEM TEST K1
MECHANICAL SYSTEM TEST
PREPARATION
SST
49 0378 400A For 4 9 B 0 1 9 901 For

oil p re ssu re oil p re s s u re
test Oil p re ssu re test
g auge
49 B019 902 For 49 B019 903 For

oil p re ssu re oil p re ssu re
O il p re s s u re test test
gauge
(P art o f ^=
==*\^L 49a 0 3 7 8 4 0 0 A )
49 0378 400A)
36U0KX-005
STALL TEST
This test is performed to determine if there is slippage of the friction elements or malfunction of the hydrau
lic components.
Preparation
1. Check, and correct as necessary, the engine coolant, engine oil, and ATF levels before testing.
2. Warm the engine thoroughly to raise the ATF temperature to operating level 60—70°C {140—158°F}.
3. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
4. Connect a tachometer to the engine.
ENGAGE BRAKE WARM UP ENGINE ENGINE COOLANT LEVEL
ENGINE OIL LEVEL
WHEEL CHOCK
36U0KX-282
K1-11
K1 MECHANICAL SYSTEM TEST
Procedure

2. Check the idle speed and ignition timing in P range. (Refer to Section F2.)
3. Shift the selector lever to R range.
Caution
• if the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is pressed,
the transaxle could be damaged. Therefore, do steps 4 and 5 within 5 seconds of each other.
4. Firmly depress the foot brake with the left foot, and gently depress the accelerator pedal with the right.
5. When the engine speed no longer increases, quickly read the engine speed and release the accelerator.
6. Shift the selector to N and let the engine idle for 1 minute or more to cool the ATF.
K 1-1 2
7. Perform stall tests for the remaining ranges in the same manner.
(1) D range
(2) S range
(3) L range
Engine stall speed: 2,270—2,500 rpm

46U0K1-006
Evaluation of Stall Test

Condition Possible cause
W o rn oil p u m p
O il le a k in g fro m oil p u m p , c o n tro l valve,

a n d /o r tra n s a x le ca se
In su fficie n t line
In all ra n g e s
p re ssu re P re ssu re re g u la to r v a lve stickin g
L in e p re ssu re s o le n o id v a lve m a lfu n c tio n
P re ssu re m o d u la to r va lve stickin g
F o rw a rd c lu tc h s lip p in g
In fo rw a rd ra n g e s
O n e -w a y c lu tc h 1 s lip p in g
A b o v e s p e c ific a tio n In D ra n g e O n e -w a y c lu tc h 2 s lip p in g
In D (H o ld ) a n d S (H o ld )
2-4 b ra k e b a n d s lip p in g
ra n g e s
In L a n d R ra n g e s L o w a n d re ve rse b ra k e s lip p in g
L o w a n d re ve rse b ra k e s lip p in g
R e ve rse c lu tc h slip p in g
P e rfo rm ro a d te st to d e te rm in e w h e th e r p ro b le m is lo w
a n d re ve rse b ra ke o r re ve rse c lu tch
In R ra n g e
a) E n g in e b re a k in g fe lt in L ra n g e (H o ld )
... R e ve rse clu tch
b) E n g in e b re a k in g n o t fe lt in L ra n g e (H o ld )
... L o w a n d re ve rse b ra ke
E n g in e o u t o f tu n e
B e lo w s p e c ific a tio n
O n e -w a y c lu tc h s lip p in g w ith in to rq u e c o n v e rte r
46U0K1-007
TIME LAG TEST
If the selector lever is shifted while the engine is idling, there will be a certain time lapse, or time lag, before
shock is felt. This step measures this time lag for checking conditions of the N-D, 1-2, and N-R accumula
tors, forward and one-way clutches, 2-4 brake band, and low and reverse brake.
Preparation
Perform the preparation procedure outlined in STALL TEST. (Refer to page K1-11.)
Procedure
46U0K1-008

3. Shift from N range to D range.
4. Use a stopwatch to measure the time it takes from shifting until shock is felt.
5. Shift the selector to N range and run the engine at idle speed for at least one (1) minute.
6. Do the time lag test for the following shifts in the same manner. Make three measurements for each test
and average the results.
7. Perform the test for the following shifts in the same manner.
(1) N -*• D range
(2) N -> D range (Hold mode)
(3) N -*• R range
Time lag: N - > D range... below approx. 0.9 second

N -*• R range... below approx. 1.1 second
K 1-1 4
Evaluation of Time Lag Test
Condition Possible Cause
In su fficie n t lin e p re ssu re
F o rw a rd c lu tc h slip p in g
M o re th a n s p e c ific a tio n
O n e -w a y c lu tc h 1 slip p in g
N - * D shift O n e -w a y c lu tc h 2 slip p in g
N -D a c c u m u la to r not o p e ra tin g p ro p e rly
L ess th a n s p e c ific a tio n
E xce ssive line p re ssu re
In su fficie n t line p re ssu re
F o rw a rd c lu tc h s lip p in g
M o re th a n s p e c ific a tio n
2-4 b ra k e b a n d slip p in g
N -» D (H o ld ) shift O n e -w a y c lu tc h 1 slip p in g
1-2 a c c u m u la to r n o t o p e ra tin g p ro p e rly
Less th a n s p e c ific a tio n
E xce ssive line p re ssu re
In su fficie n t line p re ssu re
M o re th a n sp e c ific a tio n L o w a n d re ve rse b ra k e s lip p in g
N -► R shift R e ve rse c lu tc h slip p in g
N-R a c c u m u la to r n o t o p e ra tin g p ro p e rly
L e ss th a n s p e c ific a tio n
E xce ssive lin e p re ssu re
16E0KX-018
LINE PRESSURE TEST

This test measures line pressures as a means of checking the hydraulic components and inspecting for
oil leakage.
Preparation
1. Perform the preparation procedure outlined in STALL TEST. (Refer to page K1-11.)
Warning
• Remove the square-head plug when the ATF is hot can be dangerous.
Hot ATF can come out of the opening and badly burn. Before removing the square-head plug,
allow the ATF to cool.
3. Connect the SST (49 B019 901 and 49 B019 903) to the line pressure inspection port,
(square head plug L)
46U0K1-009
K 1-15
3. Shift the selector lever to D range and read the line pressure at idle.
4. Connect the SST (49 B019 902) to the line pressure inspection port.
Caution
• If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is pressed,
the transaxle could be damaged. Therefore, do step 5 and 6 within 5 seconds of each other.
Warning
• Slight variations in line pressure data are due to changes in ATF temperature, which are brought
about by line pressure control.
The following line pressure date is for ATF temperature of 80°C (176°F j.
5. Depress the brake pedal firmly with the left foot and gradually depress the accelerator pedal with the right foot.
6. Read the line pressure as soon as the engine speed becomes constant, then release the accelerator pedal.
7. Shift the selector to N range and let the engine at idle for 1 minute or more to cool the ATF.
8. Read the line pressure at idle and at the engine stall speed for each range in the same manner.
Specified line pressure:

Line pressure kPa (kgf/cm2, psi)
Range
Idle Stall
D, S, L 4 2 0 — 5 3 0 ( 4 .2 — 5.5, 6 0 - 7 8 ) 1 ,1 0 0 -1 ,1 7 0 (1 1 .2 - 1 2 .0 , 1 6 0 - 1 7 0 )
R 7 3 0 — 1 ,0 1 0 ( 7 . 4 - 1 0 . 3 , 1 1 0 - 1 4 6 ) 1 ,9 1 0 — 2 ,0 3 0 ( 1 9 . 4 - 2 0 . 7 , 2 7 6 — 2 9 4 )
46U0K1-010
9. Install a new square head plug in the inspection port.
Tightening torque: 5.0—9.8 N-m {50—100 kgf-cm, 44—86 in-lbf]
Evaluation of Line Pressure Test

Line pressure Possible cause
W o rn oil p u m p
O il le a k in g fro m oil p u m p , c o n tro l v a lve b o d y , a n d /o r tra n s a x le ca se
L o w p re s s u re in e v e ry p o sitio n P re ssu re re g u la to r va lve stic k in g
L in e p re ssu re so le n o id v a lve m a lfu n ctio n
P re ssu re m o d u la to r va lve s tickin g
L o w p re s s u re in D a n d S o n ly O il le a k in g fro m h y d ra u lic c irc u it o f fo rw a rd c lu tc h

L o w p re s s u re in L a n d R o n ly Oil le a k in g fro m h y d ra u lic c irc u it o f lo w a n d reve rse b ra ke
L o w p re s s u re in R o n ly Oil le a k in g fro m h y d ra u lic c irc u it o f reve rse c lu tch
L in e p re s s u re so le n o id v a lve m a lfu n ctio n

H ig h e r th a n s p e c ific a tio n P re ssu re re g u la to r va lve s tickin g
P re ssu re m o d u la to r v a lve stickin g
46U0K1-011
SOLENOID REDUCING PRESSURE TEST
This test measures solenoid reducing pressure as a means of checking the hydraulic components and
inspecting for oil leakage.
Preparation
1. Perform the preparation procedure outlined in STALL TEST. (Refer to page K1-11.)
Warning
• Remove the square-head plug when the ATF is hot can be dangerous.
Hot ATF can come out of the opening and badly burn.
Before removing the square-head plug allow the ATF to cool.
3. Connect the SST (49 B019 901 and 49 B019 903) to the solenoid reducing pressure inspection port,
(square head plug T)
Procedure
49 B 019 901
ENGAGE PARKING BRAKE IDLE SPEED 49 801 9 903
SOLENOID REDUCING PRESSURE (AT IDLE)
W HEEL CHOCK
46U0K1-012

3. Read the solenoid reducing pressure at idle in P range.
Specifed solenoid reducing pressure: 360—400 kPa {3.6—4.1 kgf/cm2, 52—58 psi)
4. Install a new square head plug in the inspection port.
Tightening torque: 5.0—9.8 N-m {50—100 kgf-cm, 44—86 in-lbf)
K 1-1 7
Evaluation of Solenoid Reducing Pressure Test
Solenoid reducing pressure Possible cause
N o t w ith in s p e c ific a tio n S o le n o id re d u c in g v a lv e s tic k in g
36U0KX-011
K 1-18
ROAD TEST K1
ROAD TEST
A road test is necessary to inspect for problems in the different gear ranges. If a range or function targeted
by the road test is found to have any problem, refer to the ELECTRONIC SYSTEM COMPONENT seg
ment or the TRANSAXLE, OIL COOLER, DRIVE PLATE, and SHIFT MECHANISM segments of this section.
Do the road test only when the ATF is 60—70°C {140—158 °F).
46U0K1-013
D RANGE TEST
Shift Point, Shift Pattern, and Shift Shock
Note
• The power mode and the normal mode are automatically selected by the Powertrain control module
(Transaxle).
1. Shift the selector lever to D range.
Note
• There is no shift to Fourth gear in any of the following conditions.
1. The ATF temperature is below 10°C {50°F}.
2. The cruise control is operating, and there is a 8 km/h {5 mph) difference between the preset cruise
speed and the vehicle speed.
3. The RESUME/ACCEL switch is ON
2. Accelerate the vehicle with half- and wide open throttle.

3. Verify that 1-2, 2-3, and 3-4 upshifts and downshifts are obtained. The shift points must be as shown
in the D range shift diagram.
4. Drive the vehicle in Fourth, Third, and 2nd gears and verify that kickdown occurs for 4-»3, 4-»2, 4-»1,
3->2, 3 —*-1, 2 —*-1, and that the shift points are as shown in the D range shift diagram.
5. Decelerate the vehicle and verify that engine braking effect is felt in Fourth and Third gears.
Note
• There is no lockup in the following conditions.
1. The engine coolant temperature is below 60°C {140°F}.
2. The idle switch is ON.
3. The stop light switch is ON.
• There is no slip lockup in the following conditions.
2. The ATF temperature is below 20°C {68°F}.
3. The accelerator pedal is depressed rapidly.
6. Drive the vehicle and verify that lockup is obtained.

7. Select hold mode.
8. Accelerate the vehicle with half- and full-throttle opening, and verify that 2-3 upshift and downshift are
obtained. The shift points must be as shown in the D range (hold mode) shift diagram.
9. Drive the vehicle in Third and 2nd gears and verify that kickdown does not occur.
10. Decelerate the vehicle and verify that engine braking effect is felt in Third gear.
Note
2. The idle switch in ON.
3. The stoplight switch in ON.
K 1-19
K1 ROAD TEST
D range (power mode) shift diagram
46U0K1-015
D range (normal mode) shift diagram
LOCKUP AVAILABLE W HEN ACCELERATING AND CRUISING
j LOCKUP AVAILABLE W HEN COASTING
VEHICLE SPEED km/h (mph)
46U0K1-016
K 1-2 0
ROAD TEST K1
D range (hold mode) shift diagram
lo c k u p a v a ila b le w h e n a c c e l e r a t in g a n d c r u is in g
ED LOCKUP AVAILABLE WHEN COASTING
7/8"
wm
wm
mm
LU 6/ 8 ' lit
0
i
MB
5/8- # :I
0
Z
1
i :iL O C K U P IN 3.0.R:? •• I
Z
LOCKUP>
LU 4/8~J IN 3GR::
Q_ IL O C K U P
O ::i n 4 g r
LU
3/8- mm
0
CC -SHIFT U P
1
-SHIFT D O W N
1/ 8 “
----1--- -1- -----1--- -----1—

20 ( 12) 40 (25) 60 [371 80 (50) 100 {63 ] 120 [75! 140 {87) 160 ( 99)
46U0K1-017
Noise and Vibration

Drive the vehicle in 2nd gear (Hold) and listen closely for any out of the ordinary noise or vibration. The
torque converter, drive shaft, and differential can be sources of abnormal noise and vibration if they are
not functioning properly. Check these when searching for sources of noise and vibration.
K1 ROAD TEST
S RANGE TEST
1. Shift the selector lever to S range.
2. Accelerate the vehicle with half- and full-throttle opening.
3. Verify that 1-2 and 2-3 upshifts and downshifts are obtained. The shift points must be as shown in the
S range shift diagram.
4. Drive the vehicle in Third and 2nd gears and verify that kickdown occurs for 3->2, 3-»1, 2-»1, and that
the shift points are as shown in the S range shift diagram.
Note
3. The stoplight switch is ON.

8. Accelerate the vehicle with half- and full-throttle opening, and verify that 2nd gear is held.
9. Decelerate the vehicle and verify that engine braking effect is felt.
Note
3. The stoplight switch is ON.

46U0K1-018
S range (normal mode) shift diagram
| LOCKUP AVAILABLE WHEN ACCELERATING AND CRUISING
] LOCKUP AVAILABLE WHEN COASTING
46U0K1-019
K 1-22
ROAD TEST K1
S range (hold mode) shift diagram
----------------------------------1---------------------------------1---------------------------------1-------------------------------- 1--------------------------------- , l fcviv.v iv . y .v . y .y .y *.*■*■*.*■*■*.*.*■v .v .v . '. v .y . v . v ■*■*■*■V i Y »v «v . v . y . y j

0 20 [121 4 0 |2 5 | 6 0 [3 7 | 80 150) .1 0 0 163] 120 1751 140 ( 871 160 1991
46U0K1-020
Noise and vibration

K1 ROAD TEST
L RANGE TEST
1. Shift the selector lever to L range.
3. Verify that 1-2 upshift and downshift are obtained. The shift points must be as shown in the L range shift
diagram.
4. Drive the vehicle in 2nd gear and verify that kickdown occurs for 2 -*1 , and that the shift point is as shown
in the L range shift diagram.
5. Decelerate the vehicle and verify that engine braking effect is felt in 2nd gear.
7. Accelerate the vehicle with half- and full-throttle opening, and verify that 1st gear is held.
36U0KX-C118
46U0K1-021
ROAD TEST K1
L range (hold mode) shift diagram
7/8
I j 6 / 8 -I
0
Z
<
5/8.
o
z
z
111 4/8
Q.
3/8-
2/ 8 -
SHIFT DOWN
0/8
0 20 f 12J 40 [25| 60 ( 37 | 80 ( 501 .1 0 0 1631 120 ( 751 140 1871 160 ( 991
VEHICLE SPEED km/h (m ph)
46U0K1 -022
Noise and Vibration

P RANGE TEST
Shift into P range on a gentle slope, release the brake, and verify that the vehicle does not roll.
Evaluation
Condition Possible Cause
S tu c k 1 -2 sh ift s o le n o id va lve
N o 1-2 u p - o r d o w n s h ift
S tu c k 1 -2 sh ift va lve
S tu c k 2-3 sh ift s o le n o id v a lve
N o 2-3 u p - o r d o w n s h ift
S tu ck 2-3 shift va lve
S tu ck 3-4 sh ift s o le n o id va lve
N o 3 4 G R u p - o r d o w n s h ift
S tu ck 3-4 sh ift va lve
S tu ck lo c k u p c o n tro l s o le n o id va lve
N o lo c k u p shift
S tu c k lo c k u p c o n tro l va lve
M isa d ju ste d th ro ttle se n so r
In c o rre c t sh ift p o in t
S tu ck sh ift va lve s
S tu ck a c c u m u la to rs
E x c e s s iv e sh ift s h o c k o r s lip p a g e S tu ck o r no o n e -w a y c h e c k o rifice
W o rn clu tch e s, b rakes, o r o n e -w a y clu tch
N o e n g in e b ra k in g e ffe ct W o rn c lu tc h e s o r b ra ke s
46U0K1-023
K 1-25
K1 ROAD TEST
Vehicle Speed at Shiftpoint Table
Throttle condition
Range Mode (throttle position Shift Vehicle speed
sensor voltaqe) km/h [mph)
D 1- D 2 5 7 -6 3 (3 5 -3 9 )
W id e o p e n th ro ttle (3 .0 — 4.4V) D2 -+ D 3 9 9 -1 0 7 (6 1 -6 6 )
D3-+ D 4 1 6 2 -1 7 2 (1 0 0 -1 0 7 )
D 1-+ D 2 4 0 -4 9 (2 5 -3 0 )
H a lf th ro ttle D2->D 3 6 9 -8 7 (4 3 -5 4 )
Power D3->D 4 1 1 4 -1 3 9 ( 7 1 - 8 6 )
D 4 -*D 3 17 — 23 ( 1 1 — 1 4 )
C lo s e d th ro ttle p o sitio n (0 .1 — 1.1V)
D 3 -D 1 1 1 -1 7 ( 7 -1 1 )
D4->D3 1 3 5 -1 4 5 ( 8 4 - 9 0 )
K ic k d o w n D3->D2 8 6 - 9 4 (5 3 — 5 8 )
D 2 -D 1 4 4 -5 0 (2 7 -3 1 )
D D i -*D 2 5 7 -6 3 (3 5 -3 9 )
D2->D 3 9 9 -1 0 7 (6 1 -6 6 )
D3->D4 1 6 2 -1 7 2 (1 0 0 -1 0 7 )
'L o c k u p O N (D4) 1 4 7 -1 5 7 ( 9 1 - 9 7 )
D 1- D 2 3 3 -4 1 (2 0 -2 5 )
D2->D 3 5 4 -6 9 (3 3 -4 3 )
H a lf th ro ttle
Normal D 3 -*D 4 9 2 -1 2 0 (5 7 -7 4 )
'L o c k u p O N (D4) 1 2 4 -1 4 9 ( 7 7 -9 2 )
D4->D3 1 7 -2 3 (1 1 -1 4 )
D 3- + D 1 1 1 -1 7 (7 -1 1 )
D4->D3 1 3 5 -1 4 5 ( 8 4 - 9 0 )
K ic k d o w n D3-+ D 2 8 6 -9 4 (5 3 -5 8 )
D2->D1 4 4 -5 0 (2 7 -3 1 )
S l~ *S 2 5 7 -6 3 (3 5 -3 9 )
W id e o p e n th ro ttle (3 .0 — 4.4V ) S2-+ S 3 9 9 -1 0 7 (6 1 -6 6 )
'L o c k u p O N (S3) 1 0 8 -1 1 6 (6 7 — 72)
S 1- S 2 3 9 -4 9 (2 4 -3 0 )
C H a lf th ro ttle S2->S3 6 9 -8 7 (4 3 -5 4 )
'L o c k u p O N (S3) 1 0 4 -1 1 6 ( 6 4 - 7 2 )
D4 ( S 4 )-S 3 1 6 2 -1 6 8 (1 0 0 -1 0 4 )
S 3 -*S i 1 1 - 1 7 (7 — 11)
S3->S2 8 6 -9 4 (5 3 -5 8 )
K ic k d o w n
S 2_>Sl 4 4 — 50 ( 2 7 - 3 1 )
W id e o p e n th ro ttle (3 .0 — 4.4V) L1-»L2 5 7 -6 3 (3 5 -3 9 )
H a lf th ro ttle L i ->L2 3 9 -4 9 (2 4 -3 0 )
L
c lo s e d th ro ttle p o sitio n (0 .1 — 1.1V) L 2 -> L i 1 1 -1 7 (7 - 1 1 )
K ic k d o w n L 2 -*-L i 1 1 -1 7 (7 -1 1 )
D2->D 3 1 5 -2 5 (9 -1 6 )
'L o c k u p O N (D3) 1 0 5 -1 1 5 ( 6 5 - 7 1 )
D
D4-*D3 1 6 2 -1 6 8 (1 0 0 — 104)
D3- D 2 7 -1 3 (4 -8 )
Hold
'L o c k u p O N (S3) 1 0 5 -1 1 5 ( 6 5 - 7 1 )
S — D4(S4)->S3 1 6 2 -1 6 8 (1 0 0 -1 0 4 )
S3-»S2 7 -1 3 (4 -8 )
L — L 2 -» L i 4 3 -4 9 (2 7 -3 0 )
'C o m p le te lo c k u p 46U0K 1-024
Input the voltages displayed on the engine signal monitor into the following formula to calculate the half
throttle voltage.
Wide open throttle voltage - Closed throttle position voltage ,, .

-------------------------------- 2---------------------------------------------- = Half throttle voltage
AUTOMATIC TRANSAXLE FLUID (ATF) K1
AUTOMATIC TRANSAXLE FLUID (ATF)
ATF
Inspection
INGAGE PARKING BRAKE Level
Note
• Park the vehicle on level groud.
W HEEL CHOCK
46U0K1-026 2. Warm up the engine until the ATF reaches 60—70°C
{140—158°F).
4. Shift back to P.
_ 16E0KX-052
Note
HOT RANGE • In some cases it may be necessary to inspect the ATF
ATF TEM PERATURE 60— 7 0 °C [ 140— 158°F )
in the cool range 15—25°C {59—77°F) before warm
ing up the engine.
C 2 0 ’C 6 5 - C ____ 5. Ensure that the ATF level is in the HOT (65°C) range. Add
ATF to the specification, if necessary.
ATF type: Dexron®n or M-m

COOL RANGE
ATF TEM PERATURE 15— 25°C (59 —7 7 °F )
46U0K1-027
Condition
Determine whether the transaxle should be disassembled by
noting:
1. If the ATF is muddy or varnished.
2. If the ATF smells strange or unusual.
46U0K1-028
K1__________ AUTOMATIC TRANSAXLE FLUID (ATF)
Fluid leaks
Check for ATF leaks of the transaxle at the points shown below and repair or replace as necessary.
1. Gaskets, O-rings, and plugs.
2. Oil hoses, oil pipes, and connections.
3. Oil cooler.
16E0KX-Q55
K 1-28
ELECTRICAL SYSTEM COMPONENTS K1
ELECTRICAL SYSTEM COMPONENTS
PREPARATION
SST
4 9 G 0 1 9 031 For 4 9 9 2 0 0 162 For

d is a s s e m b ly / in s p e c tio n o f
W re n c h a s s e m b ly o f M on ito r, E n g in e p o w e rtra in
ATF S ignal c o n tro l m o d u le
th e rm o s e n s o r (Transaxle)
te rm in a l v o lta g e
49 G 018 904 For 49 D 019 902 F or

in s p e c tio n of in s p e c tio n o f
Sheet p o w e rtra in A d a p te r H a rne ss p o w e rtra in
c o n tro l m o d u le co n tro l m o d u le
(Transaxle) (Transaxle)
te rm in a l v o lta g e te rm in a l v o lta g e
46U0K1-029
HOLD SWITCH
Inspection
Inspection of operation
1. Turn the ignition switch from OFF to ON.
2. Verify that the hold indicator is not illuminated. Depress the
hold switch and verify that the hold indicator light illuminates.
3. If not as specified, check the terminal voltage of the hold
switch.
46U0K1-387
Inspection of voltage
1. Remove the front console.
3. Measure voltage at the hold switch connector.
C o n n e c to r te rm in a l
P osition
A B
N o rm a l (V) B+ 0
D e p re sse d (V) 0 0
(V): V o lta g e
46U0K1-388
4. If not as specified, check the continuity of the hold switch.
K1 ELECTRICAL SYSTEM COMPONENTS
In sp ectio n o f c o n tin u ity
2. Disconnect the hold switch connector.
Terminal
Position
A B
Normal
Depressed O ----- ----- O
O — O: Continuity
4. If not as specified, replace the selector lever knob assem

bly. (Refer to below.)
5. If the switch is OK, check the wiring harness. (Hold switch—
powertrain control module (Transaxle), Hold switch—Body
ground.)
6. Install the front console.
Replacement
2. Remove the front console.
3. Remove the indicator panel installation screws.
4. Disconnect the connector and remove the hold switch ter
minals.
5. Remove the selector lever knob assembly.
6. Install a new selector lever knob assembly.
Tightening torque:
2.0—2.9 N-m {20—30 kgf-cm, 18—26 in-lbf)
7. Install the hold switch terminals and connect the connector.

8. Install the indicator panel installation screws.
(Refer to page K1-184.)
9. Install the front console.
46U0K1 -030
P A R K /N E U T R A L S W ITC H
In sp ectio n
In sp ectio n o f op eratio n
1. Verify that the starter operates only with the ignition switch
at the START position and the selector lever in P and N
ranges.
2. Verify that the back-up lights illuminate when shifted to R
range with the ignition switch in the ON position.
3. Verify that the positions of the selector lever and the selec
tor indicator lamp of the instrument cluster are aligned.
4. Check the Park/Neutral switch if not as specified.
46U0K1-Q31
K 1 -3 0
Inspection of continuity
2. Remove the resonance chamber, fresh air duct, and air
cleaner assembly.
3. Disconnect the park/neutral switch connector.
4. Check continuity of the park/neutral switch.
Connector terminal
Position
A B c D E F G H I
o— —O
P
R o— —0
o— —u
N
{J u
D 0— - 0
S ---KJ
L 0 — —0
O — O : C o n tin u ity
5. If not as specified, replace or adjust the park/neutral switch.

6. Connect the park/neutral switch connector.
7. Install the resonance chamber, fresh air duct, and air cleaner
assembly.
46U0K1-033
Replacement
2. Remove the resonance chamber,fresh air duct, and air
cleaner assembly.
4. Remove the clip.
5. Remove the selector cable in the order shown in the figure.
©Disconnect the selector cable from the manual shaft lever.
©Pull out the selector cable from the cable bracket and
remove it.
6. Remove the manual shaft nut.
7. Remove the lock-washer and lever.
8. Remove the park/neutral switch.
9. Rotate the manual shaft to N position.
10. Turn the park/neutral switch so that the neutral mark is in
line with the flat, straight surfaces on either side of the manual
shaft.
11. Loosely tighten the inhibitor switch bolts.
12. Verify that there is continuity between terminals A and H
of the park/neutral switch connector.
13. Tighten the park/neutral switch mounting bolts.
Tightening torque:
7.9—10.7 N m {80—110 kgf cm, 70—95 in-lbf}
14. Install the lever and spring washer.

15. Tighten the manual shaft nut by using a torque wrench.
Tightening torque:
32—46 N-m {3.2—4.7 kgf m, 24—33 ft lbf)
46U0K1-036
K1-31
16. Verify that the selector lever range position and park/neu
tral switch are aligned; then connect the selector cable and
install a new spring pin and clip.
17. Check continuity of the park/neutral switch.
19. Install the air cleaner assembly, fresh air duct, and reso
nance chamber.
21. Check operation of the park/neutral switch.
Adjustment
cleaner assembly.
3. Remove the spring pin and clip and disconnect the selec
tor cable.
4. Rotate the manual shaft to N range position.
6. Loosen the park/neutral switch mounting bolts.
7. Connect an ohmeter between terminals (a) and © .
8. Adjust the switch to the point where there is continuity be
tween the terminals.
9. Tighten the park/neutral switch mounting bolts.
Tightening torque:
7 .9 -1 0 .7 Nm {80—110 kgf cm, 70—95 in-lbf}
10. Verify that the selector lever range position and park/neu
tral switch are aligned.
12. Connect the selector cable and install a new spring pin and
clip.
13. Install the air cleaner assembly, fresh air duct, and reso
nance chamber.
ATF THERMOSENSOR
Inspection
1. Refer to “ Replacement” below for removal of the ATF ther
mosensor.
2. Place the ATF thermosensor in ATF with a thermosensor
as shown and heat the ATF gradually.
3. Measure resistance between the terminals of the ATF ther
mosensor.
ATF temperature°C (°F) Resistance (kQ)

-2 0 (-4 ) 1 3 .4 7 -1 7 .1 7
0 (3 2 ) 5 .4 4 5 -6 .6 7 8
20 (6 8 ] 2 .4 4 1 — 2 .8 9 4
4 0 (1 0 4 ) 1 .1 9 3 — 1 .3 74
6 0 (1 4 0 ) 0 .6 2 8 4 — 0 .7 0 4 8
8 0 (1 7 6 ) 0 .3 5 2 7 — 0 .3 8 6 5
1 0 0 (2 1 2 ) 0 .2 0 9 1 — 0 .2 2 4 5
120 (2 4 8 ) 0 .1 3 0 1 - 0 . 1 3 7 2
130 (2 6 6 ) 0 .1 0 4 4 — 0 .1 0 9 0
4. If not correct, replace the ATF thermosensor.

5. Refer to “ Replacement” for installation of the ATF ther
mosensor.
16E0KX-071
K1—32
Replacement
1. Remove the control valve body cover.
2. Disconnect the ATF thermosensor connector.
3. Remove the ATF thermosensor by using the SST.
4. Install a new ATF thermosensor by using the SST.
Tightening torque:
7.9—10.7 Nm [80—110 kgf cm, 70—95 in Ibf)
5. Connect the ATF thermosensor connector.

6. Install the control valve body cover.
VEHICLE SPEED PULSE GENERATOR

Inspection
1. Refer to "Replacement” below for disconnection of the ve
hicle speed pulse generator connector.
2. Measure resistance between the terminals of the vehicle
speed pulse generator.
Resistance: 253—604 ft
(ATF temperature: -4 0 —160°C {-40—320°F))
3. If not correct, replace the vehicle speed pulse generator.

4. Refer to "Replacement” for connection of the vehicle speed
pulse generator connector.
Replacement
cleaner assembly.
3. Remove the fuel filter mounting nuts.
4. Disconnect the vehicle speed pulse generator connector.
5. Remove the vehicle speed pulse generator.
36U0KX-037 6. Apply ATF to a new O-ring and install it on a new vehicle
7. Install the vehicle speed pulse generator.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95 in-lbf]
8. Connect the vehicle speed pulse generator connector.

9. Install the fuel filter mounting nuts.
10. Install the resonance chamber, fresh air duct, and air cleaner
assembly.
SPEEDOMETER
Inspection of vehicle speed sensor
1. Remove the instrument cluster. (Refer to Body Electrical
Troubleshooting segment Section C1.)
2. Measure voltage between terminal 1H and a ground when
rotating the front wheels.
Meter needle Action

M o v e s s lig h tly u n d e r 5V R e p a ir w irin g h a rn e ss
(In stru m e n t c lu s te r— p o w e rtra in
c o n tro l m o d u le (Transaxle)
Does not m ove G o to n e xt step
46U0K1-041
3. Measure voltage between terminals 1B and 1F of the vehi

cle harness when rotating the front wheels.
46U0K1-042
Meter needle Action

M o v e s slig h tly u n d e r 5V R e p la ce s p e e d o m e te r
(R efer to B o d y E le ctrica l
T ro u b le s h o o tin g s e g m e n t
S e ctio n C 1)
D o e s n o t m o ve G o to n e xt step
Inspection of vehicle speedometer sensor

1. Remove the vehicle speedometer sensor.
2. Measure voltage between terminals of the vehicle speedom

eter sensor while rotating the driven gear.
Meter needle Action
M o v e s s lig h tly u n d e r 5V R e p a ir w irin g h a rn e ss
(In stru m e n t c lu s te r— v e h ic le
s p e e d o m e te r sensor)
D o e s n o t m o ve R e p la ce v e h ic le s p e e d o m e te r
se n so r
3. Install the vehicle speedometer sensor.

STOPLIGHT SWITCH
Inspection of voltage
2. Measure voltage at the stoplight switch connector.
Connector terminal (V)
Condition
A B
P edal d e p re s s e d B+ 0
P e d a l released 0 0
(V): V o lta g e
3. If not as specified, check the wiring harness (Stop fuse—

Stoplight switch, Stoplight switch—powertrain control mod
ule (Transaxle)) and the continuity of the switch.
2. Disconnect the stoplight switch connector.
3. Check continuity between terminals A and B of the switch.
Terminal
Condition
A B
P e d a l d e p re s s e d
P edal released 0 ---------------- ---------------- O
46U0K1-046 O — O : C o n tin u ity
4. If not as specified, replace the stoplight switch.

5. Connect the stoplight switch connector.
SOLENOID VALVES
Inspection
2. Remove the resonance chamber, fresh air duct and air
cleaner assembly.
4. Measure resistance between terminals A through G and a
ground.
s ,— — ,s| AT F te m p e ra tu re : - 4 0 — 1 6 0 ° C ( - 4 0 — 3 2 0 ° F )
G E C A
F D B
Terminal Solenoid valve Resistance (fi)
V— — '/ A 1-2 shift 1 1 -2 7
B 2-3 shift 1 1 -2 7
16E0KX-Q82
C 3-4 shift 1 1 -2 7
D L o c k u p co n tro l 11 — 27
E 3-2 tim in g 1 1 -2 7
F Lockup 9 -1 8
G L in e p re ssu re 9 — 18
5. If not correct, check the wiring harness or replace the sole

noid valve(s), if necessary.
6. Connect the solenoid valve connector.
7. Install the resonance chamber, fresh air duct and air cleaner
assembly.
K 1-35
Replacement
1. Remove the control valve body.
2. Remove the solenoid valve(s).
3. Apply ATF to a new O-ring and install it on the solenoid
valve.
4. Install the solenoid valve in the control valve body.
Tightening torque:
6.5—7.8 N m {66—80 kgf cm, 58—69 in lbf)
46U0K1-047 5. Install the control valve body. (Refer to page K1-135.)

6. Pour in ATF, and with the engine idling, check the ATF lev
el and check for leaks. (Refer to page K1-27.)
7. Drive the vehicle and check the shift points, shift schedule,
and shift shock.
(Refer to Road test, page K1-19.)
HOLD INDICATOR LIGHT

Inspection
1. Turn the ignition switch from OFF to ON.
Note
• The hold indicator light will flash if a malfunction exists
in any of the EC-AT system components.
2. Verify that the hold indicator light is not illuminated.

3. Depress the switch and verify that the hold indicator il
luminates.
Note
• If a malfunction occurs in any of the EC-AT system com
ponents, the hold indicator light flashes.
4. If the hold switch function is not as specified, after check

ing the hold switch (refer to page K1-29) check the termi
nal voltage of the hold indicator light.
inspection of voltage
3. Measure voltage between terminal 2G and a ground.
Voltage Action
B+ G o to n e xt step
O th e r • R e p la ce M ETER fu se
• R e p a ir w irin g h a rn e ss
(M E TE R fu s e — In stru m e n t
clu ste r)
K 1 -3 6
2. Disconnect the instrument cluster connector.
3. Check continuity between terminal 1K and powertrain con
trol module (Transaxle) 1B terminal.
Terminals Continuity
1 K -1 B Yes
4. If not correct, check the wiring harness (instrument cluster—

powertrain control module (Transaxle)).
5. If correct, go to the next step.
6. Check continuity between terminals 2G and 1K.

Terminals Continuity
2 G -1 K Yes
7. If not correct, replace the instrument cluster or bulb.

8. Install the instrument cluster. (Refer to Body Electrical
K 1 -3 7
POWERTRAIN CONTROL POWERTRAIN CONTROL MODUL (TRANSAXLE)

MODULE (TRANSAXLE) Inspection
1. Remove the powertrain control module (Transaxle). (Refer
to page K1-44.)
2. Disconnect the control module connectors.
3. Connect the SSTs (Engine Signal Monitor and Adapter
Harness) to the powertrain control module (Transaxle) as
shown.
46U0K1-052
4. Place the SST (sheet) on the Engine Signal Monitor.
6. Measure the terminal voltage at each terminal.
7. If any control module terminal voltage is incorrect, check
the related input of output devices and wiring. If no prob
lem is found, replace the powertrain control module
(Transaxle).
Caution
• Applying voltage to terminals A and B of this SST
will damage the SST.
46U0K1 -054
Terminal Voltage Chart (Reference Data)

Connected Voltmeter Correct
Terminal Component Condition Possible cause
to + terminal - terminal voltage
1A A /C sw itch A /C sw itch 1A G ro u n d B e lo w A /C sw itch O N • A /C sw itch
(Inp u t) 1.0V
B+ A /C sw itch O FF
1B H o ld in d ic a to r In stru m e n t 1B B e lo w H o ld m o d e • In stru m e n t c lu s te r
(O u tp u t) lig h t c lu s te r (h o ld 1.0V (h o ld in d ic a to r
in d ic a to r light) light)
B+ O th e r m o d e s
1C F A T te rm in a l FA T te rm in a l 1C B e lo w H o ld m o d e • W irin g a n d /o r c o n
(O u tp u t) (d a ta lin k c o n (d a ta lin k c o n 2 .5 V n e c to r fro m 1C te r
n e cto r) n e ctor) m in al to d a ta link
B+ O th e r m o d e s
c o n n e c to r FAT
te rm in a l
1D In h ib ito r sig n a l P o w e rtra in 1D B e lo w P a n d N ra n g e s • W irin g a n d /o r c o n
(O u tp u t) co n tro l 1.0V n e c to r fro m 1 D te r
m o d u le m in al to p o w e rtra in
B+ O th e r ra n g e s
(E n g in e ) c o n tro l m o d u le
(E n g in e ) 1R
te rm in a l
1E T A T te rm in a l T A T te rm in a l 1E B+ Ig n itio n sw itch O N • W irin g a n d /o r c o n
(Inp u t) (d a ta lin k c o n (d a ta lin k c o n (ve h icle sto p p e d ) n e c to r fro m 1 E te r
n e ctor) n e ctor) m in al to d a ta lin k
0V T A T te rm in a l
c o n n e c to r TA T
g ro u n d e d (veh icle
te rm in a l
s to p p e d )
1F S to p lig h t S to p lig h t 1F B+ B ra ke p e d a l • S to p lig h t sw itch

(Inp u t) sw itch sw itch d e p re s s e d
0V B ra ke p e d a l
relea se d
1G ATF AT F 1G 2R A p p ro x . V e rify th a t vo lta g e • A T F th e rm o s e n s o r

(Inp u t) th e rm o s e n s o r th e rm o s e n s o r 0 .6 — d e c re a s e s a c c o rd • W irin g a n d /o r c o n
4 .8 V in g to A T F te m p e r n e c to r fro m 1G te r
a tu re rise m in al to AT F
Note th e rm o s e n s o r
• F or re fe re n ce , if
th e A T F is 2 0 ° C
( 6 8 ° F ) th e v o lt
a g e s h o u ld be
3.5V .
If th e A T F is
1 3 0 °C { 2 6 6 ° F )
th e v o lta g e
s h o u ld b e 0 .6 V
46U0K1-055
K 1-39

1H H o ld s w itch H o ld sw itch 1H G ro u n d B+ S w itch relea se d • H o ld sw itch
(Inp u t)
OV S w itch d e p re s s e d
11 P a rk /n e u tra l P a rk/n e u tra l 11 B+ R ra n g e • P ark/neutral sw itch
(Inp u t) s w itc h sw itch • W irin g a n d /o r c o n
ov O th e r ra n g e s
(R ra n g e ) n e c to r fro m 11 te r
m in al to
p a rk/n e u tra l sw itch
1J R educe to rq u e P o w e rtra in 1J B e lo w 1 - 2 , 2 - 3 shift, • W irin g a n d /o r

(O u tp u t) signal 1 c o n tro l 1.0V a n d th ro ttle o p e n c o n n e c to r fro m
m o d u le in g 4 /8 o r m ore 1J te rm in a l to
(E n g in e ) p o w e rtra in c o n tro l
B+ O th e r th a n a b o v e
m o d u le (E n ig n e )
1S te rm in a l
1K T o rq u e P o w e rtra in 1K B+ W a te r te m p e ra tu re : • W ir in g a n d /o r
(In p u t) re d u c e d c o n tro l m o re th a n 6 0 ° C c o n n e c to r fro m
s ig n a l/e n g in e m o d u le ( 1 4 0 °F ) 1K te rm in a l to
c o o la n t (E n g in e ) p o w e rtra in co n tro l
B e lo w W a te r te m p e ra tu re :
te m p e ra tu re m o d u le (E nigne)
1.0V less th a n 6 0 ° C
s ig n a l { 1 4 0 °F ) or
1K te rm in a l
to rq u e co n tro l
d u rin g sh iftin g
1L R e d u c e to rq u e P o w e rtra in 1L B e lo w 4 -2 , 4 -1 , 3 -2 , • W irin g a n d /o r
(O u tp u t) s ig n a l 2 c o n tro l 1.0V 3 - 1 , 2 - 1 shift c o n n e c to r fro m
m o d u le a n d th ro ttle o p e n 1 L te rm in a l to
(E n g in e ) in g 3 /8 o r m o re p o w e rtra in co n tro l
m o d u le (E n g in e )
B+ O th e r th a n a b o v e
1V te rm in a l
1M 4 G R in h ib it C ru is e co n tro l 1M B e lo w T h e v e h ic le sp e e d • W irin g a n d /o r
(Inp u t) s ig n a l (au to u n it 1.0V d ro p s 8 km /h c o n n e c to r fro m
s p e e d c o n tro l ( 5 m p h ] b e lo w 1 M te rm in a l to
s ig n a l) th e set sp e e d o r c ru is e co n tro l unit
R E S U M E /A C C E L 1G te rm in a l
s w itch is o p e ra te d
d u rin g cru ise c o n
tro l o p e ra tio n
B+ O th e r th a n a b o ve
1N E n g in e rp m D is trib u to r 1N OV o r E n g in e sto p p e d • W irin g a n d /o r

(In p u t) s ig n a l (Ne1 4 .5 — (ig n itio n sw itch O N ) c o n n e c to r fro m
sig n a l) 5 .5 V 1N te rm in a l to
d is trib u to r
2 .0 - E n g in e ru n n in g at
• D istrib u to r
3 .0 V idle
10 Id le sw itc h T h ro ttle p o si 10 B+ A c c e le ra to r pe d al • Throttle position

(Inp u t) tio n se n so r d e p re s s e d sensor
• W iring a n d /o r co n
OV A c c e le ra to r p e d a l
nector from 1 0
relea se d
term inal to throttle
position sensor
46U0K1 -056
K 1 -4 0

to -i- terminal - terminal voltage
1P V e h ic le s p e e d S p e e d o m e te r 1P G ro u n d OV o r V e h icle s to p p e d • S p e e d o m e te r
(Input) se n so r 4 .0 - •V e h ic le s p e e d
5 .0 V se n so r
2 .0 - V e h icle m o v in g
3 .0 V
2A V ref (thro ttle T h ro ttle p o s i 2A 0V Ig n itio n sw itch O FF • W iring a n d /o r co n
(Input) p o sitio n tio n s e n so r nector from 2A
4 .5 — Ig n itio n sw itch O N
s ensor) term inal to throttle
5 .5 V
position sensor
2B P a rk/n e u tra l P a rk/n e u tra l 2B OV P a n d N ra n g e s • W iring a n d /o r c o n
(Input) s w itc h (P a n d sw itch nector from 2B
N ran g e s) term inal to
B+ Park/Neutral
O th e r ra n g e s
switch
• W iring a n d /o r c o n
nector from 2B
term inal to ignition
switch
• Park/Neutral
switch
• Ignition switch
2C L o c k u p so le L o c k u p s o le 2C B e lo w N o lo c k u p • Lockup Solenoid
(O u tp u t) n o id v a lve n o id va lve 1.0V valve
• W iring a n d /o r co n
B+ - S lip lo c k u p - *
nector from 2C
B e lo w Lockup
term inal to lo cku p
1.0V
solenoid valve
2D P a rk/N e u tra l P a rk/N e u tra l 2D B+ D ra n g e • P a rk/N e u tra l
(Inp u t) s w itch sw itch sw itch
OV O th e r ra n g e s
(D ran g e ) • W iring and /o r co n
nector from 2D
term inal to
Park/Neutral
switch
2E 1-2 shift 1-2 sh ift 2E B+ S o le n o id v a lve ON • 1-2 shift s o le n o id

(O utp u t) s o le n o id va lve so le n o id v a lv e v a lve
• W irin g a n d /o r
OV S o le n o id va lve
c o n n e c to r fro m
O FF
2E te rm in a l to
s o le n o id 1-2 shift
va lve
2F P a rk/N e u tra l P a rk/N e u tra l 2F B+ S ra n g e • P a rk/N e u tra l

(Input) s w itc h (S sw itch sw itch
ra n g e ) • W irin g a n d /o r
OV O th e r ra n g e s
2F te rm in a l to
P a rk/N e u tra l
sw itch
46U0K1 -057
K1-41

2G 2 -3 sh ift so le 2 -3 sh ift S o le 2G G ro u n d B+ S o le n o id v a lve O N • 2-3 sh ift S o le n o id
(O u tp u t) n o id v a lv e n o id va lve va lve
2G te rm in a l to
O FF
2-3 sh ift s o le n o id
va lve
2H P a rk /N e u tra l P a rk/N e u tra l 2H B+ L ra n g e • P a rk/N e u tra l
(Inp u t) s w itc h (L sw itch sw itch
ran g e ) • W irin g a n d /o r
OV c o n n e c to r fro m
O th e r ra n g e s
2H te rm in a l to
P a rk/N e u tra l
sw itch
21 3-4 sh ift s o le 3-4 sh ift so le 21 B+ S o le n o id va lve O N • 3-4 shift S o le n o id

(O u tp u t) n o id v a lv e n o id va lve va lve
c o n n e c to r fro m 21
te rm in a l to so le
O FF
n o id va lve
(3-4 shift)
2J V e h ic le s p e e d V e h ic le s p e e d 2J* 2L A p p ro x . E n g in e s to p p e d • Pulse g e n e ra to r
(Inp u t) p u lse p u lse OV (AC) • W irin g a n d /o r
g e n e ra to r g e n e ra to r c o n n e c to r fro m
0 .1 - E n g in e ru n n in g
(P ran g e ) 2J te rm in a l to ve
1.0V
hicle s p e e d p u lse
(AC)
g e n e ra to r
2K L o c k u p c o n tro l L o c k u p co n tro l 2K G ro u n d B+ Lockup • L o c k u p co n tro l

(O u tp u t) so le n o id v a lve s o le n o id va lve so le n o id va lve
OV N o lo c k u p
c o n n e c to r from
2 K te rm in a l to
lo c k u p co n tro l
so le n o id va lve
2L G ro u n d (ve h i V e h ic le s p e e d 2L OV C o n sta n t • V e h icle s p e e d

(G ro u n d ) c le s p e e d p u lse p u lse g e n e ra to r
pu lse g e n e ra to r • W irin g a n d /o r
g e n e ra to r) c o n n e c to r from
2 L te rm in a l to
p u lse g e n e ra to r
2M 3-2 tim in g 3 -2 tim in g 2M B+ 1 - 2, 2 - 3, 3 • 3-2 tim in g so le

(O u tp u t) s o le n o id va lve so le n o id v a lve - 4, 3 - 2, 3 - n o id va lve
1 , 2 — 1 shift or • W irin g a n d /o r
se le ct R ra n g e c o n n e c to r fro m
fro m o th e r ra n g e s 2M te rm in a l to
3-2 tim in g s o le
OV O th e r th a n a b o v e
n o id va lve
....
* C h e c k th e 2J (v e h ic le s p e e d p u lse g e n e ra to r) te rm in a l v o lta g e b y u sin g th e A C ran g e .
K 1-42
2S 2Q 20 2M 2K 21 2G 2E 20 2A 1M 1K 11 1G 1E 1C 1A
10
2T 2R 2 P 2N 2L 2J 2H 2F 2D 2B 1N 1L 1J 1H 1F 1D 1B
1P

2N L in e p re s s u re L in e p re s s u re 2N G ro u n d A p p ro x . T h ro ttle va lve • L in e p re s s u re
(O utp u t) s o le n o id v a lv e so le n o id va lve 8 .0 V c lo s e d th ro ttle p o si S o le n o id v a lv e
tio n (e n g in e • W irin g a n d /o r
run n in g ) c o n n e c to r fro m
2 N te rm in a l to
A p p ro x . T h ro ttle v a lv e w id e
lin e p re s s u re
1.6V o p e n th ro ttle (en
so le n o id v a lv e
g in e ru n n in g )
20 B a tte ry R O O M fu se 20 B+ C o n sta n t • W irin g a n d /o r
(b a c k u p ) c o n n e c to r fro m
2 0 te rm in a l to
R O O M fu se
•R O O M fu s e
2P G ro u n d AT F 2P OV C o n sta n t •A T F therm osensor
(G ro u n d ) (p o w e rtra in th e rm o s e n s o r • W irin g a n d /o r
c o n tro l m o d u le c o n n e c to r fro m
(T ransaxle) 2 P te rm in a l to
a n d A T F th e r A T F th e r
m o se n so r) m o se n so r
2Q B a tte ry M ETER fu se 20 B+ Ig n itio n sw itch ON • W irin g a n d /o r
2 0 te rm in a l to
OV Ig n itio n sw itch O FF
M E T E R fu s e
•M E T E R fu se
2R B a ro m e tric P o w e rtra in 1R A bove A tm o s p h e ric • W irin g a n d /o r

(Inp u t) a b s o lu te c o n tro l a p p ro x . p re ssu re m o re c o n n e c to r fro m
p re ssu re m o d u le 3 .5 V th a n 8 9 .6 kPa 1 R te rm in a l to
s e n so r (E n g in e ) [6 7 2 m m H g , 2 6 .5 p o w e rtra in c o n tro l
in H g ) (b e lo w m o d u le (E n g in e )
a p p ro x . 1 ,5 0 0 m 2 A te rm in a l
(4,9 2 1 ft) )
B e lo w A tm o s p h e ric p re s
a p p ro x . su re less th a n 89 .6
3 .5 V kP a (6 7 2 m m H g ,
2 6 .5 in H g ) (ab o ve
a p p ro x . 1 ,5 0 0 m
(4,9 2 1 f t) )
2S B a tte ry M E T E R fu se 2S B+ Ig n itio n sw itch O N • W irin g a n d /o r

OV Ig n itio n sw itch O FF
2S te rm in a l to
M ETER fu se
• M ETER fu se
2T T h ro ttle p o s i T h ro ttle p o s i 2T 0.1 — T h ro ttle va lve • W irin g a n d /o r

(Inp u t) tio n se n so r tio n s e n so r 1.1V clo s e d th ro ttle p o si c o n n e c to r fro m
(TVO) tio n clo se d 2T te rm in a l to
th ro ttle p o sitio n
3 .1 - T hro ttle va lve w id e
se n so r
4 .4 V o p e n th ro ttle o p e n
• T h ro ttle p o sitio n
se n so r
46U0K1-059
K1—43
Replacement
2. Remove the side wall. (Refer to Body Electrical
3. Disconnect the powertrain control module (transaxle) con
nector.
4. Remove the bolts shown in the figure, and remove the
powertrain control module (transaxle).
5. Install the new powertrain control module (transaxle).
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf]
6. Connect the powertrain control module (transaxle).

7. Install the side wall. (Refer to Body Electrical Troubleshoot
ing segment Section C1.)
SELECTOR INDICATOR LAMP

Inspection
tor indicator lamp of the instrument cluster are aligned.
2. If not as specified, check the Park/Neutral switch, and the
selector indicator lamp.
46U0K1-062
3. Check continuity of the terminals.
C o n n e c to r te rm in a l
P osition
1K 3A 2A 2E 2B 2D 2C 2F
P O— —O
R o— —O
N —0
D o— L h i- -O
S o— H #--- —O
I ■
O — O : C o n tin u ity
4. If not as specified, replace the selector indicator lamp bulb

or instrument cluster.
5. Install the instrument cluster. (Refer to Body Electrical
K 1 -4 4
TRANSAXLE K1
TRANSAXLE
TRANSAXLE UNIT (REMOVAL)
Preparation
SST
49 G 017 5A 0 For 49 G 017 503 For

s u p p o rt o f e n g in e s u p p o rt o f e n g in e
S u p p o rt, e n g in e ^ Hook
V (Part of
4 9 G 017 5A0)
4 9 G 0 1 7 501 For 49 G 030 455 fT '7 7 /& l\ For

s u p p o rt o f e n g in e h o ld in g s id e g e a r
B ar H o ld e r, diff. sid e ___
(P art of
49 G 017 5A0) 9ear
49 G 017 502 p . For 49 0118 850C F or

s u p p o rt o f e n g in e rem o va l o f tie rod
S u p p o rt « Puller, ball jo in t end
(P art of
49 G 017 5A0) I
16EQKX-104
Removal
The oil pan could contain small chips, shavings, and other particles helpful in checking the condition of the
transaxle and diagnosing certain problems.
To ensure that all foreign particles stay in the oil pan, make sure that the transaxle is never tipped completely
over while the oil pan is still installed.
2. Raise the vehicle on a vehicle hoist.
3. Drain the ATF into a suitable container.
5. After removal, remove the oil pan to check the condition of the transaxle.
46U0K1-064
K1 TRANSAXLE
TRANSAXLE K1
46U0K1-065
1. Battery 23. Transverse member

2. Battery carrier 24. Exhaust pipe
3. Fresh air duct 25. Lower arm
4. Air cleaner assembly Removal Note.......................... page K1-48
5. Clip 26. Tie rod end
6. Selector cable Removal Note.......................... page K1-48
Removal Note...........................page K1-48 27. Stabilizer control link
7. Bolt 28. Drive shaft
8. Park/Neutral switch connector Removal Note.......................... page K1-48
9. Solenoid valve connector 29. Joint shaft
10. Harness bracket 30. Engine mount rubber No.5
11. Ground 31. Engine mount No.1 bolts
12. Nut 32. Engine mount member
13. Fuel filter mounting nuts Removal Note.......................... page K1-49
14. Vehicle speed sensor connector 33. Drive shaft
15. Vehicle speed pulse generator connector Removal Note.......................... page K1-48
16. Ground 34. Undercover
17. Bolt 35. Torque converter nuts
18. Engine mount stay Removal Note.......................... page K1-49
19. Starter 36. Engine mount No.4
20. Oil hose 37. Transaxle
21. Wheel and tire Removal Note.......................... page K1-50
22. Splash shield 38. Engine mount No.2
K1—47
K1 TRANSAXLE
Removal Note
Selector cable
1. Disconnect the selector cable from the manual shaft lever.
2. Pull out the selector cable from the cable bracket and re
move it.
36U0KX-322
46U0K1-Q66
Tie rod end
Caution
• The sharp edges of the SST can slice the tie rod end
dust boot. Install the SST so that the sharp edges
are between the dust boot and the knuckle.

SST
Drive shaft
1. Remove the clip.
nuts.
16E0KX-109
K 1-4 8
TRANSAXLE K1
3. Separate the drive shaft (right side) from the joint shaft by
using a brass bar and a hammer.
Caution
slice or puncture the oil seal.
Be careful when removing the drive shaft from the
transaxle.
4. Separate the left-side drive shaft from the transaxle by pry

1 ing with a bar inserted between the outer ring and the trans
axle, as shown in the figure.
46U0K1 -068
6. Install the SST into the transaxle to hold the side gear.
Engine mount member

1. Support the engine by using the SST before removing the
engine mount member.
Torque converter nuts

Hold the drive plate and remove the torque converter nuts.
46U0K1-069
K 1-49
K1 TRANSAXLE
Transaxle
1. Loosen the SST (engine support) and lean the engine to
ward the transaxle.
16E0KX-118
46U0K1-070
TRANSAXLE K1
TRANSAXLE UNIT (DISASSEMBLY)
Preparation
SST
49 0107 680A
E n a in e s ta n d
0
A
1 For
d is a s s e m b ly o f
tra n sa xle
4 9 G 0 1 9 0A0
H a n g e r, tra n s a x le
,___
IV , k
For
d is a s s e m b ly of
tra n sa xle
s)
4 9 G 0 1 9 001 For 49 G 019 002 For

d is a s s e m b ly o f d is a s s e m b ly of
Body S T • |\ tra n s a x le Stay tra n sa xle
(P a rt of (P a rt of
4 9 G 0 19 0 A 0 ) 4 9 G 0 1 9 0A 0)
49 G 019 003 For 49 G 019 0A7A For

d is a s s e m b ly of d is a s s e m b ly of
tra n sa xle C o m p re s s o r set, lo w a n d reve rse
re tu rn s p rin g < b ra k e pisto n
4 9 G 0 1 9 0A0)
Vile
49 G 019 028 For 49 G 019 029 For

d is a s s e m b ly of d is a s s e m b ly of
lo w a n d reverse lo w a n d reve rse
£ , * aas5a® = ® b ra k e p isto n b ra k e pisto n
49 G 019 0A7A) 49 G 019 0A7A) ^ ----------
49 G 019 030 For 4 9 FT01 361 r For

rem o va l of
1
d is a s s e m b ly of
P late ( O J se rvo b e a rin g o u te r
(P art o f K A race
49 G 019 0A7A) N Q --------
36U0KX-297
K1 TRANSAXLE
Precaution
General notes:
1. Disassemble the transaxle in a clean area (dustproof work space) to prevent entry of dust into the
mechanisms.
2. Inspect the individual transaxle components in accordance with the QUICK DIAGNOSIS CHART during
disassembly. (Refer to page K1-192.)
3. Use only plastic hammers when applying force to separate the light alloy case joints.
4. Never use rags during disassembly; they may leave particles that can clog fluid passages.
5. Several parts look alike; organize them so they do not get mixed up.
6. Disassemble the control valve assembly and thoroughly clean it when a clutch or brake band is burnt
or when the ATF has degenerated.
Cleaning notes:
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before disassembly.
2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and pas
sages with compressed air, and verify that there are no obstructions.
3. Wear eye protection when using compressed air to clean components.
46U0K1-071
TRANSAXLE K1
Components
46U0K1-072
1. Torque converter 9. Oil strainer

Inspection.................................page K1-65 10. Control valve body cover
2. Oil pump shaft 11. Coupler assembly
3. ATF dipstick and oil filler tube 12. Control valve body
4. Vehicle speed pulse generator Disassembly / Inspection....... page K1-107
Inspection.................................page K1-33 Assembly............................... page K1-125
5. Park/Neutral switch On-vehicle removal /
Inspection................................. page K1-30 installation............................ page K1-135
Adjustment...............................page K1-32 13. Oil pump
6. Breather hose Disassembly / Inspection /
7. Oil pipe Assembly............................. page K1- 68
8. Oil pan
K1—53
K1 TRANSAXLE
46U0K1 -073
1. Piston stem 6. Anchor strut and shaft

2. Snap ring 7. Band servo
3. Clutch assembly 8. One-way clutch 2 and carrier hub assembly
Preinspection...............................page K 1-72 Preinspection........................... page K1-84
Disassembly / Inspection / Disassembly / Inspection /
Assembly................................page K1-73 Assembly................................page K1-84
4. 2-4 brake band 9. Friction plate
Disassembly / Inspection / 10. Snap ring
Assembly................................page K1-94 11. Internal gear
On-vehicle adjustment............. page K1-97 12. 3-4 clutch
5. Small sun gear and one-way clutch 1 Preinspection........................... page K1-86
Preinspection............................page K1-81 Disassembly / Inspection /
Disassembly / Inspection / Assembly................................page K1-97
Assembly................................page K1-81 13. Turbine shaft
K 1-5 4
TRANSAXLE K1
Components (Cont’d)
46U0K1-074
1. Transaxle case 4. Plug, packing, spring, and detent ball

2. Output shell 5. Bracket
3. Low and reverse brake 6. Manual shaft and manual plate
Preinspection............................ page K1-90 7. Actuator support
Disassembly / Inspection / 8. Parking assist lever
Assembly.................................page K1-91 9. Parking pawl
K1 TRANSAXLE
46U0K1-O75
1. Differential 8. Idler gear

Preinspection.......................... page K1-138 Disassembly / Inspection /
Disassembly / Inspection / Assembly...............................page K 1 - 99
Assembly...............................page K1-139 9. Output gear
2. 2-3 accumulator Disassembly / Inspection /
Disassembly / Inspection / Assembly...............................page K1-102
Assembly...............................page K 1 - 66 10. Bearing cover assembly
3. Orifice check valve spring Disassembly / Inspection /
Inspection................................page K 1- 67 Assembly...............................page K1-104
4. Orifice check valve 11. Bearing races
5. Roll pin 12. Adjustment shim (bearing preload)
6. Baffle plate Adjustment..............................page K1-142
7. Bearing housing 13. Oil seal
On-vehicle replacement......... page K1-106
14. Converter housing
TRANSAXLE K1
Disassembly Procedure
Note
• The oil pan could contain small chips, shavings, and other
particles helpful in checking the condition of the trans
axle and diagnosing certain problems. To ensure that all
foreign particles stay in the oil pan, make sure that the
transaxle is never tipped completely over while the oil pan
is still installed.
• Remove the torque converter, and immediately turn it so
that the hole faces upward.
46U0K1-076
This will help keep any remaining fluid from spilling.
1. Remove the torque converter from the converter housing.
2. Pull out the oil pump shaft by hand.
16E0KX-127
3. Remove the ATF dipstick and oil filler tube.
4. Remove the O-ring from the oil filler tube.
5. Remove the breather hose.
16E0KX-128
6. Assemble the SST.
49 G019 OAO
49 0107 680A
16E0KX-129
7. Attach suitable hangers to the oil pump as shown.
16E0KX-130
K 1-5 7
K1 TRANSAXLE
Warning
• Although the stand has a self-locking brake system,
there is a possibility that the brake may not hold
when the transaxle is held in a lopsided position on
the stand. This would cause the transmission to turn
suddenly, causing serious injury. Never keep the
transaxle tilted to one side. Always hold the rotat
ing handle firmly when turning the transaxle.
16E0KX-132
9. Remove the vehicle speed pulse generator, and park/neu
tral switch.
10. Remove the O-ring from the vehicle speed pulse generator.
46U0K1-CI78
11. Remove the connector bolt.
12. Remove the packings, oil pipe, spring, and steel ball.
46U0K1-079
13. Remove the oil pan and gasket.
Examine any material found in the pan or on the magnet
to determine the condition of the transaxle.
Clutch facing material....... Drive plate and brake band
wear
Steel (magnetic)................. Bearing, gear, and driven
plate wear
Aluminum (nonmagnetic)... Bushing of cast aluminum
part wear
If large amounts of material are found, replace the torque
converter and carefully check the transaxle for the cause.
46UQK1-080
K 1-5 8
TRANSAXLE K1
14. Remove the oil strainer and O-ring.
46U0K1-081
15. Remove the control valve body cover and gasket.
46U0K1-082
16. Disconnect the solenoid connectors and ATF thermosen
sor connector.
17. Remove the coupler assembly.
18. Remove the O-ring from the coupler assembly.
46U0K1-083
19. Loosen the indicated bolts evenly and gradually.
20. Remove the control valve body as an assembly.
46U0K1-084
21. Remove the oil pum p and gasket.
46U0K1-085
K 1-59
K1 TRANSAXLE
22. Remove the clutch assembly.
(1) Remove the turbine shaft snap ring.
(2) Pull the reverse forward drum and remove the clutch
assembly.
23. Remove the small sun gear and one-way clutch 1.
24. Remove the 2-4 brake band, and hold it together with a
piece of wire as shown the figure.
25. Pull the anchor shaft while holding the anchor strut, then
remove the strut.
46U0K1-089
K 1 -6 0
TRANSAXLE K1
26. Remove the piston stem from the band servo.
27. Remove the band servo.

49 G019 028
(1) Remove the snap ring by using the SST.
(2) Remove the band servo and spring.
49 G 019 030
49 G 019 029
46U0K1-091
28. Remove the one-way clutch 2 and carrier hub assembly.
(1) Remove the snap ring.
46U0K1-092
(2) Remove the one-way clutch 2 together with the carrier
hub assembly.
(3) Remove the friction plate.
46U0K1-093
K1-61
K1 TRANSAXLE
(2) Remove the internal gear from the output shell.
16E0KX-151
30. Remove the 3-4 clutch assembly.
(1) Remove the O-ring from the turbine shaft at the con
verter housing side.
46U0K1-094
(2) Pull out the turbine shaft to remove the 3-4 clutch as
sembly.
(3) Remove the 3-4 clutch assembly.
16E0KX-153
31. Remove the bolts, and remove the transaxle case by tap
ping lightly with a plastic hammer.
46U0K1-095
32. Remove the output shell from the output gear.
46U0K1 -096
K 1-6 2
TRANSAXLE K1
33. Remove the manual shaft and manual plate.
(1) Remove the plug, packing, spring, and detent ball.
(2) Remove the bracket.
16E0KX-157
(3) Loosen the nut and pull out the manual shaft.
(4) Remove the nut, washer, spacer, and manual plate.
16E0KX-158
34. Remove the actuator support.
46U0K1-098
35. Remove the snap ring and remove the parking assist lever.
46U0K1-099
K 1-63
K1 TRANSAXLE
36. Remove the parking pawl.
(1) Remove the snap ring.
(2) Pull the parking shaft, and remove the spring and park
ing pawl.
46U0K1-100
37. Remove the differential assembly.
46U0K1-101
38. Remove the 2-3 accumulator.
39. Remove the orifice check valve spring and orifice check
valve.
46U0K1-102
40. Remove the bearing housing.
(1) Remove the bolt indicated in the figure for access to
the roll pin.
(2) Remove the roll pin by using a pin punch.
(3) Remove the baffle plate.
(4) Remove the bearing housing by tapping lightly with a
plastic hammer.
46U0K1-103
Caution
• Support the idler gear and output gear with one
hand to keep them from falling.
41. Remove the idler gear and output gear by tapping out from
the torque converter side.
46U0K1-104
K 1-64
TRANSAXLE K1
42. Remove the bearing cover assembly.
(1) Remove the converter housing from the SST (transax
le hanger).
(2) Remove the bearing cover bolts.
46U0K1-105
Caution
• Support the bearing cover with one hand to keep
them from foiling.
(3) Press the bearing cover assembly out of the converter

housing by using a suitable pipe [approx. 80mm [3.1
in) dia].
46U0K1-106
43. Press out the bearing races by using the SST.
BEARING RACE
TORQUE CONVERTER
The torque converter is welded together and cannot be dis
assembled.
46U0K1-107
Inspection
1. Check the outer part of the converter for damage or cracks,
and replace if necessary.
2. Check whether there is any rust on the pilot hub of the con
verter or on the boss. If there is any, remove it completely.
3. Measure the bushing of the converter boss. Replace the
converter assembly if the bushing is excessively worn.
Bushing inner diameter

Standard: 53.030mm [2.0878 in)
Maximum: 53.075mm [2.0896 in)
16E0KX-169
Wash Inside of Converter
1. Drain any ATF remaining in the converter.
2. Pour in ATF [approx. 0.5 L [0.5 US qt, 0.4 Imp qt}].
3. Shake the converter to clean the inside. Pour out the ATF.
4. Pour in ATF again.
5. Shake the converter to clean the inside. Pour out the ATF.
46U0K1-108
K 1-65
K1 TRANSAXLE
2-3 ACCUMULATOR
Disassembly / Inspection / Assembly
3. Assemble in the reverse order of disassembly, referring to Assembly Procedure.
APPLY SPECIFIED ATF TO INDIVIDUAL PARTS
36U0KX-071
1. Snap ring 5. 2-3 accumulator piston

2. Stopper plug 6. 2-3 accumulator body
3. O-ring Inspect for wear and damage
4. 2-3 accumulator spring
Inspection................ below
Inspection
2-3 accumulator spring
1. Measure the spring free length.
Specification
Outer diameter Free length Wire diameter
No. of coils
mm (in) mm (in) mm (in)
11.5 (0.453) 77.7 (3.06) 23.3 1.4 (0.055)
2. If not as specified, replace the spring.
Assembly procedure
1. Apply ATF to the large and small seal rings and install them
on to the accumulator piston.
Seal ring inner diameter

Large seal ring: 23.6mm (0.929 in)
Small seal ring: 14.6mm (0.575 in)
2. Install the 2-3 accumulator piston.
16E0KX-173
K 1-66
TRANSAXLE K1
3. Install the spring to the piston.
4. Install the stopper plug.
(1) Apply ATF to the O-ring and install it onto the stopper
plug.
O-ring inner diameter: 23.7mm (0.933 in)
(2) Install the stopper plug.
36U0KX-323
5. Install the spring to the piston.
6. Apply ATF to a new O-ring and install it onto the stopper
plug.
7. Install the stopper plug into the accumulator body by ap
plying even pressure to the perimeter of the stopper plug
and accumulator piston.
8. Install the snap ring while holding in the stopper plug.
46U0K1-110
Inspection
Orifice check valve spring
Specification
No. of coils
8 .0 ( 0 .3 1 5 ) 1 3 .0 ( 0 .5 1 2 ) 3 .5 0 .4 ( 0 .0 1 6 )
46U0K1-111
K1 TRANSAXLE
OIL PUMP
1. Bearing race 7. Plug

Inspect bearing for scoring and scratches 8. Packing
2. Seal rings 9. Spring
3. Oil pump cover Inspection................................. page K1-69
Disassembly Note.............. ................ below 10. Spool
4. Oil pump flange Inspection................................. page K1-69
5. Inner rotor 11. Oil pipe
Disassembly N ote............. page K1-69 12. Packing
Inspection........................... page K1-69 13. Oil pump housing
6. Outer rotor Inspection................................. page K1-69
Disassembly Note............. page K1-69
Inspection........................... page K1-69
Disassembly note
Oil pump cover
1. Loosen the mounting bolts evenly in the order shown.
2. Remove the oil pump cover from the oil pump housing.
16E0KX-177
K 1-6 8
TRANSAXLE K1
Inner rotor, outer rotor
Mark the outer and inner rotors without scratching or dent
ing them, and remove them from the oil pump housing.
46U0K1-113
Inspection
Oil pump housing, outer rotor, inner rotor
1. Measure the clearance between the end of the oil pump
housing and the outer rotor and inner rotor at four places
along their circumferences.
Clearance
Standard: 0.02—0.04mm (0.0008—0.0015 in)
Maximum: 0.05mm (0.0019 in]
2. If not as specified, replace the pump assembly.
3. Measure the clearance between the oil pump boss and the
inner rotor.
Oil clearance
Standard: 0.040—0.115mm (0.0016—0.0045 in}
Maximum: 0.125mm (0.0049 in}
4. If not within the specification, replace the oil pump assembly.
36U0KX-Q73
Spring
Specification
No. of coils
1 3 .0 ( 0 .5 1 2 ) 5 3 .0 ( 2 .0 9 ) 12.0 1.2 ( 0 .0 4 7 )
46U0K1-114
Spool
1. Measure the spool diameter.
Outer diameter
Standard:
13.970—13.980mm (0.5500—0.5503 in}
Minimum: 13.970mm (0.5500 in}
2. If not as specified, replace the oil pump assembly.
16E0KX-182
K 1-69
K1 TRANSAXLE
Assembly procedure
1. Install a new packing and the oil pipe.
Tightening torque:
16—23 N m {1.6—2.4 kgf m, 12—17 ft-lbf}
16E0KX-183
2. Apply ATF to the spool.
3. Install the spool and spring into the oil pump housing.
4. Verify that the spool moves smoothly.
5. Install a new packing and the plug.
Tightening torque:
3 2 - 4 7 N m {3.2—4.8 kgf m, 24—34 ft-lbf}
46U0K1-115
6. Apply ATF to the outer and inner rotors and oil pump flange.
7. Align the marks and install the outer and inner rotors.
8. Install the oil pump flange.
46U0K1-116
9. Mount the oil pump cover onto the oil pump housing.
10. Tighten the bolts evenly and gradually in the order shown.
Tightening torque:
8.1—10.9 N m {82—112 kgf cm, 72—97 in-lbf}
46U0K1-117
46U0K1-118
K 1-7 0
TRANSAXLE K1
12. Apply ATF to the new seal rings and install them onto the
oil pump cover.
Seal ring inner diameter: 55.9mm (2.20 in]
46U0K1-119
13. Apply petroleum jelly to the bearing race and secure it onto
the oil pump cover.
Bearing race outer diameter: 88.0mm {3.46 in}
46UQK1-120
CLUTCH ASSEMBLY
Preparation
SST
49 G 019 0A 7A For 4 9 G 0 1 9 0 24 For

d is a s s e m b ly / d is a s s e m b ly /
C o m p re s s o r set, a s s e m b ly of a sse m b ly of
re tu rn s p rin g co a s tin g c lu tc h reve rse c lu tc h
a n d reve rse 49a G 0 1 9 0 A 7 A )
clu tc h
49 G 019 025 @ I For 49 G 019 026 For

Body B n Q -, a s s e m b ly of Plate a sse m b ly of
(P art o f L I \ c o a s tin g c lu tc h (Part of co a s tin g c lu tc h
49 G 019 0A7A) 49 G 019 0A7A) a n d reverse
clu tch
4 9 G 0 19 0 2 7 For 49 G 019 029 ^ \ For

A tta c h m e n t A a s s e m b ly of a s s e m b ly o f
(Part of c o a s tin g c lu tc h (Part of co a s tin g c lu tc h
4 9 G 0 19 0 A 7 A ) a n d reve rse 49 G 019 0A7A) a n d reverse
c lu tc h clu tch
16E0KX-190
K1—71
K1 TRANSAXLE
Preinspection
Reverse, forward, coasting clutch operation
1. Set the clutch assemblies onto the oil pump.
2. Check the clutch operation by applying compressed air
through the fluid passages shown.
Air pressure: 390 kPa (4.0 kgf/cm2, 57 psi) max.
16E0KX-191
Clutch clearance
Reverse clutch
1. Measure the clearance between the retaining plate and the
drive plate. Make several measurements and calculate the
average value.
Clearance: 1.5— 1.8mm {0.059—0.071 in)

3. Select and install the correct snap ring when assembling.
46U0K1-121
Forward clutch
snap ring. Make several measurements and calculate the
average value.
Clearance: 1.0—1.2mm {0.039—0.047 in)

46U0K1-122
Coasting clutch
1. Remove the snap ring, retaining plate, drive plates, driven
plates and dished plate of the forward clutch.
average value.
Clearance: 1.0—1.2mm {0.039—0.047 in)

46U0K1-123
K1—72
TRANSAXLE K1
2. Inspect all parts, and repair or replace as necessary.
46U0K1-124
1. Thrust bearing 13. Coasting piston

Inspect for dam age and rough rotation Disassembly Note................... page K1-74
—Forward clutch— Inspection.................................page K1-75
2. Snap ring 14. Outer seal
3. Retaining plate 15. Inner seal
4. Drive and driven plates 16. Outer seal
Inspect for wear and burning 17. Seal rings
Inspection.....................................page K 1 -7 5 —Reverse clutch—
5. Dished plate 18. Snap ring
—Coasting clutch— 19. Retaining plate
6. Snap ring 20. Drive and driven plates
7. Retaining plate Inspect for wear and burning
8. Drive and driven plates Inspection.................................page K1-75
Inspect for wear and burning 21. Snap ring
Inspection.....................................page K 1 -7 5 Disassembly Note................... page K1-74
9. Dished plate 22. Return spring stopper
10. Snap ring 23. Piston return spring
Disassembly N o te ......................page K 1 -7 4 24. Reverse piston
11. Spring and retainer assembly Disassembly Note................... page K1-75
Inspection.....................................page K 1 -7 5 Inspection................................ page K1-76
12. Coasting clutch drum 25. Seal rings (inner and outer)
Disassembly N o te ......................page K 1 -7 4 26. Reverse forward drum
K 1-73
K1 TRANSAXLE
Disassembly note
Snap ring (Coasting clutch)
Caution
• Depress the piston return spring only enough to re
move the snap ring. Overpressing will damage the
retainer assembly edges.
1. Install the SST in the coasting clutch drum as shown.

2. Compress the spring and retainer assembly.
49 G019 027 3. Remove the snap ring.
46U0K1-125 4. Remove the SST, and remove the spring and retainer as
sembly.
Coasting clutch drum

1. Set the reverse forward drum onto the oil pump.
2. Remove the coasting clutch drum from the reverse forward
drum by applying compressed air through the fluid passage.
Air pressure: 390 kPa {4.0 kgf/cm2, 57 psi) max.
16E0KX-197
Coasting piston
Remove the coasting clutch piston from the coasting clutch
drum by applying compressed air through the fluid passage.
16E0KX-198
Snap ring (Reverse clutch)
Caution
• Depress the piston return spring only enough to re
move the snap ring. Overpressing will damage the
1. Install the SST in the reverse forward drum as shown.

2. Compress the piston return spring.
46U0K1-126
3. Remove one end of the snap ring from the groove with snap
ring pliers.
16E0KX-200
TRANSAXLE K1
4. Remove the SST from the reverse forward drum.
5. Remove the snap ring by using a screw driver.
16E0KX-201
Reverse piston
1. Place the reverse forward drum on the oil pump.
2. Remove the reverse piston by applying compressed air
through the fluid passage.
16E0KX-202
inspection
Drive plates
1. Measure the facing thickness in three places and calculate
the average value.

Minimum: 1.4mm {0.055 in)
2. If not within the specification, replace the drive plates.
36U0KX-075
Spring and retainer assembly
1. Measure the free length of the spring assembly and check
for deformation.
Free length: 20.6mm {0.811 in)
2. If not within the specification, replace the spring and retainer

assembly.
46U0K1-127
Coasting piston
1. Verify that there is no air leakage when applying compressed
air through the oil hole opposite the return spring.
2. Verify that there is air flow when applying compressed air
through the oil hole on the return spring side.
3. Replace the coasting piston if damaged of malfunctioning.

L^ J
46U0K1-128
K 1-75
K1 TRANSAXLE
Reverse piston
3. Replace the reverse piston if damaged of malfunctioning.
46U0K1-129
Assembly procedure
Reverse clutch
1. Install the reverse piston.
(1) Apply ATF to the inner and outer faces of the seals and
install them to the reverse piston.

Inner seal: 160.5mm {6.319 in)
Outer seal: 188.0mm {7.402 in}
36U0KX-077
(2) Face the outer seal lip toward the inside by gently roll
ing it down around the circumference for easier instal
lation into the reverse forward drum.
(3) Install the reverse piston by pushing evenly around the
circumference, being careful not to damage the seal
rings.
16E0KX-208
2. Install the piston return spring with the tabs facing up ward
away from the reverse piston.
3. Install the return spring stopper with the step facing upward.
36U0KX-327
4. Install the snap ring half-way down the reverse forward drum
as shown.
TRANSAXLE K1
5. Install the SST on the reverse forward drum.
Caution
• Depress the piston return spring only enough to in
stall the snap ring. Overpressing will damage the
6. Compress the piston return spring assembly.

7. Install the snap ring by using a screwdriver.
8. Remove the SST.
46U0K1-130
9. Install the drive and driven plates in the following order.
Driven-Drive-Driven-Drive.
10. Install the retaining plate.
11. Install the snap ring by using a screwdriver.
12. Measure the reverse clutch clearance.
(1) Measure the clearance between the retaining plate and
the drive plate.
(2) If the clearance is not within the specification, adjust it
by selecting a proper snap ring from below.
Reverse clutch clearance:

1.5—1.8mm (0.059—0.071 in}
Snap ring sizes

mm [in]
2.0 (0.079) 2.2 (0.087) 2.4 (0.094)
2.6 (0.102) 2.8 (0.110) —
Coasting clutch
1. Install the coasting clutch drum.
(1) Apply ATF to the inner and outer faces of the seals, and
install them onto the coasting clutch drum.
16E0KX-213
Inner seal: 71.02mm (2.796 in}
Outer seal: 137.0mm (5.394 in}
lation into the reverse forward drum.
(3) Install the coasting clutch drum into the reverse forward
drum as shown.
36UQKX-079
16E0KX-215
K 1-77
K1 TRANSAXLE
2. Install the coasting piston.
(1) Apply ATF to the inner and outer faces of the seals and
install them onto the coasting piston.

Outer seal: 122.0mm (4.803 in)
36U0KX-080
lation into the coasting clutch drum.
16E0KX-217
(3) Install the coasting piston by pushing evenly around the
circumference being careful not to damage the outer
seal.
16E0KX-218
3. Install the spring and retainer assembly.
16E0KX-219
4. Install the SST in the coasting clutch.
Caution
• Depress the piston return spring only enough to in
stall the snap ring. Overpressing will damage the

6. Install the snap ring.
7. Remove the SST.
K1—78
TRANSAXLE K1
8. Install the dished plate with the dished side upward.
Driven-Drive-Driven-Driven-Drive
11. Install the coasting clutch snap ring in the direction shown
in the figure.
average value. If the clearance is not within specification,
adjust it by selecting a proper snap ring from below.
REVERSE Coasting clutch clearance:

SNAP RING 1.0—1.2mm {0.039—0.047 in}
COASTING CLUTCH SNAP RING

46U0K1-133
Snap ring sizes
mm (in)
1.50 (0.059) 1.65 (0.065) 1.80 (0.071)
1.95 (0.077) 2.10 (0.083) 2.25 (0.089)
36U0KX-082
Forward clutch
1. Install the dished plate with the dished side downward.
Driven-Drive-Driven-Drive-Dirven-Drive.
46U0K1-134
REVERSE CLUTCH
SNAP RING 4. Install the snap ring in the direction shown in the figure.
COASTING FORWARD
CLUTCH CLUTCH
SNAP RING SNAP RING
46U0K1-135
K1—79
K1 TRANSAXLE
adjust it by selecting a proper snap ring from below.
Forward clutch clearance:

1.0—1.2mm [0.039—0.047 in)
46U0K1-136
Snap ring sizes
mm (in)
2.00 (0.079) 2.15 (0.085) 2.30 (0.091)
2.45 (0.097) 2.60 (0.102) 2.75 (0.108)
6. Check the clutch operation as follows.

(1) Set the clutch assembly onto the oil pump.
(2) Check the clutch operation by applying compressed air
through the fluid passages shown.
7. Apply petroleum jelly to the thrust bearings, and secure them

on the reverse forward drum.
Thrust bearing outer diameter

Oil pump side: 86.0mm (3.39 in)
Small sun gear and one-way clutch side:
56.1mm {2.21 in}
16E0KX-228
TRANSAXLE K1
SMALL SUN GEAR AND ONE-WAY CLUTCH 1
Preinspection
One-way clutch 1 operation
While holding the one-way clutch outer race, verify that the
one-way clutch inner race rotates smoothly when turned
counterclockwise and locks when turned clockwise. If not
as specified, replace the one-way clutch 1.
16E0KX-229

(2 ) REPLACE
46U0K1-137
1. Thrust bearing 6. Small sun gear

Inspect for damage and rough rotation Inspection...............................page K1-82
2. Snap ring 7. Sun gear drum
3. One-way clutch inner race Inspection...............................page K1-82
4. Thrust bearing 8. Thrust bearing
Inspect for damage and rough rotation Inspect for damage and rough rotation
5. Snap ring 9. One-way clutch outer race
10. One-way clutch 1
K1—81
K1 TRANSAXLE
Inspection
Small sun gear, sun gear drum
1. Measure the small sun gear and sun gear drum inner di
ameters.
Inner diameter
Small sun gear: 24.0mm {0.945 in} max.
Sun gear drum: 33.4mm {1.31 in} max.
2. If not within the specification, replace the small sun gear
or sun gear drum.
36U0KX-085
Assembly procedure
1. Install the small sun gear into the sun gear drum.
2. Install a new snap ring.
46U0K1-138
3. Apply petroleum jelly to the thrust bearing and secure it to
the one-way clutch inner race.
Thrust bearing outer diameter: 62.5mm {2.46 in)
4. Verify that the spring cage of the one-way clutch faces to
ward the outer race as shown.
46U0K1-139
the one-way clutch 1.
Thrust bearing outer diameter: 62.5mm {2.46 in}
6. Apply ATF to the one-way clutch and one-way clutch outer

race.
7. Install the one-way clutch inner race into the one-way clutch
outer race by turning the inner race counterclockwise. If the
one-way clutch inner race turns or locks in both directions
replace one-way clutch 1.
8. Apply ATF to the one-way clutch inner race.

9. Hold the one-way clutch outer race. Verify that the inner race
rotates smoothly in the counterclockwise direction only. If
the one-way clutch inner race turns only clockwise, the
spring cage could be installed backwards.
46U0K1-141
K 1-82
TRANSAXLE K1
8. Align the splines of the one-way clutch inner race with the
splines on the small sun gear hub as shown in the figure.
46U0K1-142
10. Verify that when the small sun gear is held, the one-way
clutch outer race turns smoothly and only clockwise.

the sun gear drum.
Thrust bearing outer diameter: 72.0mm (2.83 in}
K 1-8 3
K1 TRANSAXLE
ONE-WAY CLUTCH 2 AND CARRIER HUB ASSEMBLY
ONE-WAY CLUTCH Preinspection
While holding the one-way clutch inner race, verify that the
one-way clutch rotates smoothly when turned clockwise and
locks when turned counterclockwise. If not as specified, re
place the one-way clutch 2.
INNER RACE
36U0KX-301

46U0K1-144
1. One-way clutch 2 3. Snap ring

Inspection.......................................... below 4. Carrier hub assembly
2. Bearing race Inspection............................... page K1-85
Inspect for wear and damage 5. Inner race (low and reverse hub)
Inspection
ONE-WAY CLUTCH One-way clutch 2
1. Inspect for detached rollers, damage, or wear.
2. Install the inner race into the one-way clutch 2, and verify
that the one-way clutch 2 turns smoothly and only clock
wise. If the one-way clutch 2 turns or locks in both direc
tions replace the one-way clutch 2. If the one-way clutch
2 turns only counterclockwise, it is installed backwards.
INNER RACE
46U0K1-145
K 1 -8 4
TRANSAXLE K1
Carrier hub assembly
(1) Damaged or worn gear and operation.
(2) Clearance between pinion washers and planetary
carrier.
Clearance: 0.2—0.7mm (0.008—0.028 in]

(3) If not within the specification, replace the carrier hub as
sembly.
36U0KX-089
Assembly procedure
1. Install the carrier hub assembly to the inner race.
36U0KX-302
36U0KX-303
3. Apply petroleum jelly to the bearing races and the thrust
bearing.
4. Install the tabs of the bearing races into the alignment holes
on each side of the one-way clutch/carrier hub assembly.
5. Install the thrust bearing to the sun gear drum side of the
one-way clutch and carrier hub assembly.
Bearing race outer diameter

Sun gear drum side: 72.0mm {2.83 in]
3*4 clutch side: 57.0mm {2.24 in]
K 1-85
K1 TRANSAXLE
3-4 CLUTCH
preparation
SST
49 G019 0A7A n For 49 G019 025 @ For

Compressor set, assembly of Body B M J assembly of
return spring 3-4 clutch (Part of { . 3-4 clutch
49 G019 0A7A) S
49 G019 026 For 49 G019 027 For

Plate assembly of Attachment A assembly of
(Part of 3-4 clutch (Part of ^ 3-4 clutch
49 G019 0A7A) 49 G019 0A7A)
49 G019 029 \ For 49 G019 012 p For

disassembly / clutch operation
assembly of Leak checker L® inspection
(Part of ( ^ \ / / / ^ 3-4 clutch
49 G019 0A7A)
16E0KX-248
Preinspection
3-4 clutch operation
1. Remove the thrust bearing.
2. Install the SST to the 3-4 clutch.
3. Check the 3-4 clutch operation by applying compressed
air as shown.
Air pressure: 390 kPa (4.0 kgf/cm2, 57 psi} max.
46U0K1-147
Clearance
replace parts as necessary.
3. Select and install the correct retaining plate when as
sembling.
Clearance: 1.3—1.5mm {0.051—0.059 in}
46U0K1-148
TRANSAXLE K1
@ ©
(jjD REPLACE
( D REPLACE
46U0K1-149
1. Thrust bearing 7. Return spring

Inspect for damage and rough rotation Inspection............................... page K1-82
2. Snap ring 8. 3-4 clutch piston
3. Retaining plate Disassembly Note.................. page K1-82
4. Drive and driven plates Inspection............................... page K1-82
Inspect for wear and burning 9. Outer seal
Inspection............................... page K1-82 10. Inner seal
5. Snap ring 11.3-4 clutch drum
Disassembly Note............................. below 12. Bearing race
6. Spring retainer Inspect for wear and damage
Disassembly Note
Snap ring
1. Install the SST to the 3-4 clutch as shown.
2. Compress the spring retainer and return spring.
3. Remove the snap ring.
4. Remove the SST, then remove the spring retainer and re
turn spring.
16E0KX-252
K 1-87
K1 TRANSAXLE
3-4 clutch piston
Remove the 3-4 clutch piston by using the SST and com
pressed air.
16E0KX-253
Inspection
Drive plates
1. Measure the facing thickness in three places, and calcu
late the average value.
Standard: 1.6mm (0.063 in}

Minimum: 1.4mm {0.055 in}
36U0KX-092
Return spring
Specifications
Outer diameter Free length No. of coils Wire diameter
mm (in) mm (in) mm [in)
83.3 (3.28) 38.7 {1.52) 1.0 5.5 (0.22)
2. If not within the specifications, replace the spring.
46U0K1-150
3-4 clutch piston
Air pressure: 390 kPa {4.0 kgf/cm2, 57 psi} max.

3. Replace the 3-4 clutch piston if damaged of malfunctioning.
46U0K1-151
Assembly Procedure
1. Install the 3-4 clutch piston.
(1) Apply ATF to the inner and outer seals, and install them
onto the 3-4 clutch piston.
(2) Install the piston by pushing evenly around the circum
ference, being careful not to damage the seal rings.

Inner seal: 59.0mm {2.32 in}
Outer seal: 105.5mm {4.154 in}
36U0KX-330
K 1-88
TRANSAXLE K1
2. Install the return spring and spring retainer.
3. Install the SST to the 3-4 clutch as shown.
Caution
• Depress the return spring only enough to install the
snap ring. Overpressing will damage the retainer as
sembly edges.
4. Compress the return spring and spring retainer.
Caution
46U0K1-152 • Do not align the snap ring end gap with the return
spring stopper.
• Do not deform the snap ring when installing it.

6. Remove the SST.
Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive.
46U0K1-153
Caution
• Do not align the snap ring end gap with the return
spring stopper.
• Do not deform the snap ring when installing it.
adjust it by selecting a proper retaining plate from below.
46U0K1-154 3-4 clutch clearance: 1.3—1.5mm {0.051—0.059 in}
Retaining plate
mm (in)
3.8 (0.15) 4.0 (0.16) 4.2 (0.17)
4.4 (0.17) 4.6 (0.18) 4.8 (0.19)
46U0K1-155
1. Install the SST as shown, and check clutch operation by
applying compressed air.
16E0KX-262
K1—89
K1 TRANSAXLE
2. Apply petroleum jelly to the thrust bearings and secure them
to both sides of the 3-4 clutch drum.
Thrust bearing outer diameter

Carrier hub side: 56.0mm {2.20 in}
Bearing race outer diameter
Output shell side: 72.0mm {2.83 in}
46U0K1-156
LOW AND REVERSE BRAKE
Preparation
SST
49 G019 0A7A For 49 G019 026 For

Compressor set, assembly of Plate assembly of low
return spring nC low and reverse (Part of (T and reverse
brake 49 G019 0A7A) brake
49 G019 027 | For 49 G019 029 \ For

Attachment A assembly of low assembly of low
(Part of and reverse (Part of s ' and reverse
49 G019 0A7A) brake 49 G019 0A7A) brake
49 G019 024 For

disassembly /
Body A assembly of low — —
(Part of and reverse
49 G019 0A7A) brake
36U0KX-305
Preinspection
Low and reverse brake operation
Check the low and reverse brake operation by applying
compressed air as shown.
46U0K1-157
Low and reverse brake clearance
replace parts as necessary.
Low and reverse brake clearance:

1.5—1.8mm {0.059—0.071 in}
3. Select and install the correct retaining plate when as
sembling.
K 1 -9 0
TRANSAXLE K1
1. Disassemble as shown in the figure, referring to Disassembly Note.
46U0K1-159
1. Snap ring 6. Spring and retainer assembly

2. Retaining plate Inspection...............................page K1-92
3. Drive and driven plates 7. Low and reverse brake piston
Inspect for wear and burning Disassembly Note.................. page K1-92
Inspection............................... page K1-92 8. Outer seal
4. Dished plate 9. Inner seal
5. Snap ring 10. Transaxle case
Disassembly Note.................. page K1-92
K1-91
K1 TRANSAXLE
Disassembly Note
Snap ring
1. Install the SST in the transaxle case as shown.
Caution
• Depress the return spring only enough to install the
snap ring. Overpressing will damage the retainer as
sembly edges.
3. Remove the snap ring.
4. Remove the SST and remove the spring and retainer as
sembly.
Low and reverse brake piston

Remove the low and reverse brake piston by applying com
pressed air through the fluid passage.
46UOK1-390
Inspection
Drive plates
1. Measure the facing thickness in three places, and deter
mine the average of the three readings.

Minimum: 1.4mm {0.055 in )
Spring and retainer assembly

1. Measure the free length of each spring and check for defor
mation.
Free length: 18.07mm {0.7114 in)
2. If not within the specification, replace the spring and retainer

assembly.
Assembly Procedure
1. Install the low and reverse brake piston.
(1) Apply ATF to the new inner and outer seals, and install
them onto the low and reverse brake piston.

Inner seal: 156.5mm {6.161 in]
Outer seal: 188.0mm {7.402 in)
lation into the case.
K1—92
TRANSAXLE K1
(3) Install the low and reverse brake piston by pushing even
ly around the circumference, being careful not to dam
age the outer seal.
16E0KX-273
2. Install the spring and retainer assembly.
16E0KX-274
3. Install the SST in the transaxle case as shown.
Caution
• Depress the spring and retainer assembly only
enough to install the snap ring. Overpressing will
damage the retainer assembly edges.
46U0K1-162
6. Remove the SST.
7. Install the dished plate as shown in the figure.
Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive
46U0K1-163
46U0K1-164
K1—93
K1 TRANSAXLE
11. Measure the clearance between the low and reverse retain
ing plate and the snap ring. Make several measurements
and calculate the average value. If the clearance is not within
specification, adjust by selecting a proper retaining plate
from below.
Low and reverse brake clearance:

1.5—1.8mm {0.059—0.071 in)
Retaining plate sizes

mm (in)
7.0 (0.276) 7.2 (0.283) 7.4 (0.291)
7.6 (0.299) — —
12. Check the low and reverse brake operation by applying

compressed air through the fluid passage as shown in the
figure.
Air pressure: 390 kPa {4.0 kgf/cm2, 57 psi] max.
2-4 BRAKE BAND (DISASSEMBLY / INSPECTION / ASSEMBLY)

Preparation
SST
49 G019 0A7A For 49 G019 028 For

Compressor set, 2-4 brake 2-4 brake
Bolt
return spring band (part of band
* 49 G019 0A7A)
49 G019 029 For 49 G019 030 For

) assembly of assembly of
Nut X :\ s ' 2-4 brake Plate f 2-4 brake
(Part of A / band (Plate of band
49 G019 0A7A) s ^ 49 G019 0A7A)
16E0KX-280
_____________________________ TRANSAXLE________ ________________ K1
46U0K1-166
1. Nut 6. Servo return spring

2. Washer Inspection........... below
3. Piston stem 7. D-ring
4. Servo retainer 8. O-ring
Assembly Note.. page K1-96 9. Band strut
5. Band servo piston 10. 2-4 brake band
Assembly Note.. page K1-96 Inspection........... page K1-96
Inspection
Servo return spring
Specifications
No. of coils
27.7 (1.09) 43.25 (1.703) 4.5 3.2 (0.13)
2. If not within specifications, replace the spring.
46U0K1-167
K 1-95
K1 TRANSAXLE
2-4 brake band
1. Remove the 2-4 brake band, and hold it together as shown
in the figure.
2. Check the 2-4 brake band for wear and burning.
3. Replace the 2-4 brake band if damage of malfunction.
Assembly note
Servo retainer, Band servo piston
Install the servo into the transaxle case.
(1) Apply ATF to a new D-ring and install it onto the band
servo piston.
D-ring inner diameter

Small D-ring: 29.4mm {1.16 in)
Large D-ring: 65.9mm {2.59 in}
(2) Assemble the servo piston and servo retainer.

46U0K1-169
(3) Apply ATF to new O-rings and install them onto the servo
retainer.
O-ring inner diameter: 72.9mm {2.87 in}
(4) Install the servo return spring and servo retainer assem
bly into the transaxle case.
(5) Press the servo retainer assembly by using the SST.
(6) Install the snap ring.
16E0KX-285
(7) Install the piston stem, w asher, a n d nut to the b a n d se rv o
piston.
Note
• Refer to page K1-162 to adjust the brake band during
transaxle assembly.
46U0K1-170
TRANSAXLE K1
2-4 BRAKE BAND (ON-VEHICLE ADJUSTMENT)
Preparation
SST
On-vehicle Adjustment
Warning
• A vehicle that is lifted but not securely supported
on safety stands is dangerous. It can slip or fall,
causing death or serious inlury. Never work around
or under a lifted vehicle if it is not securely support
ed on safety stands.
1. Disconnect negative battery cable.

2. Clean the transaxle exterior thoroughly with a steam clean
er or cleaning solvents.
4. Jack up the vehicle and support it with safety stands.
5. Drain the ATF into a container.
6. Remove the splash shield (left side).
7. Remove the transverse member.
8. Remove the engine mounting member.
9. Remove the oil pan and gasket.
46U0K1-172
10. Loosen the locknut and tighten the piston stem to the speci
fied torque.
Tightening torque:
11.8—14.7 N m {120—150 kgf cm, 105—130 in Ibf}
46U0K1-173
K 1 -9 7
K1 TRANSAXLE
11. Loosen the piston stem 1.5 turns.
12. Hold the piston stem and tighten the locknut to the speci
fied torque.
Tightening torque:
25—39 N m {2.5—4.0 kgf m, 19—28 ft-lbf)
46U0K1-174
13. Install a new gasket and the oil pan.
Tightening torque:
8.4—10.7 N m {85—110 kgf cm, 73.8—95.4 in lbf}
14. Install the engine mount bushings as shown in the figure.

15. Install the engine mount member, making sure that the No.2
installation hole.
16. Install the nuts ® a s shown.
Tightening torque
A: 67—93 N m {6.8—9.5 kgf m, 50—68 ft Ibf)
17. Loosely tighten the nut (§)as shown.

19. Tighten the bolts ® as shown.
Tightening torque
B: 75—104 N m {7.6—10.7 kgf-m, 55.0—77.3 ft-lbf}
46U0K1-176
20. Install the transverse member.
Tightening torque:
94—126 N-m {9.5—12.9 kgf m, 68.8—93.3 ft-lbf)
21. Install the splash shield (left side).

22. Pour in ATF,and with the engine idling, check the ATF lev
el and check for leaks. (Refer to page K1-27.)
and shift shock. (Refer to Road test, page K1-19.)
46U0K1-177
TRANSAXLE K1
IDLER GEAR
Preparation
SST
49 FT01 439 For 49 G019 013 For

removal / removal of
Holder, installation of Remover, bearing bearing race
idler gear shaft locknut
49 F027 0A1 For 49 F027 007 For

Installer set, bearing race Attachment 72 bearing race
bearing (Part of
49 F027 0A1)
49 0180 510B For

adjustment of
Preload bearing preload
attachment
36U0KX-306

3. Assemble in the reverse order of disassembly, referring to assembly Procedure.
APPLY SPECIFIED
ATF TO INDIVIDUAL ©
SELECTIVE
46U0K1-178
1. Locknut 6. Idler g e a r sh aft

Disassembly N ote................. page K1-100 Inspect for wear and rough rotation
2. Bearing 7. Bearing race
Inspect for wear and rough rotation Disassembly Note................. page K1-100
3. Spacer Inspect bearing surface for scoring and
4. Idler gear scratches
Inspect for wear and cracks. 8. Bearing race
5. Bearing Disassembly Note................. page K1-100
Inspect for wear and rough rotation Inspect bearing surface for scoring and
scratches
9. O-ring
K 1-99
K1 TRANSAXLE
Disassembly Note
Locknut
1. Secure the SST and the idler gear assembly in a vise.
2. Remove the locknut.
46U0K1-179
Bearing race
Remove the bearing race from the idler gear by using the
SST
16E0KX-298
Assembly Procedure
1. Press the new bearing race in by using the SST.
49 F027
16E0KX-299
2. Install the bearing onto the idler gear shaft, then install the
idler gear, spacer,and bearing.
SPACER
16E0KX-300
3. Secure the SST and the idler gear assembly in a vise.
Tightening torque:
128—176 N m {1 3 .0 -1 8 .0 kgf m, 95—130 ft Ibf}
5. Apply ATF to a new O-ring and install it onto the idler gear
shaft.
O-ring inner diam eter: 33.0m m {1.30 in)
46U0K1-180
TRANSAXLE K1
6. Secure the idler gear in a vise.
7. Use the SST to measure the bearing preload at the point
that the idler shaft starts to turn.
Preload:
0.03—0.88 N-m (0.3—9.0 kgf-cm, 0.3—7.8 in-lbf)
Pull scale reading:
0.3—8.8 N {0.03—0.90 kgf, 0.07—1.98 Ibf)
8. If the specified preload cannot be obtained within the speci

fied tightening torque, adjust by selecting the proper ad
justment spacers from below. A thicker spacer reduces the
preload, and a thinner spacer increases the preload.
Thickness of shim mm (in)
4.540 (0.179) 4.575 (0.180) 4.610 (0.181) 4.645 (0.183)
4.680 (0.184) 4.715 (0.186) 4.750 (0.187) 4.785 (0.188)
4.820 (0.190) 4.855 (0.191) 4.890 (0.193) 4.925 (0.194)
4.960 (0.195) 4.995 (0.197) 5.030 (0.198) 5.065 (0.199)
5.100 (0.201) 5.135 (0.202) 5.170 (0.204) 5.205 (0.205)
5.240 (0.206) 5.275 (0.208) 5.310 (0.209)
46U0K1-182
K1 TRANSAXLE
OUTPUT GEAR
Preparation
SST
49 G017 1AO For 49 F401 366A For

Remover set,
bearing uS**'
bearing Plate
(Part of
49G017 1A0)
G bearing
49 G019 022 For 49 G019 011 For

removal of installation of
Attachment K bearing Installer, bearing bearing
16E0KX-305

16E0KX-306
1. Seal rings 3. Bearing

2. Output gear Disassembly Note............................... below
Inspect for wear and cracks Inspect for wear and rough rotation
Disassembly note
Bearing
Remove the bearings from the output gear by using the
SST.
49 F401 366A 49 G 0 19 022
36U0KX-307
K1—102
TRANSAXLE K1
Assembly procedure
1. Press the new bearings onto the output gear by using the
SST
2. Apply ATF to new seal rings and assemble them to each

side of the output gear.
Seal ring outer diameter: 36.9mm {1.45 in}
K 1-103
K1 TRANSAXLE
BEARING COVER ASSEMBLY
Preparation
SST
16E0KX-310

16E0KX-311
1. Oil seal 3. O-ring

2. Bearing race 4. Bearing cover
Disassembly Note............................... below
Inspect bearing surface for scoring and
scratches
Disassembly note
Bearing race
Remove the bearing race by using a pin punch and a
hammer.
K 1-104
TRANSAXLE K1
Assembly procedure
1. Press the new bearing race into the bearing cover.
2. Apply ATF to a new O-ring and install it onto the bearing
cover.
O-ring inner diameter: 85.1mm {3.35 in)
16E0KX-313
3. Press a new oil seal into the bearing cover by using the
SST
16E0KX-314
K1 TRANSAXLE
OIL SEAL (TRANSAXLE)
Preparation
SST
49 G030 795 For 49 G030 796 For

installation of oil installation of oil
Installer, oil seal ^ ^ seal seal
I j
49 G030 795)
49 G030 797 For

installation of oil
Handle seal — —
(Part of
49 G030 795)
16E0KX-315
On-Vehicle Replacement
1. Remove the drive shaft and joint shaft.
2. Remove the oil seal by using a screwdriver.
3. Tap the new oil seal into the transaxle case by using the
SST
4. Install the drive shaft and joint shaft.
5. Using the SST and a hammer, tap the new oil seal in even
ly until the SST contacts the transaxle case.
46U0K1-184
TRANSAXLE K1
CONTROL VALVE BODY (DISASSEMBLY / INSPECTION)
Preparation
49 G019 031 For

V removal of
ATF
Wrench s & is ' /
thermosensor
16E0KX-317
K 1-107
K1 TRANSAXLE
Disassembly / Inspection
Caution
• Denting or scratching these components will reduce the ability of the transaxle to shift properly.
When handing these components or the valve body that contains them, be careful not drop
or hit them.
1. Disassemble in the order shown in the figure, referring to Disassembly Procedure.

2. Neatly arrange the removed parts to avoid confusing the similar parts.
Warning
• Using compressd air can cause dirt and other particles to fly out, causing injury to the eyes.
4. Clean the removed parts with cleaning solvent, and dry them with compressed air. Clean out all holes
and passages with compressed air.
46U0K1-185
1. ATF thermosensor 8. Front/premain front gasket

2. Line pressure solenoid valve 9. Premain separator plate
Inspection.................................page K1-35 10. Front/premain rear gasket
3. L o c k u p s o le n o id v a lv e 11. Rubber balls
Inspection.................................page K1-35 12. Premain control valve body
4. 3-2 timing solenoid valve Disassembly / Inspection /
Inspection.................................page K1-35 Assembly............................. page K1-114
5.1-2 shift solenoid valve 13. Jet orifices and nuts
Inspection.................................page K1-35 14. Rubber ball
6. Lockup control Solenoid valve 15. Oil strainer
Inspection.................................page K1-35 Inspect for clogging and damage
7. Front control valve body 16. Premain/main front gasket
Inspect for clogging and damage 17. Main separator plate
K 1-108
TRANSAXLE K1
O-RINQ,
REPLACE
REPLACE
46U0K1-186
18. Premain/main rear gasket 26. Main/rear rear gasket

19. Rubber balls 27. Rear separator plate
20. Oil strainer 28. M a in /re a r front g a s k e t
Inspect for clogging and damage 29. Rubber balls
21. Oil pipe assembly 30. Oil strainers
22. Oil baffle Inspect for clogging and damage
23. 2-3 shift solenoid valve 31. Rubber balls
Inspection...............................page K1- 35 32. Oil strainers
24. 3-4 shift solenoid valve 33. Main control valve body
Inspection............................... page K 1- 35 Disassembly / Inspection /
25. Rear control valve body Assembly............................. page K1-118
Disassembly / Inspection /
Assembly..............................page K1-122
K 1-109
K1 TRANSAXLE
1. Remove the ATF thermosensor by using the SST.
49 G019 031
16E0KX-320
2. Remove the line pressure, lockup, 3-2 timing, 1-2 shift, and
lockup control solenoid valves.
3. Remove the O-rings from the solenoid valves.
46U0K1-187
4. Remove the bolts indicated and remove the front control
valve body and premain separator plate and gaskets.
16E0KX-322
5. Remove the front/premain gaskets and separator plate from
the front control body.
36U0KX-116
6. R e m o v e the ru b b e r ball from the front con trol v a lv e b o d y .
16E0KX-324
K 1-110
TRANSAXLE K1
7. Remove the rubber ball from the premain control valve
body.
8. Remove the bolts and remove the premain control body

and the main separator plate and gaskets.
16E0KX-325
9. Remove the premain/main gaskets and separator from
the premain control body.
10. Remove the jet orifices and nuts from the main separator
plate.
16E0KX-326
16E0KX-328
K1-111
K1 TRANSAXLE
13. Turn the assembly over and remove the oil pipe, oil baffle,
2-3 shift and 3-4 shift solenoid valves.
14. Remove the bolts shown in the figure and remove the rear
separator plate and gaskets.
15. Remove the main/rear gaskets and separator from the rear
control valve body.
16. Remove the rubber balls and oil strainers from the rear con
trol valve body.
16E0KX-331
K 1-112
K1
MEMO
K 1-113
K1 TRANSAXLE
PREMAIN CONTROL VALVE BODY
Caution
• Denting or scratching these precisely machined components will reduce the ability of the trans
axle to shift properly. When handling these components or the valve body that contains them,
be careful not drop or hit them.
Note
• If a valve does not slide out under its own weight, place the valve body open-side down and tap on
the valve body lightly with a plastic hammer.
1. Disassemble in the order shown in the figure, noting the proper reassembly direction of the valves and
internal parts.
Warning
3. Clean all parts and bores with compressed air and apply ATF to them immediately before assembly.
46U0K1-189
K 1-114
TRANSAXLE K1
1. Spring retainer 15. Bypass valve
2. Pressure modifier accumulator spring Inspect for sticking, scoring and scratches
Inspection............................................ below 16. Bypass spring
3. Pressure modifier accumulator valve Inspection............................................below
Inspect for sticking, scoring, and scratches 17. Bolts
4. Stop pin 18. 1-2 accumulator plate
5. Stop plug 19.1-2 accumulator gasket
6. 3-2 timing valve 20.1-2 accumulator spring
Inspect for sticking, scoring, and scratches Inspection............................................below
7. 3-2 timing spring 21.1-2 accumulator piston
Inspection............................................ below 22.1-2 accumulator seal rings
8. Stop pin 23. Bolts
9. Stop plug 24. N-R accumulator plate
10. Cut back valve A 25. N-R accumulator gasket
Inspect for sticking, scoring, and scratches 26. N-D accumulator spring
11. Cut back valve B Inspection............................................below
Inspect for sticking, scoring, and scratches 27. N-D accumulator piston
12. Cut back spring 28. N-D accumulator seal rings
Inspection............ ............................... below 29. N-R accumulator piston
13. Stop pin 30. N-R accumulator spring
14. Stop plug Inspection............................................below
31. N-R accumulator seal rings
16E0KX-334
Inspection
46U0K1-190
-- Item Outer diameter Free length Wire diameter Identification

No. of coils
Spring mm (in) mm (in) mm (in) color
Pressure modifier accumulator spring 8.2 (0.32) 38.2 (1.50) 16.5 1.2 (0.047) Light green
3-2 tinning spring 8.25 (0.325) 35.4 (1.394) 12.5 0.85 (0.033) Light blue
Cut back spring 8.2 (0.32) 29.8 (1.17) 7.4 0.6 (0.02) Purple
Bypass spring 6.3 (0.25) 29.5 (1.16) 11.7 0.6 (0.02) Dark green
1-2 Small 14.8 (0.583) 81.6 (3.21) 17.7 1.7 (0.067) Gray
accumulator
spring Large 20.2 (0.795) 81.6 (3.21) 12.5 2.3 (0.091) Dark green
N-D accumulator spring 9.8 (0.39) 52.9 (2.08) 12.0 1.0 (0.039) White
N-R accumulator Small 7.2 (0.28) 60.1 (2.37) 26.2 1.0 (0.039) —
spring Large 11.2 (0.441) 56.0 (2.20) 15.2 1.6 (0.063) —
46U0K1-191
K1 TRANSAXLE
Assembly procedure
1. Apply ATF to the seal rings, and install them to the N-D ac
cumulator piston.
2. Insert the piston and N-D accumulator spring.
3. Apply ATF to the seal rings, and install them to the N-R ac
cumulator piston.
4. Insert the piston and N-R accumulator spring.
5. Insert the N-R accumulator gasket plate.

6. Tighten the plate bolt.
Tightening torque:
6.5—7.8 Nm (66—80 kgf-cm, 58—69 in-lbf)
7. Apply ATF to the seal rings, and install them onto the 1-2
accumulator piston.
8. Install the piston and 1-2 accumulator spring.
16E0KX-339
9. Install the 1-2 accumulator gasket and plate.
10. Tighten the plate bolt.
Tightening torque:
6.5—7.8 Nm (66—80 kgf-cm, 58—69 in-lbf)
' t
16E0KX-34Q
11. Install the bypass valve spring, bypass valve, stop plug,
and stop pin.
12. Install the cut back spring, cut back valve B, cut back
valve A, stop plug, and stop pin.
13. Install the 3-2 timing spring, 3-2 timing valve, stop plug,
and stop pin.
Install the pressure modifier accumulator valve, pressure
modifier accumulator spring, and spring retainer.
16E0KX-341
K 1-116
TRANSAXLE K1
K1 TRANSAXLE
MAIN CONTROL VALVE BODY
Caution
axle to shift properly. When handling these components or the valve body that contains them,
Note
internal parts.
Warning
46U0K1-192
K 1-118
TRANSAXLE K1
1. Spring retainer 17. 2-3 shift valve
2. Converter relief spring Inspect for sticking, scoring, and scratches
Inspection............................................ below 18. 2-3 shift spring
3. Converter relief valve Inspection............................................below
Inspect for sticking, scoring, and scratches 19. Stop pin
4. Stop pin 20. Stop plug
5. Stop plug 21. Coast timing spring
6. Solenoid reducing spring Inspection............................................below
Inspection............................................below 22. Coast timing valve
7. Solenoid reducing valve Inspect for sticking, scoring, and scratches
Inspect for sticking, scoring, and scratches 23. Stop pin
8. Spring retainer 24. Stop plug
9. Low reducing spring 25. Lockup shift valve A
Inspection............................................ below Inspect for sticking, scoring, and scratches
10. Low reducing valve 26. Lockup shift valve B
Inspect for sticking, scoring, and scratches Inspect for sticking, scoring, and scratches
11. Stop pin 27. Lockup shift spring
13. 1-2 shift valve 28. Stop pin
Inspect for sticking, scoring, and scratches 29. Stop plug
14. 1-2 shift spring 30. 3-4 shift valve
Inspection............................................below Inspect for sticking, scoring, and scratches
15. Stop pin 31. 3-4 shift spring
16E0KX-343
Inspection
---------------- Item Outer diameter Free length Wire diameter Identification

No. of coils
Spring — — _____ mm (in) mm (in) mm (in) color
Convertor relief spring 7.4 (0.29) 32.3 (1.27) 13.5 1.1 (0.043) —
Solenoid reducing spring 8.0 {0.31 ) 39.7 (1.56) 12.0 0.9 (0.03) Red
Low reducing spring 8.7 (0.34) 38.3 (1.51) 12.5 0.9 (0.03) Yellow
1-2 shift spring 7.4 (0.29) 36.6 (1.44) 12.0 0.8 (0.031) Purple
Coast timing spring 6.2 (0.24) 28.0 (1.10) 16.0 0.6 (0.02) Light blue
Lockup shift spring 6.0 (0.24) 40.0 (1.57) 13.8 0.5 (0.02) White
46U0K1-194
K 1-119
K1 TRANSAXLE
Assembly procedure
1. Install the 3-4 shift spring, 3-4 shift valve, stop plug, and
stop pin.
2. Install the lockup shift spring, lockup shift valve B, lockup
shift valve A, stop plug, and stop pin.
36U0KX-332
3. Install the coast timing valve, coast timing spring, stop
plug, and stop pin.
16E0KX-347
stop pin.
stop pin.
36U0KX-333
6. Install the low reducing valve, low reducing spring, spring
retainer.
7. Install the solenoid reducing valve, stop plug, and stop
pin.
8. Install the converter relief valve, converter relief spring,
and spring retainer.
16E0KX-349
TRANSAXLE K1
MEMO
K1 TRANSAXLE
REAR CONTROL VALVE BODY
Caution
axle to shift properly. When handing these components or the valve body that contains them,
Note
internal parts.
Warning
46U0K1-195
K 1-122
TRANSAXLE K1
1. Manual valve 9. Lockup control plug
Inspect for sticking, scoring and scratches 10. Lockup control valve
2. Stop pin Inspect for sticking, scoring, and scratches
3. Pressure regulator plug sleeve 11. Lockup control spring
4. Pressure regulator plug Inspection............................................below
5. Pressure regulator spring seat 12. Stop pin
6. Pressure regulator spring 13. 2-3 timing plug
Inspection............................................ below 14. 2-3 timing spring
7. Pressure regulator valve Inspection............................................below
Inspect for sticking, scoring, and scratches 15. 2-3 timing valve
8. Stop pin Inspect for sticking, scoring and scratches
36UOKX-308
Inspection
46U0K1-196
------------ Item Outer diameter Free length Wire diameter Identification

No. of coils
Spring ----- -— mm {in ) mm (in) mm (in) color
Pressure regulator spring 12.0 (0.472) 33.9 (1.34) 7.0 1.1 (0.043) —
Lockup control spring 5.8 (0.23) 33.1 (1.30) 12.6 0.55 (0.022) White
2-3 timing spring 4.7 (0.19) 22.3 (0.878) 14.0 0.65 (0.026) White
46U0K1-197
Assembly Procedure
1. Install the 2-3 timing valve, 2-3 timing spring, 2-3 timing plug,
and stop pin.
16E0KX-354
2. Install the lo c k u p control sp rin g , lo c k u p control valve, lo c k
u p con trol plu g, a n d sto p pin.
16E0KX-355
K 1-123
K1 TRANSAXLE
3. Install the pressure regulator valve, pressure regulator spr
ing, pressure regulator spring seat, pressure regulator
plug, pressure regulator plug sleeve, and stop pin.
4. Install the manual valve.
16E0KX-357
TRANSAXLE K1
CONTROL VALVE BODY (ASSEMBLY)
Preparation
SST
49 G019 031 For

v Installation
Wrench / of
ATF
thermosensor
16E0KX-358
K 1-125
K1 TRANSAXLE
1. Verify that all parts are clean and free of dust or other small particles.
2. A pply ATF to all O-rings and gaskets.
3. Assemble as shown in the figure, referring to Assembly Procedure.
46U0K1-198
1.7—2.2 N-m
[17—23 kgfcm,
6.5—7.8 N m
15—19 in-lbf]
(66—80 kgf-cm,
5 8 -6 9 In-lbf)
6.5—7.8 N-m
(66—80 kgf-cm,
5 8 - 6 9 In-lbf)
>4) NEW
1. Main control valve body 9. Rear control valve body

2. Oil strainers Bolt installation position.......... page K 1-13 0
Installation p osition.................. page K 1-12 8 10. 3-4 shift solenoid valve
3. Rubber balls 11.2-3 shift solenoid valve
Installation p osition.................. page K 1-12 8 12. Oil baffle
4. Oil strainers 13. Oil pipe assembly
Installation p osition .................. page K 1-12 8 14. Oil strainer
5. Rubber balls Installation position.................. page K 1-12 8
Installation p osition .................. page K 1-12 8 15. Rubber balls
6. Main/rear front gasket Installation position.................. page K 1-12 8
7. Rear separator plate 16. Premain/main rear gasket
8. Main/rear rear gasket
K 1-126
TRANSAXLE K1
46U0K1-199
17. Main separator plate 24. Front/premain rear gasket

18. Premain/main front gasket 25. Premain separator plate
19. Oil strainer 26. Front/premain front gasket
Installation p osition .................. page K 1-12 8 27. Front control valve body
20. Rubber ball Bolt installation position.......... page K 1-13 0
Installation p osition.................. page K 1-12 8 28. Lockup control solenoid valve
21. Jet orifices and nuts 29.1-2 shift solenoid valve
22. Premain control valve body 30. 3-2 timing solenoid valve
Bolt installation position.......... page K 1-13 0 31. Lockup solenoid valve
23. Rubber balls 32. Line pressure solenoid valve
Installation p osition .................. page K 1-12 8 33. ATF thermoswitch
K 1-127
K1 TRANSAXLE
Rubber ball, oil strainer installation positions
FRONT CONTROL VALVE BODY
PREMAIN CONTROL VALVE BODY

(MAIN CONTROL VALVE BODY SIDE) (FRONT CONTROL VALVE BODY SIDE)
16E0KX-361
K 1-128
TRANSAXLE K1
MAIN CONTROL VALVE BODY
(REAR CONTROL VALVE BODY SIDE) (PREMAIN CONTROL VALVE BODY SIDE)
OIL STRAINER
OIL STRAINER
RUBBER
BALL RUBBER BALL
» j y
RUBBER
BALL
OIL STRAINER
RUBBER BALL
REAR CONTROL VALVE BODY
OIL STRAINER
OIL STRAINER
RUBBER BALL
K 1-129
K1 TRANSAXLE
Bolt installation positions and external parts locations
16E0KX-362
Identification Bolt Length Tightening torque

mark mm in N-m [kgfcm, inlbf)
50 (2.0)
40 (1.6 )
B
30 (1.2 )
6 . 5 — 7.8
( 6 6 — 80, 5 8 — 6 9 )
20 ( 0 .7 9 )
12 ( 0 . 4 7 )
mnonnnnnnt 16 ( 0 . 6 3 )
16E0KX-363
K 1-130
TRANSAXLE K1
Assembly procedure
1. Install the oil strainers and rubber balls into the main con
trol valve body.
(Refer to Installation position, page K1-128.)
2. Install the oil strainers and rubber balls into the rear control
valve body. (Refer to Installation position, page K1-128.)
3. Set the new main/rear front gasket, rear separator plate, and
new main/rear rear gasket on the rear control valve body.
Refer to the figure to distinguish the two gaskets.
4. Set the rear control valve body onto the main control valve
body.
5. Install and hand tighten the bolts shown in the lefthand fig
ure. Each type of bolt has a different letter on its head. Match
the bolt letter with the letter stamped next to its installation
hole on the valve body. Refer to page K1-130 for bolt in
stallation position and description.
46U0K1-203
6. Install the oil strainer and rubber balls into the main control
valve body. (Refer to Installation position, page K1-128.)
K1 TRANSAXLE
7. Install the oil strainer and rubber balls into the premain con
trol valve body.
46U0K1-205
8. Install the jet orifices and nuts to the main separator plate.
Tightening torque:
1 .7 -2 .2 Nm (17—23 kgf cm, 15—19 in lbf}
16E0KX-371
9. Set a new premain/main rear gasket, main separator plate,
and new premain/main front gasket on the premain con
trol valve body. Refer to the figure to distinguish the two
gaskets.
46U0K1-206
10. Set the premain control valve body onto the main control
valve body.
11. Install and hand tighten the bolts shown in the figure. Each
type of bolt has a different letter on its head. Match the bolt
letter with the letter stamped next to its installation hole on
the valve body. Refer to page K1-130 for bolt installation
position and description.
46U0K1-208
K1—132
TRANSAXLE K1
13. Install the rubber ball into the front control valve body.
46U0K1-209
14. Set a new front/premain rear gasket, premain separator
plate, and new front/premain front gasket on the front con
trol valve body. Refer to the figure to distinguish the two
gaskets.
REAR GASKET FRONT GASKET
46U0K1-21Q
15. Set the front control valve body onto the premain control
valve body.
16. Install and hand tighten the bolts shown in the lefthand fig
ure. Each type of bolt has a different letter on its head. Match
the bolt letter with the letter stamped next to its installation
hole on the valve body. Refer to page K1-130 for bolt in
stallation position and description.
46U0K1-211
17. Install four control valve body bolts as shown for alignment.
16E0KX-379
18. Tighten the mounting bolts.
(1) Tighten the front control body.
Tightening torque:
6.5—7.8 N m (66—80 kgf cm, 58—69 in-lbf}
16E0KX-380
K 1-133
K1 TRANSAXLE
(2) Tighten the rear control valve body.
Tightening torque:
6.5—7.8 Nm (66—80 kgf cm, 58—69 in-lbf)
19. Apply ATF to new O-rings and install them onto the sole
noid valves.
20. Install the solenoid valves.
Tightening torque:
6.5—7.8 Nm (66—80 kgf cm, 58—69 in-lbf)
21. Apply ATF to new O-rings and install them onto the oil pipe
assembly.
22. Install the oil pipe assembly.
Tightening torque:
6.5—7.8 Nm (66—80 kgf-cm, 58—69 in-lbf)
23. Install the oil baffle.
Tightening torque:
6.5—7.8 Nm (66—80 kgf-cm, 58—69 in-lbf)
24. Install the ATF thermosensor by using the SST.
Tightening torque:
7.9—10.7 Nm (80—110 kgf cm, 70—95 in Ibf)
K 1-134
TRANSAXLE K1
CONTROL VALVE BODY
(ON-VEHICLE REMOVAL / INSTALLATION)
On-vehicle Removal
1. Clean the transaxle exterior throughly with a steam cleaner
or cleaning solvents.
3. Drain the ATF and engine coolant into separate suitable con
tainers.
4. Remove the splash shield.
5. Remove the oil cooler hose and radiator hose.
46U0K1-212
6. Remove the control valve body cover and gasket.
46U0K1-213
7. Disconnect the solenoid connectors and ATF thermosen
sor connector.
46U0K1-214
8. Remove the control valve body assembly.
46U0K1-215
On-vehicle installation
1. Align the manual plate and the manual valve.
46U0K1-216
K 1-135
K1 TRANSAXLE
2. Install the control valve body assembly.
Tightening torque:
10.8—14.7 Nm {110—150 kgf cm, 96—130 in-lbf)
3. Match the harness colors and connect the solenoid con

nectors and ATF thermosensor connector.
4. Install a new gasket and the control valve body cover.
Tightening torque:
8 .4 -1 0 .7 Nm {85—110 kgf cm, 74—95 in-lbf)
Caution
• If reusing the hose clamp, position it in the original
location on the hose and squeeze the clamp lightly
with large pliers to ensure a tight fit.
5. Align the marks, and slide the oil cooler hose onto the oil
cooler pipe until it is fully seated as shown.
6. Install the hose clamp onto the hose at the center of the
mark and at the angle shown.
7. Verify that the hose clamp does not interfere with any other
parts.
8. Slide the radiator hose onto the radiator pipe until it is fully
seated.
9. Install the hose clamp on the hose.
10. Squeeze it lightly with large pliers to ensure a good fit.
K 1-136
TRANSAXLE K1
11. Install the splash shield.
12. Fill the radiator and reservoir with the specified amount and
type of engine coolant. (Refer to Sections E1, E2.)
14. Pour in ATF and with the engine idling, check the ATF lev
el and check for ATF and engine coolant leakage.
and shift shock. (Refer to Road test, page K1-19.)
46U0K1-220
K 1-137
K1 TRANSAXLE
DIFFERENTIAL
Preparation
SST
49 0839 425C For 49 F401 366A For

Puller set, bearing Plate bearing
bearing
49 B092 371 For 49 F401 330B For

Attachment E bearing Installer set, bearing
bearing
49 F401 337A For

installation of
Attachment C bearing
(Part of
49 F401 330B)
36U0KX-311
Preinspection
Backlash of side gear and pinion gear
1. Before disassembly, measure the backlash of the side gears.
Backlash
Standard : 0.05—0.15mm [0.0020—0.0059 in)
Maximum : 0.50mm [0.020 in)
2. If not within the specification, replace worn and damage

parts.
36U0KX-136
TRANSAXLE K1
Note
• The bearings do not need to be removed unless you are replacing them.

j APPLY SPECIFIED ATF TO INDIVIDUAL PARTS
REPLACE
REPLACE
N m fkgf-m, ft lbf)
46U0K1-221
1. Side gear 7. Bearing

Preinspection..........................page K1-138 Disassembly Note................. page K1-140
Inspect for wear and cracks Inspect for wear and rough rotation
2. Thrust washer 8. Speedometer drive gear
3. Roll pin 9. Bearing
Disassembly Note...............................below Disassembly Note................. page K1-140
4. Pinion shaft Inspect for wear and rough rotation
5. Pinion gear 10. Gear case
Inspect for wear and cracks 11. Ring gear
6. Thrust washer Inspect for wear and cracks
Disassembly Note
Roil pin
1. Place the gear case in a vise.
2. Insert a 2.0mm {0.079 in} punch into the roll pin hole from
the ring gear side, and remove the roll pin.
K 1-139
K1 TRANSAXLE
Bearing
1. Remove the bearing (speedometer drive gear side) from
the gear case by using the SST.
16E0KX-401
2. Remove the bearing (ring gear side) by using a combina
tion of parts from the SST.
16E0KX-402
Assembly procedure
1. Install the ring gear to the gear case.
Tightening torque:
79—93 Nm (8.0—9.5 kgf m, 58—68 ft-lbf}
46U0K1-223
2. Set the speedometer drive gear onto the gear case as
sembly.
16E0KX-404
3. Install the new bearings and bearing races by using the
SST.
(1) Press the new bearing (speedometer drive gear side)
onto the gear case by using the SST.
(2) Press on the other new bearing (ring gear side) in the
same manner.
46U0K1-224
K1—140
TRANSAXLE K1
4. Apply ATF to the thrust washers and pinion shaft.
5. Install the pinion gears and thrust washers into the gear case.
6. Install the pinion shaft.
16E0KX-406
7. Install the roll pin, and crimp it to prevent it from coming
out of the gear case.
36U0KX-138
8. Apply ATF to the thrust washers.
9. Install the thrust washers and side gears into the gear case,
then turn the side gears and align them with the drive shaft
holes.
16E0KX-408
10. Measure the backlash of the side gears as follows:
(1) Install the left and right drive shafts in the differential as
sembly.
(2) Support the drive shafts on V-blocks.
(3) Measure the backlash of both side gears.
Backlash
Standard : 0.05—0.15mm (0.0020—0.0059 in}
Maximum : 0.50mm (0.020 in}
11. If the backlash is not within the specification, rebuild or re

place the differential assembly.
K1 TRANSAXLE
BEARING PRELOAD
Procedure
1. Use the SSTs shown below to measure and adjust the output gear bearing preload.
46U0K1-225
(1) Align the bearing cover with guide bolts as shown.

(2) Press in the bearing cover by using the SST.
(3) Remove the guide bolts and install the bearing cover
installation bolts.
Tightening torque:
10.8—13.7 Nm [110—140 kgf cm, 96—121 in lbf}
(4) Mount the converter housing onto the SST (transaxle

hanger).
(5) Remove the bearing race and adjustment shims from
the bearing housing using a pin punch and hammer.
(6) Set the output gear into the converter housing.
16E0KX-412
K 1-142
TRANSAXLE K1
(7) Install the bearing race removed in Step (5) to the selec
tor, and install the selector and bearing race to the ouput
gear.
(8) Turn the selector to eliminate the gap indicated by the
arrow.
46U0K1-226
(9) Set the four SSTs on the converter housing in the posi
tions shown.
46U0K1-227
(10) Set the bearing housing on the SSTs (selector) and in
stall the four SSTs (bolts). Tighten the bolts to the speci
fied torque.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14—18 ft lbf)
(11) Turn the SST (selector) to increase the clearance (ar

row) with the SST (bars) until it no longer turns.
(12) Turn the selector in the opposite direction until the
preload is eliminated (gap is reduced).
46U0K1-228
(13) Mount the SST and a pull scale or a torque wrench on
the output gear.
(14) Adjust the clearance of the SST (selector) to obtain the
specified preload/pull scale reading.
Preload:
1.1—1.9 N m {11—20 kgf-cm, 10—17 in-lbf)
Reading on pull scale:
11—19 N {1.1—2.0 kgf, 2.5—4.4 Ibf)
46U0K1-392
K 1-143
K1 TRANSAXLE
(15) Measure the bearing preload at the point that the out
TORQUE WRENCH
put gear starts to turn.
46U0K1-229
(16) Measure the gap around the circumference of the SST
(selector) by using a feeler gauge.
(17) Take the maximum reading and determine the shim to
be used. Use no more than one shim.
Thickness of shim mm [in)

0.350 [0.0138) 0.375 (0.0148) 0.400 (0.0157)
0.425 (0.0167) 0.450 (0.0177) 0.475 (0.0187)
0.500 (0.0197) 0.525 (0.0207) 0.550 (0.0217)
0.575 (0.0226) 0.600 (0.0236) 0.625 (0.0246)
0.650 (0.0256) 0.675 (0.0266) 0.700 (0.0276)
0.725 (0.0285) 0.750 (0.0295) 0.775 (0.0305)
0.800 (0.0315) 0.825 (0.0325) 0.850 (0.0335)
0.875 (0.0344) 0.900 (0.0354) 0.925 (0.0364)
0.950 (0.0374) 0.975 (0.0384) 1.000 (0.0394)
1.025 (0.0404) 1.050 (0.0413) 1.075 (0.0423)
1.100 (0.0433) 1.125 (0.0443) 1.150 (0.0453)
1.175 (0.0463) 1.200 (0.0472) 1.225 (0.0482)
1.250 (0.0492) 1.275 (0.0502) 1.300 (0.0512)
1.325 (0.0522) 1.350 (0.0531) 1.375 (0.0541)
1.400 (0.0551)
16E0KX-420
(18) Remove the bearing housing and SST.
(19) Install the required shim(s) and press the bearing race
into the bearing housing by using the SST.
(20) Install the bearing housing.
Tightening torque:
19—25 N m {1.9—2.6 kgf m, 14— 18 ft-lbf}
(21) Check that the preload/pull scale reading is within the

specification. If not, return to Step (5).
Preload:
1.1—1.9 N m {11—20 kgf-cm, 10—17 in-lbf)
11—19 N {1.1—2.0 kgf, 2.5—4.4 Ibf)
(22) Remove the bearing housing and output gear assembly.

46U0K1-232
K 1-144
TRANSAXLE K1
2. Use the SSTs shown below to measure and adjust the differential side bearing preload.
46U0K1-233
(1) Remove the bearing race and adjustment shims from

the transaxle case. (Refer to page K1-65.)
(2) Install the bearing race into the converter housing by
using a suitable pipe.
46U0K1-234
(3) Set the differential assembly into the converter housing.
49 G 03 0 381 (4) Turn the selector to eliminate the gap indicated by the
arrow.
(5) Install the bearing race removed in step (1) into the SST
and set them onto the differential assembly.
46U0K1-235
K 1-145
K1 TRANSAXLE
(6) Install the SST as slown in the figure.
49 G 019 021
49 D 019 001
46U0K1-236
(7) Set the six SSTs in the positions shown.
46U0K1-237
(8) Set the transaxle case on the SSTs (selectors).
(9) Tighten the SSTs (bolts) to the specified torque.
Tightening torque:
38—51 Nm {3.8—5.3 kgf m, 28—38 ft lbf)
46U0K1-238
(10) Turn the SST (selector) to increase the clearance (ar
row) by using the SST (bars), until it no longer turns.
(11) Turn the selector in the opposite direction until the
preload is eliminated (gap is reduced).
46U0K1-239
(12) Insen the SST through the oil seal hole of the transaxle
case and attach it to the pinion shaft.
49 0 1 8 0 5 1 0B
(13) Mount the SST and a pull scale or a torque wrench to
the SST.
(14) Measure the bearing preload at the point that the
differential starts to turn.
(15) Adjust the clearance of the SST (selector) to obtain the
specified preload/pull scale reading.
PU LL SC ALE
Preload: 0.49 Nm (5.0 kgf cm, 4.3 in-lbf)
Reading on pull scale: 4.9 N {0.5 kgf, 1.1 Ibf)
46U0K1-240
K 1-146
TRANSAXLE K1
TORQUE W RENCH (16) Measure the gap between A and B around the circum
ference of the SST (selector) by using a feeler gaude.
(17) Select a maximum of three adjustment shims to equal
the measurement clearnce plus 0.3mm (0.012 in).
46U0K1-241
Thickness of shim mm (in)

0.10 (0.004) 0.15 (0.006) 0.20 (0.008) 0.25 (0.010)
0.30 (0.012) 0.35 (0.014) 0.40 (0.016) 0.45 (0.018)
0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026)
0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033)
0.90 (0.035) 0.95 (0.037) 1.00 (0.039) 1.05 (0.041)
1.10 (0.043) 1.15 (0.045) 1.20 (0.047)
(18) Remove the transaxle case and SST (selector).

(19) Install the required shim(s) and tap the bearing race into
the transaxle case.
46U0K1-243
(20) Install the transaxle case.
Tightening torque:
38—51 Nm (3.8—5.3 kgf m, 28—38 ft-lbf}
(21) Check that the preload is within the specification. If not,

return to Step (1).
49 FT01 51 5A Preload:
3.0—3.9 Nm (30—40 kgf cm, 27—34 in lbf)
46U0K1-244 30—39 N (3.0—4.0 kgf, 6.6—8.8 Ibf]
(22) Remove the transaxle case.
K 1-147
K1 TRANSAXLE
TRANSAXLE UNIT (ASSEMBLY)
Preparation
SST
49 0107 680A (T For 49 G019 0A0 ___ For

Engine stand \ transaxle Hanger, transaxle transaxle
VU
49 G019 001 For 49 G019 002 For

Body f ' \ transaxle Stav ^ transaxle
(Part of \' ^ (Part of 4~------ -------- ^ V )
49 G019 0A0) ^<^3 49 G019 0A0) "
49 G019 003 For 49 G019 0A7A | For

transaxle Compressor set, low and reverse
return spring brake piston
\ \
49 G019 028 For 49 G019 029 . / '" X For

Bolt low and reverse low and reverse
(Part of brake piston (Part of brake piston
49 G019 0A7A ^ 49 G019 0A7A)
49 G019 030 ------------- For 49 G019 0A2 For

assembly of holding turbine
Plate C ^ J band servo Holder, turbine ®»» « . shaft
(Part of ---------- ■ '/ shaft
49 G019 0A7A) -------------
49 G019 014 For 49 G019 015 For

holding turbine holding turbine
Stay shaft Adaptor shaft
(Part of (Part of /A
49 G019 0A2) 49G019 0A2)
49 G019 016 For 49 G030 455 (~ T ~ 7 7 ^^\ For

holding turbine holding
» o, » w m § 9 shaft Hoider, r - r - ^ T * v P differential
differential side gear
49 G019 0A2) side gear
49 G019 017 For 49 F027 007 For

installation installation
Installer, oil of bearing Attachment 4>72 of bearing
cover rece
16E0KX-435
K1—148
TRANSAXLE K1
Precaution
1. Select the adjustment shim(s), referring to Bearing Preload.
2. If the drive plates or 2-4 brake band are replaced with new ones, soak the new part in ATF for at least
two hours before installation.
3. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
4. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
5. Use petroleum jelly, not grease, during reassembly.
6. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
7. Assemble the housing within 10 minutes after applying sealant, and allow it to cure at least 30 minutes
after assembly before filling the transaxle with ATF.
16E0KX-436
Bearing and race locations
© (D (D©(D © ®
46U0K1 -245
Outer diameter of bearing and race
1 2 3 4 5 6 7
Bearing mm {in} 86.0 {3.39} *56.1 {2.21} *62.5 {2.46} *62.5 {2.46} 72.0 {2.83} 56.0 {2.20} 72.1 {2.84}
Race mm {in} 88.0 {3.46} — — — 72.0 {2.83} 57.0 {2.24} 72.0 {2.83}
’ One-piece units
K1 TRANSAXLE
Components
BOLT, NEW
M 10.8— 13.7 110— 140 kgf-cm, 96— 121 ln-lbf]
OIL SEAL. NEW (D NEW A

Q 0
O-RING, NEW
7.9— 10.7 N fli

[80— 110 kgf-cm,
O-RING, N E W 70— 95 irvlbf} NEW
N-m [kgf-m, ft-lbf)

36U0KX-334
1. Converter housing 9. Bearing housing

2. O-rings 10. Baffle plate
Oil seals 11. Roll pin
. Adjustment shim 12. Orifice check valve
5. Bearing races 13. Orifice check valve spring
6. Bearing cover assembly 14. 2-3 accumulator
7. Output gear 15. Differential
8. Idler gear
TRANSAXLE K1
11.8—17.6 N*n
{120—180 kgf-cm, 105—156 in-lbf}
7.9—10.7 N-m
(80—110 kgfcm, 70—95 in-lbf)
O-RING, NEW
42—54 ( 4.2—5.6, 31—40
10.8—13.7 N-m
(110—140 kgf-cm, 96—121 in-lbf)
N m (kgf-m, ft Ibf)
16E0KX-43''
1. Parking pawl 6. Plug, packing, spring, and detent ball

2. Parking assist lever 7. Low and reverse brake
3. Actuator support 8. Output shell
4. Manual shaft and manual plate 9. Transaxle case
5. Bracket
nine MQQd K 1 —151

K1 TRANSAXLE
16E0KX-440
1. Turbine shaft 8. Anchor strut and shaft

° 3-4 clutch 9. 2-4 brake band
Internal gear 10. Small sun gear and one-way clutch 1
4. Snap ring 11. Clutch assembly
5. Friction plate 12. Snap ring
6. One-way clutch 2 and carrier hub assembly 13. Piston stem
7. Band servo
K 1 -1 5 2
TRANSAXLE K1
Components (cont’d)
11.8—17.6 N-m (120—180 kgf-cm, 105—156 in-lbf)

7.9— 10.7 N-m (80— 110 kgf-cm, 70—95 in-lbf)
6.9—9.8 N-m
(70— 100 kgf-cm,
61—86 in-lbf)
GASKET, NEW
— 1 9 -2 5
(1.9—2.6, 14— 18)
O-RING, NEW
GASKET, NEW
7 .9 -1 0 .7 N m
(80— 110 kgf-cm, 70—95 in-lbf)
(110-150 kgf-cm,
96—130 in-lbf)
8.4—10.7 Nm (85—110 kgf-cm, 74—95 in-lbf)
8 .4 — 1 0.7 N-m (8 5 — 110 kgf-cm, 74— 95 in-lbf)
N m (kgf m, ft lbf ]
46U0K1-246
1. Oil pump 8. Breather hose

2. Control valve body 9. Park/Neutral switch
3. Coupler assembly 10. Vehicle speed pulse generator
4. Control valve body cover 11. ATF dipstick and oil filler tube
5. Oil strainer 12. Oil pump shaft
6. Oil pan 13. Torque converter
7. Oil pipe
K 1-153
K1 TRANSAXLE
Assembly Procedure
1. Remove any old locking compound from the bolt holes.
2. Align the bearing cover with guide bolts as shown and press
it in. Install and tighten the new mounting bolts.
Tightening torque:
10.8—13.7 Nm (110—140 kgf cm, 96—121 in lbf)
46U0K1-247
3. Press the bearing race into the converter housing.
46U0K1-248
49 G 0 1 9 OAO
49 0 1 0 7 6 8 0A
46U0K1-249
5. Install the idler gear and output gear by tapping in with a
plastic hammer.
46U0K1-250
6. Install the selected shim(s) and bearing race into the bear
ing housing by using the SST.
46U0K1-251
TRANSAXLE K1
7. Install the bearing housing.
(1) Install the bearing housing and tighten the bolts evenly
and gradually.
Tightening torque:
26—30 Nm {2.6—3.1 kgf m, 19—22 ft Ibf)
46U0K1-252
(2) Align the slot of the idler shaft with the mark on the bear
ing housing.
(3) Tap a new roll pin in by using a pin punch and a
hammer.
16E0KX-448
8. Install the 2-3 accumulator piston.
(1) Install the orifice check valve spring and orifice check
valve.
(2) Apply ATF to new O-rings and install them into the 2-3
accumulator.
(3) Install the 2-3 accumulator piston.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 69.5—95.4 in-lbf)
46U0K1-253
9. Install the bearing race into the bearing housing.
10. Install the differential.
11. Install the selected shim(s) and bearing race into the trans
axle case.
46U0K1-254
12. Install the parking pawl.
(1) Install the parking pawl and shaft.
(2) Install the spring and snap ring.
46U0K1-255
K 1-155
K1 TRANSAXLE
13. Install the parking assist lever and snap ring.
14. Install the actuator support.
Tightening torque:
t ' 10.8—13.7 N m {110—140 kgf cm, 96—121 in-lbf}
46U0K1-257
15. Install the manual shaft and manual plate.
(1) Install the manual plate, spacer, washer, and nut.
(2) Tighten the nut to the specified torque.
Tightening torque:
42—54 N m {4.2—5.6 kgf m, 31—40 ft lbf}
(3) Install the bracket.
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 70—95 in Ibf)
36U0KX-313
(4) Install the detent ball, spring, washer and plug. Tighten
the plug.
Tightening torque:
11.8—17.6 N m {120—180 kgf cm, 105—156 in Ibf)
(5) Move the manual shaft and verify that the parking pawl
operates correctly.
16E0KX-456
TRANSAXLE K1
16. Install the output shell to the output gear, and install the thrust
bearing onto the output shell.
Thrust bearing outer diameter: 71.0mm {2.80 in)
46U0K1-259
OUTPUT
17. Apply a light coat of silicone sealant to the contact surfaces
SHELL of the converter housing and the transaxle case.
18. Install new O-rings into the converter housing.
19. Install the transaxle case on the converter housing, and tight
en the bolts evenly and gradually.
Tightening torque:
38—51 N-m {3.8—5.3 kgf m, 28—38 ft-lbf]
SEALANT
46U0K1-260
20. Install the engine mount No.1.
Tightening torque:
68—77 N m {6.9—7.9 kgf m, 50—57 ft Ibf]
21. Install the SST into the differential side gears.
r &
46U0K1-261
22. Install the SST to hold the turbine shaft.
49 G 0 19 0 A 0
49 01 07 680A
46U0K1-262
23. Install the turbine shaft and 3-4 clutch assembly.
(1) Assemble the turbine shaft and 3-4 clutch assembly.
46U0K1-263
1/•* 4 C T
K1 TRANSAXLE
(2) Verify that the thrust bearing and race are properly in
stalled.
(3) Install the turbine shaft and 3-4 clutch assembly into the
transaxle case.
24. Adjust the SST position so that it contacts and holds the
turbine shaft.
46U0K1-264
25. Install the internal gear.
(1) Install the internal gear to the output shell.
46U0K1-265
26. Install the carrier hub assembly.
(1) Verify that the thrust bearing and bearing race are in
stalled in the correct position.
BEARING
46U0K1-266
(2) Hold the turbine shaft with one hand to prevent it from
rotating.
(3) Install the carrier hub assembly into the 3-4 clutch drum
by rotating it.
16E0KX-466
TRANSAXLE K1
27. Install the friction plate.
46U0K1-267
28. Install the one-way clutch 2.
(1) Hold the one-way clutch 2 horizontally.
(2) Install it by turning the carrier hub assembly counter
clockwise.
46U0K1-268
29. Install the band servo to the transaxle case.
(1) Install the servo return spring and band servo.
(2) Compress the servo by using the SST.
(4) Remove the SST.
46U0K1-269
30. Install the piston stem.
31. Loosely tighten the piston stem by hand.
46U0K1-270
32. Install the a n c h o r strut.
46U0K1-271
K 1-159
K1 TRANSAXLE
33. Install the 2-4 brake band in the transaxle case, and inter
lock it to the anchor strut as shown.
46U0K1-272
34. Install the small sun gear and one-way clutch 1.
BEARING (1) Verify that the thrust bearing and bearing race are in
stalled in the correct position.
BEARING RACE
46U0K1-273
(2) Install the small sun gear and one-way clutch 1 assem
bly by rotating it.
16E0KX-474
35. Install the clutch assembly.
(1) Verify that the thrust bearing is installed in the correct
position.
46U0K1-274
(2) Install the clutch assembly by rotating it.
16E0KX-476
TRANSAXLE K1
(3) Measure the height difference between the reverse and
foward drum and the transaxle case, if not within specifi
cation, reassemble beginning with step 22.
Height difference:
0.7—1.9mm (0.028—0.075 in) max.
36. Install the new snap ring into the bottom ring groove of the
turbine shaft.
37. Use the following procedure to adjust the total end play and
select a suitable bearing race.
(1) Set the thrust bearing onto the clutch assembly.
46U0K1-277
(2) Remove the bearing race and the oil pump gasket.
(3) Set the thickest bearing race (2.2mm {0.087 in}) onto
the oil pump.
(4) Set the oil pump onto the clutch assembly.
16E0KX-480
(5) Measure clearnce A between the transaxie case and
the oil pump. Take several measurements and calcu
CLEARANCE (A)
late the average value.
(6) Select a suitable bearing race from the chart below.
Clearance A mm (in) Select this bearing race mm (in)
0 .91-1.10 (0.036-0.043) 1.2 (0.047)
0.71 -0 .9 0 (0.028—0.035) 1.4 (0.055)
0.51—0.70 (0.020-0.027) 1.6 (0.063)
0.31 -0 .5 0 (0.012-0.019) 1.8 (0.071)
0.11—0.30 (0.004—0.011) 2.0 (0.078)
0—0.10 (0—0.003) 2.2 (0.087)
46U0K1-278
K1-161
K1 TRANSAXLE
(7) Remove the oil pump.
(8) Place the selected bearing race and a new gasket onto
the oil pump.
(9) Install the oil pump onto the clutch assembly, and tighten
the bolts evenly and gradually.
Tightening torque:
19—25 Nm [1.9—2.6 kgf m, 14—18 ft-lbf}
(10) Install the oil pipe.
38. Adjust the 2-4 brake band.

(1) Loosen the locknut and tighten the piston stem to the
specified torque.
Tightening torque:
11.8—14.7 N m [ 120—150 kgf-cm, 105—130 in-lbf}
(2) Loosen the piston stem 1.5 turns.

(3) Hold the piston stem and tighten the locknut to the speci
fied torque.
Tightening torque:
25—39 Nm [2.5—4.0 kgfm, 19—28 ft-lbf}
39. Install a new O-ring and oil strainer to the transaxle.
Tightening torque:
7.9—10.7 Nm [80—110 kgf cm, 70—95 in-lbf}
40 Install the magnets inside the oil pan in the positions shown
in the figure.
41. Install a new gasket and the oil pan.
Tightening torque:
8.4—10.7 Nm [85—110 kgf cm, 74—95 in-lbf)
46U0K1-282
K 1-162
TRANSAXLE K1
42. Align the manual valve with the pin on the manual plate.
43. Install the control valve body into the transaxle case, and
tighten the bolts evenly and gradually.
Tightening torque:
10.8—14.7 N m {110—150 kgf-cm, 96—130 in-lbf}
46U0K1-283
44. Install a new O-ring to the coupler assembly.
45. Install the coupler assembly.
46. Match the harness colors, and connect the solenoid con
nectors and ATF thermosensor connector.
46U0K1-284
47. Install a new gasket and control valve body cover, and tight
en the bolts evenly and gradually.
Tightening torque:
8.4—10.7 Nm {85—110 kgf cm, 74—95 in-lbf)
46U0K1-285
48. Install the steel ball, spring, oil pipe, and packing.
49. Install the connecting bolt.
Tightening torque:
11.8—17.6 Nm {120—180 kgf cm, 105—156 in-lbf)
46U0K1-286
50. Install the vehicle speed pulse generator.
Tightening torque:
5.4—7.8 Nm {55—80 kgf cm, 48—69 in-lbf)
46U0K1-287
K 1-163
K1 TRANSAXLE
51. Install the park/Neutral switch.
-=S\ 52. Adjust the park/Neutral switch.
ia i i i r i (1) Connect an ohmmeter between the terminals (ft) and
IH B
^— ®.
(2) Rotate the manual shaft fully counterclockwise, then re
turn it two notches to the N position.
(3) Adjust the switch to the point where there is continuity
between the terminals.
(4) Tighten the switch.
Tightening torque:
7.9—10.7 Nm (80—110 kgf cm, 70—95 in-lbf}
53. Remove the transaxle from the SST (transaxle hanger).

54. Install the ATF dipstick and oil filler tube along with a new
O-ring to the transaxle case.
Tightening torque:
6.9—9.8 Nm (70—100 kgf-cm, 61—86 in-lbf]
46U0K1-289
55. Install the oil pump shaft.
56. Install a new O-ring onto the turbine shaft.
46U0K1-290
57. If the torque converter is completely empty, hold it up right,
and fill it with 2.0 L {2.1 US qt, 1.8 Imp q t} of ATF. If the
torque converter has not been completely drained, add the
same amount of ATF that was drained out.
ATF type: Dexron®n or M -in
58. Carefully install the torque converter to the torque convert

er housing. Rotate the torque converter to align the splines.
46U0K1-291
59. To ensure that the torque converter is installed accurately,
measure distance A between the end of the torque con
verter and the face of the converter housing.
Distance A: 14.0mm (0.551 in)
46U0K1-292
TRANSAXLE K1
TRANSAXLE UNIT (INSTALLATION)
Preparation
SST
Installation
2. Fill the transaxle with the specified ATF after installation.
16E0KX-498
K1 TRANSAXLE
7.9—10.7 N m (80—110 kgfcm, 70—95 in-lbf)
7.9—10.7 N m
(80—110 kgfcm,
70—95 Inlbf)
7.9—10.7 N m
(80—110 kgfcm, 7.9—10.7 N-m
70—95 Inlbf] (80—110 kgf-cm, 70—95 In-lbf]
7.9—10.7 N-m
(80—110 kgf-cm,
70—95 in-lbf)
7.9—10.7 N m _
{80—110 kgf-cm.
70—95 ln-lbf)
HOSE CLAMP, NEW
K 1-166
TRANSAXLE K1
7.9—10.7 N-m 180—110 kgf-cm, 69.5—95.4 In-lbf |
7.9—10.7 N-m
180—110 kgf-cm,
69.5—95.4 in-lbf)
10.7 N-m [8 0 -1 1 0 kgf-cm, 69.5-9 5 .4 In-lbf]
7.9—10.7 N-m
(80—110 kgf-cm, 69.5—95.4 In-lbf)
46U0K1-293
1. Engine mount No.2 18. Oil hose

2. Transaxle Installation Note..................... page K1-171
Installation Note..................... page K1-168 19. Starter
3. Torque converter nuts 20. Engine mount stay
4. Undercover Installation Note..................... page K1-171
5. Engine mount No.4 21. Bolt
6. Engine mount No.1 bolts 22. Ground
Installation Note......................page K1-168 23. Vehicle speed pulse generator connector
7. Engine mount member 24. Vehicle speedometer sensor connector
Installation Note......................page K1-168 25. Fuel filter mounting nuts
8. Engine mount rubber No.5 26. Nut
9. Joint shaft 27. Ground
Installation Note..................... page K1-169 28. Harness bracket
10. Drive shaft 29. Solenoid valve connector
Installation Note..................... page K1-170 30. Park/Neutral switch connector
11. Lower arm 31. Bolt
Installation Note..................... page K1-170 32. Selector cable
12. Stabilizer control link Installation Note..................... page K1-171
13. Tie rod end 33. Clip
Installation Note..................... page K1-171 34. Air cleaner assembly
14. Exhaust pipe 35. Fresh air duct
15. Transverse member 36. Battery carrier
16. Splash shield 37. Battery
17. Wheel and tire
K 1-167
K1 TRANSAXLE
Installation Note
Transaxle
1. Set the transaxle on a jack and lift it into place.
46U0K1-294
Tightening torque:
68—99 Nm {6.9—10.1 kgf m, 50.0—73.0 ft-lbf)
3. Install the torque converter nuts.
Tightening torque:
38—60 N-m (3.8—6.2 kgf-m, 28—45 ft-lbf)
4. Loosely tighten engine mount No.4 nuts.

46U0K1-295
Engine mount No.1 bolts
Caution
• Align the transaxle bolt holes and the engine mount
exactly. Any misalignment can result in boltes and
bolt holes becoming damaged or stripped during in
stallation.
1. Use the SST (engine support) to make sure the transaxle

bolt holes and engine mount No.1 align.
2. Tighten the bolts to the specified torque.
46U0K1-296
Tightening torque:
75—104 Nm {7.6—10.7 kgf m, 55—77.3 ft Ibf)
FRONT SIDE
Engine mount member

0 1. Install the engine mount bushings as shown in the figure.
2. Install the engine mount member, marking sure that the No.2
installation hole.
46U0K1-297
3. Install the bolts and nuts (A) as shown.
Tightening torque
A: 67—93 Nm {6.8—9.5 kgf m, 50—68 ft-lbf)
4. Loosely tighten the nuts (§)as shown.
46U0K1-298
K1—168
TRANSAXLE K1
5. Tighten engine mount No.4 nuts.
Tightening torque:
67—93 N m {6.8—9.5 kgf m, 50—68 ft lbf}
46U0K1-299
7. Tighten the nuts (§)as shown.
Tightening torque
B: 75—104 Nm (7.6—10.7 kgf m, 55.0—77.3 ft lbf}
46U0K1-300
Joint shaft
46U0K1-301
3. Install the joint shaft to transaxle.
Tightening torque:
43—61 Nm (4.3—6.3 kgfm, 32—45 ft lbf}
46U0K1-302
Drive shaft
Caution
slice or puncture the oil seal. Be careful when in
stalling the drive shaft to the transaxle.
46U0K1-303
K 1-169
K1 TRANSAXLE
3. Install the clip with the gap upward.
46 UOK1-304
4. Apply ATF into the oil seal lip. Install the drive shaft.
the shaft. It must not slide out.
46U0K1-305
Lower arm
bolt.
Tightening torque:
44—58 Nm {4.4—6.0 kgf m, 32—43 ft Ibf j
36U0KX-319
Tightening torque:
7.9—10.7 Nm {80—110 kgf cm, 69.5—95.4 in Ib f}
3. Install the clip.
36U0KX-320
Tie rod end
Tightening torque:
43—56 N m {4.3—5.8 kgf m, 32—41 ft-lbf)
16E0KX-515
K 1-170
TRANSAXLE K1
Oil hose
Caution
location on the hose and squeeze the clamp lightly
with large pliers to ensure a tight fit.
16E0KX-516
MARKS mark and at the angle shown.
parts.
r 11---------------
* l1 1
16E0KX-517
Engine mount stay
Install the engine mount stay as shown.
16E0KX-518
Selector cable
1. Install the selector cable to the cable bracket.
2. Install the clip to the selector cable.
3. Connect the selector cable to the manual shaft lever.
36U0KX-337
K1-171
K1 OIL COOLER
OIL COOLER
OIL COOLER
5. Add ATF to the specified level.
7. Inspect for oil leakage from the oil pipes and oil hoses.
8. Inspect the ATF level and condition. (Refer to page K1-27.)
(T ) 24—35 12.4—3.6, 18—26)
HOSE CLAMP REPLACE
( 2 ) REPLACE
N-m {kgf m, ft-lbf)

46U0K1-306
1. Connector bolts 4. Oil pipe

Inspect for damage and clogging Inspect for damage and cracks
2. Washers 5. Radiator
3. Oil hose Service........................................Section E1
Inspect for damage and cracks
Installation Note......................page K1-173
OIL COOLER K1
Installation note
Oil hose
Caution
location on the hose, and squeeze the clamp light
ly with large pliers to ensure a tight fit.
J ilt parts.
16E0KX-523
K 1-173
K1
—
MEMO
K 1-174
DRIVE PLATE K1
DRIVE PLATE
PREPARATION
SST
49 E011 1AO For 49 E011 103 For

holding holding
Brake set, ring drive plate Shaft drive plate
gear (Part of
49 E011 1AO)
49 E011 104 For 49 E011 105 For

holding holding
Collar drive plate Stopper drive plate
(Part of (Part of
49 E011 1AO) 49 E011 1A0)
16E0KX-524
DRIVE PLATE
N m | kgf m, ft-lbf)
46U0K1-3Q7
1. Drive plate mounting bolts 3. Drive plate

Removal Note.........................page K1-176 Inspect for cracks and for ring gear wear
Installation Note..................... page K1-176 and damage
2. Backing plate 4. Adapter
K 1-175
K1 DRIVE PLATE
Removal note
Drive plate mounting bolts
1. Set the SST or equivalent against the drive plate.
2. Remove the bolts and the drive plate.
36U0KX-165
Installation note
Drive plate mounting bolts
1. Set the SST or equivalent against the drive plate.
2. Tighten the drive plate mounting bolts in two or three steps
in the order shown.
Tightening torque:
61—67 Nm {6.2—6.9 kgfm, 45—49 ft lbf)
49 E011 1AO
46U0K1-308
K 1-176
_____________ SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM)__________ K1
SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM)
SHIFT-LOCK SYSTEM COMPONENTS
STOPLIGHT SWITCH
INTERLOCK CABLE
SHIFT-LOCK ACTUATOR
16A0KX-071
K 1-177
K1 SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM)
TROUBLESHOOTING
Circuit Diagram
16A0KX-072
SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K1
Diagnosis chart
Selector lever cannot MAIN 100A fuse burned Replace K1-178
be moved from P IG KEY 40A fuse burned Replace K1-178
range with brake K1-178
pedal depressed and BTN 60A fuse burned Replace
ignition switch ON IG1 system malfunction
• Wire harness broken Repair or replace K1-178
• Poor connection Connect firmly K1-178
• METER 15A fuse burned Replace K1-178
Ignition switch malfunction Inspect and replace 'Section C1
Stoplight system malfunction
• STOP 20A fuse burned Replace K1-178
Stoplight switch remains OFF Adjust or replace 'Section C1
P range switch system malfunction
• Wire harness broken (poor ground) Repair or replace K1-178
P range switch remains OFF Inspect K1-181
Shift-lock actuator malfunction
• Shift-lock actuator malfunction Replace K1-182
Misadjustment of selector lever Adjust or repair K1-183
Selector lever can be BTN 60A fuse burned Replace K1-178
moved from P range STOP 20A fuse burned Replace K1-178
with ignition switch
ON, but without Stoplight switch remains ON Adjust or raplace ’ Section C1
brake pedal Shift-lock actuator malfunction Inspect and replace K1-182
depressed Misadjustment of selector lever Adjust or repair K1-183
Selector lever can be BTN 60A fuse burned Replace K1-178
moved from P range STOP 20A fuse burned Replace K1-178
with ignition switch
OFF and brake pedal Ignition switch malfunction Inspect and replace 'Section C1
depressed Shift-lock actuator malfunction Inspect and replace K1-182
Misadjustment of selector lever Adjust or repair K1-183
Shift-lock actuator P range switch remains ON Inspect K1-181
operation heard when Misadjustment of selector lever Adjust or repair K1-183
brake pedal
depressed with igni
tion switch ONin
other than P range
Selector lever re Emergency override key cylinder not fully turned Turn fully and hold
mains locked when emergency override
emergency override key cylinder, move
key cylinder operated selector lever
Broken emergency override key cylinder Replace K1-188
Misadjustment of indicator panel Adjust K1-184
Ignition key can be Interlock cable malfunction Inspect and replace K1-185
turned to lock posi • Disconnected
tion with selector le • Kinked
ver in other than P • Stuck
range •Spring damaged
Key cylinder malfunction Replace Section N
Ignition key cannot Interlock cable malfunction Inspect and replace K1-185
be turned to lock po • Disconnected
sition with selector • Kinked
lever In P range • Stuck
• Spring damaged
Key cylinder malfunction Replace Section N
‘ Refer to 1994 626/MX-6 Body Electrical Troubleshooting Manual. 46U0K1-309
K1-179
SHIFT-LOCK
Inspection
1. Turn the ignition switch to ON (engine off).
POSSIBLE 2. Verify that the selector lever is in P range.
TO SHIFT 3. Without the brake pedal depressed, verify that the selector
lever cannot be shifted from P range.
4. Depress the brake pedal and verify that the selector lever
can be shifted from P range.
BRAKE PEDAL 5. If not as specified, check the P range switch continuity
DEPRESSED and/or shift-lock actuator terminal voltage and continity.
(Refer to pages K1-181, 182.)
46U0K1-310
EMERGENCY OVERRIDE KEY CYLINDER

Inspection
1. Turn the ignition switch off.
2. Verify that the selector lever is in P range.
3. Without the brake pedal depressed, verify that the selector
lever cannot be shifted from P range.
4. Insert the ignition key into the emergency override key cyl
inder beside the selector lever, turn the ignition key coun
terclockwise and hold it. Verify that the selector lever can
be shifted from P range.
5. If not as specified, replace the emergency override key
cylinder.
SHIFT TO P RANGE KEY INTERLOCK

AND RELEASE THE Inspection
SELECTOR LEVER POSSIBLE TO TURN 1. Turn the ignition switch ON (engine off).
PUSH BUTTON IN LOCK POSITION
3. Verify that the ignition key cannot be turned to LOCK po
sition.
4. Shift the selector lever to P range and release the selector
lever push button.
5. Verify that the ignition key can be turnned to LOCK position.
6. If not as specified, inspect and repair as necessary, refer
46U0K1-312
ring to Troubleshooting. (Refer to page K1-178.)
P RANGE SWITCH
Inspection
2. Remove the front console. (Refer to page K1-185.)
3. Remove the indicator screws and lift up the indicator panel.
4. Disconnect the P range switch connector.
46U0K1-313
5. Check continuity between the terminals.
Range Selector lever release button Continuity

Released Yes
P
Depressed No
Except P No
TO GROUND FROM
SHIFT-LOCK
ACTUATOR 6. If not as specified, replace the selector lever assembly.
7. Install and adjust the indicator panel.
8. Install the front console. (Refer to page K1-185.)
46U0K1-314 9. Connect the negative battry cable.
10. Check for correct operation of the shift-lock system.
K1 ________SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM)_________
SHIFT-LOCK ACTUATOR
CONNECTOR B CONNECTOR A Inspection
2. Shift the selector lever to P renge.
3. Turn the ignition switch ON (engine off), and check termi
nal voltages and continuity, referring to the chart below.
¥ When checking continuity between terminal b (harness side)
FROM and ground, disconnect connector B.
P RANGE
SWITCH
FROM FROM TO
IGNITION STOPLIGHT P RANGE
SWITCH SWITCH SWITCH
46U0K1-315
Connector Terminal © probe Condition Measurement value

connected to
A a B—b P range, selector lever release button not depressed on
A b B -b Constant OQ
B a B -b Brake pedal released-*depressed 0V-*VB
B b (harness side) Body Constant on
B c B -b Ignition switch ON Vb
B d B -b Ignition switch OFF Vb
16A0KX-082
4. If not as specified, repair the wire harness and/or replace

the shift-lock actuator.
6. Verify correct operation of the shift-lock system.
Replacement
4. Disconnect the shift-lock actuator connector.
5. Disconnect the P range switch connector.
6. Remove the shift-lock actuator.
7. Install the new shift-lock actuator.

8. Connect the P range switch connector.
9. Connect the shift-lock actuator connector.
3. Verify correct operation of the shift-lock system.
46U0K1-318
K 1-182
SELECTOR LEVER
Inspection
1. Turn the ignition switch ON (engine off)
2. With the brake pedal depressed, verify that there is a “ click”
at each range when shifted in the pattern shown.
46U0K1-319
3. Verify that the selector lever can only be shifted as shown.
4. Verify that there is a “ click” at each when shifted from P->L
I p I
t T range.
5. Verify that the positions of the selector lever and the indica
5 5
I N |
,-N BUTTON NEED NOT tor are aligned.
BE DEPRESSED
0 0
6. If not as specified, adjust the indicator panel.
I D“ l ^ BUTTON MUST BE DEPRESSED
0*
I s J
I I I
46U0K1-320
tor indicator lamp in the instrument cluster are aligned.
8. If not as specified, adjust the park/neutral switch.
9. Verify that the vehicle operates in selected range.
46U0K1-321
Adjustment
Selector lever
46U0K1-322
4. Slide the lock cover.
5. Disconnect the set button.
6. Push the selector lever adjust P range.
7. Connect the set button.
8. Slide the lock cover and lock the set button.
(Refer to page K 1-184.)
10. Install the front console. (Refer to page K-185.)
11. Verify correct operation of the selector lever.
(Refer to above.)
46U0K1-323
K 1-183
Indicator panel
1. Loosen the indicator panel screws.
3. Align the alignment screws in the slider with the holes in
the indicator panel. Install suitable heavy-gauge wire to
hold the slider.
36U0KX-181
4. Tighten the indicator panel screws in the order shown in
the figure.
Tightening torque:
2.0—2.9 N-m {20—30 kgf-cm, 18—26 inlbf)
5. Remove the wire.

6. Verify that the selector lever properly aligns with the in
dicator in each range.
36U0KX-182
2. Remove in the order shown in the figure, referring to Disassembly Note.
46U0K1-324
1. Steering column cover 7. Insulator

2. Front console 8. Clip
3. Side wall 9. Selector cable
4. Indicator panel Removal note... page K1-186
Removal note........................ page K1-186 Installation note page K1-186
Installation note..................... page K1-187 10. Interlock cable
5. Clip
6. Selector lever
Removal note.........................page K1-186
Installation note..................... page K1-187
Inspection...............................page K1-183
Assembly..............................page K1-188
K 1-185
Removal Note
Indicator panel
Remove the indicator screws and lift up the indicator
panel.
36U0KX-184
Selector lever
1. Slide the lock cover.
2. Disconnect the set button.
3. Pull out the selector cable from the selector lever.
4. Remove the interlock cable from the selector lever.
5. Remove the selector lever.
36U0KX-185
Selector cable
1. Disconnect the selector cable from the manual shaft lever.
2. Pull out the selector cable from the cable bracket and
remove it.
36U0KX-186
Installation Note
Selector cable
1. Install the selector cable to the cable bracket.
2. Install the clip to the selector cable.
3. Connect the selector cable to the manual shaft lever.
36U0KX-187
Selector lever
1. Install the selector lever.
Tightening torque:
16—22 Nm {1.6—2.3 kgfm , 12— 16 ftlb f}
2. Install the selector cable to the selector lever.

3. Push the selector lever adjust P range.
4. Connect the set button.
6. Install the interlock cable to the selector lever.
Tightening torque:
9.8— 14.7 Nm {100— 150 kgf-cm, 87— 130 in-lbf}
36U0KX-189
Indicator panel
2. Align the alignment screws in the slider with the holes in
the indicator panel. Install suitable heavy-gauge wire to
hold the slider.
36U0KX-190
3. Tighten the indicator panel screws in the order shown in
the figure.
Tightening torque:
2.0—2.9 N-m {20—30 kgf-cm, 18—26 in-lbf}
4. Remove the wire.

5. Verify that the selector lever properly aligns with the in
dicator in each range.
36U0KX-191
46U0K1-325
1. Connector pin 6. Emergency override key cylinder

Disassembly note page K1-189 7. Position indicator lamp
2. Screws 8. Shift-lock actuator
3. Selector lever knob Inspection...............................page K1-182
4. Cover 9. Selector lever
5. Indicator panel
K 1-188
Disassembly note
Connector pin
1. Insert a thin piece of metal from the terminal side of the
connector, and press down the terminal locking top.
2. Pull the terminal out of the connector.
16A0KX-095
" —....
MEMO
'
K 1-190
TROUBLESHOOTING GUIDE K1
GENERAL NOTES
A problem with the EC-AT may be caused by the engine, the EC-AT powertrain, the hydraulic control
system, or the electronic control system; therefore, when troubleshooting begin with those points which
can be inspected quickly and easily. The recommended troubleshooting sequence is described below.
46U0KX-326
Step 1: Self-diagnostic System Inspection

Check for diagnostic trouble code(s) memorized in the
powertrain control module (Transaxle) with the Self-
Diagnosis Checker. (Refer to page K1-232.)
Note
• You can also check the flashing sequence of the hold
indicator light for diagnositic trouble codes.
(Refer to page K1 -234.)
46U0K1-327
Step 2: Mechanical System Test
Check the engine stall speed, time lag, line pressure, and
solenoid reducing pressure. (Refer to page K1-11.)
46U0K1-328
Step 3: Road Test
Check the shift point, shift schedule, and shift shock. (Re
fer to page K1-19).
46U0K1-329
K1 QUICK DIAGNOSIS CHART
OUTLINE
The Quick diagnosis Chart shows various problems and the various components that might be the cause
of the problem.
1. Components indicated in the "Self-diagnosis” line of the QUICK DIAGNOSIS CHART (I) are diagnosed
by the powertrain control module (Transaxle) self-diagnosis function. Self-Diagnosis Checker can be
used for easy retrieval of the diagnostic trouble code numbers.
2. Components indicated in the “ Adjustment” line of the QUICK DIAGNOSIS CHART (I) indicate that there
is a possibility that the problem may be the result of an incorrect adjustment.
Check the adjustment of each component, and readjust if necessary.
3. Input and output signals of the powertrain control module (Transaxle) for the components indicated in
the Engine Signal Monitor line of the QUICK DIAGNOSIS CHART (I) can be easily checked by using the
Engine Signal Monitor.
4. Components indicated in the “ Stall Test” line of the QUICK DIAGNOSIS CHART (I) can be checked for
malfunction by observing the results of the stall test.
5. Components indicated in the “ Time Lag Test” line of the QUICK DIAGNOSIS CHART (I) can be checked
for malfunction by observing the results of the time lag test.
6. Components indicated in the “ Line Pressure Test” line of the QUICK DIAGNOSIS CHART (I) can be checked
for malfunction by observing the results of the line pressure test.
7. Components indicated in the “ Road Test” line of the QUICK DIAGNOSIS CHART (I) can be checked
for malfunction by observing the results of the road test.
8. Components indicated in the “ Solenoid reducing pressure Test” line of the QUICK DIAGNOSIS CHART
(I) can be checked for malfunction by observing the results of the solenoid reducing pressure test.
9. QUICK DIAGNOSIS CHART (II) shows the relationship between the troubleshooting item and inspection
p O in t . 46U0K1-33O
QUICK DIAGNOSIS CHART (I)

\ Possible parts and reference page P re lim in a ry Em ission co n tro l system E le ctro n ic system
B2
F2
F2
F2
F2
F2
F2
F2
F2
F2
F2
F2
F2
F2
F2
G
G
G
0
c
K 1 -1 8 3
K 1 -1 3 0
r~. CD un C\J
I K 1 -2 7
K 1 -2 9
Section
1 Section
Section
Section
Section
Section
Section
Section
Section
K 1 -3 3
K 1 -3 3
Section
Section
Section
Section
Section
Section
Section
Section
Section
i— o n CO
T 1 T T T o I 1
1—
CD
5 5 5 5 5 CO 5
| Engine coolant temperature sensor (EGI)
| Oxygen sensor (right side, left side)
| Solenoid reducing pressure test
Vehicle speed pulse g e n e ra to r

Idle speed and ignition tim in g
| Ignition coil (in d istrib u to r)

ATF level and c o n d itio n
o
cn
Vehicle speed se n so r
I Ignitor (in d is trib u to r)
c
| Air cleaner e le m e n t
Cl)
| P a rk/N e u tra l sw itch
I ISC solenoid va lve
| Pressure re g u la to r
ATF th e rm o s e n s o r
[ Line pressure te st
C/5
C
Stoplight sw itch
o
Selector le ve r
| Airflow m ete r
I Time lag test
05
| Hold sw itch
| Air le a k a g e
o
I Spark p lu g
I Fuel p u m p
| Main re la y
Idle sw itch
a
Road te st
| A lte rn a to r
1 C a m s h a ft
I Fuel filte r
I Stall te s t
Q
)
| In je ctor
O
JZ
Item \ I—
I
[
|
|
|
S e lf-d ia g n o s is o oo o
A d ju s tm e n t O oo oo
T esters
S e lf-D ia g n o sis c h e c k e r o oo o
E n g in e sig n a l m o n ito r o o o Oo o O o
Stall test
T im e la g test
L in e p re s s u re test
S o le n o id re d u c in g p re ssu re test
R o a d test
0 4 G R in h ib it s ig n a l (cru ise c o n tro l unit) K 1 - 3 8 -------
O O o E n g in e R P M sig n a l (N e 1) K 1 -3 8
O o o B a ro m e tric a b s o lu te p re s s u re s e n s o r S ection F2
O o o Torque reduced signal/engine coolant temperature signal K 1 -3 8
0 O o 1 -2 sh ift so le n o id va lve K 1 -3 5
Electronic
0 o o 2-3 sh ift so le n o id va lve K 1 -3 5
O o o 3-4 sh ift so le n o id va lve K 1 -3 5
o O o L o c k u p co n tro l s o le n o id va lve K 1 -3 5
o O o 3 -2 tim in g so le n o id va lve K 1 -3 5
syste m
o O o L o c k u p s o le n o id va lve K 1 -3 5
O O o O o L in e p re ssu re s o le n o id va lve K 1 -3 5
o O o R e d u c e to rq u e sig n a l 1 K 1 -3 8
o O o R e d u c e to rq u e sig n a l 2 K 1 -3 8
o In h ib ito r signal K 1 -3 8
P o w e rtra in c o n tro l m o d u le (E n g in e ) Section F2
P o w e rtra in c o n tro l m o d u le (T ra nsa xle ) K 1 -3 8
O O O il p u m p K 1 -6 8
Hydraulic control
o o O O C o n tro l valve b o d y K 1 -1 0 7
system
O 1-2 a cc u m u la to r K 1 -1 0 7
2-3 a cc u m u la to r K 1 -6 6
O N -D a c c u m u la to r K 1 -1 0 7
O N-R a ccu m u la to r K 1 -1 0 7
O T o rq u e c o n v e rte r K 1 -6 5
o O O O F o rw a rd clu tch K 1 -7 1
0 C o a s tin g clu tch K 1 -7 1
O O R e ve rse clu tch K 1 -7 1
P o w e rtra in
o 3-4 c lu tch K 1 -8 6
o O 2-4 b ra k e b and K 1 -9 4
o O O O L o w a n d reverse b ra ke K 1 -9 0
0 O O O n e -w a y clu tch 1 (S p ra g typ e ) K 1 -8 1
O O O n e -w a y clu tch 2 (R oller typ e ) K 1 -8 4
P la n e ta ry g e a r K 1 -8 4
0 P a rkin g m ech a n ism K 1 -5 1
D ifferential K 1 -1 3 8
1Solenoid
|
1Time
1Self-Diagnosis
1 A d ju s tm e n t
JJ
Stall test
S e lf-d ia g no sis
Line
Engine
o
03
a
pressure
lag test
CD
signal m o n ito r
CO
reducing
test
checker
pressure
T esters
test
J>
5
Item
*
/
*
f
cn
K 1 -1 9 4
cn U i cn CJi O l Ol Ol 01 -b - -b . A 4 *. ■6. CO co CO ro ro ro
o 02 I- *
00 CD cn CO CV3 o CO co ^1 CD O l CO fNJ ro o O l Ol 00
I No engine
3 /
Vehicle
Vehicle
T ra n s a x le
Vehicle does
acceleration
Transaxle
flares u p
Shift point high
A b n o rm a l shift
ra n g e s
Surges
rough
stalls
Will start in other than

shift shock
speed
Frequent sh iftin g
No shift
Excessive
Poor fuel e c o n o m y
Lack
Poor
Engine runs
E n g in e
o
noise
No mode
Excessive
E n g in e
No
No
x
k ic k d o w n
lo c k u p
o
of p o w e r
while
moves
moves
>
changes
o
o v e rh e a ts
c re e p
braking
z
1 D, S, L, R ra n g e s
1 All ra n g e s
I When
to other ra n g e s
When upshifting a n d /
When upshifting
On a cc e le ra tio n
c ru is in g
or down sh iftin g
sh iftin g
D riv e a w a y
On d e c e le ra tio n
On
Idle when shifted

not move
P, N to R and/or N to D
o
in P ra n g e
in N ra n g e
or lo w
w
d e ce le ra tio n
(/>
a c c e le ra tin g
o
P and
in D, S, L and/or R
X
>
31
N ra n g e s
and/or d o w n
from
N or P

J
O O o 0 O O o O O O O o o O ATF level a n d c o n d itio n K 1 -2 7

Oo O O o O S e le c to r le ve r K 1 -1 8 3
tj
O Idle s p e e d a n d ig n itio n tim in g S e ctio n F2
GL
Stall test K 1 -1 1
3
T im e la g test K 1 -1 4 ZD
0 O O o OOO OO o Line p re s s u re test K 1 -1 5
a>
S o le n o id re d u c in g p re s s u re test K 1 -1 7
R o a d test K 1 -1 9
o A ir le a k a g e S e ctio n F2
OO O O A irflo w m eter S e ctio n F2
E n g in e c o o la n t te m p e ra tu re s e n s o r (EGI) S e ctio n F2
o O O x y g e n s e n s o r (rig h t side, left side) S e ctio n F2
o O ISC s o le n o id va lve S e ctio n F2
OOOO In je cto r S e ctio n F2
0 O Ig n ito r (in d istrib u to r) S e ctio n G
o Ig n itio n coil (in d is trib u to r) S e ctio n G
O S p a rk p lu g S e ctio n G
o Fuel p u m p S ection F2
o M ain relay S e ctio n F2
A lte rn a to r S ection G
O Pressure re g u la to r S e ctio n F2
oO OO Fuel filter S ection F2
O A ir c le a n e r e le m e n t S ection F2
OO O O H old sw itch K 1 -2 9
0 O OOO O o O o P a rk/N e u tra l sw itch K 1 -3 0
O o 0 O C O o OOOo OO O T hro ttle p o sitio n se n so r S ection F2
0 O Idle sw itch Section F2
O 0 O o O OO OO O V e h icle s p e e d p u lse g e n e ra to r K 1 -3 3
O 0 OOo O V e h icle s p e e d se n so r K 1 -3 3
O S to p lig h t sw itch K 1 -3 5
O 0 O o O o oo ATF th e rm o s e n s o r K 1 -3 2
4 G R in h ib it sig n a l (c ru is e c o n tro l unit) K 1 -3 8 o
o o o O E n g in e RPM s ig n a lJ N e 1 ) K 1 -3 8 c
o B a ro m e tric ab so lu te p re s s u re s e n so r Section F2 o
o Torque reduced signal/engine coolant temperature signal K 1 -3 8 71
o o o o o O o O O 1-2 sh ift solenoid va lve K 1 -3 5 g
o o o o o O o 2-3 s h ift solenoid va lve K 1 -3 5 >
o o o o 0 O o 3-4 s h ift solenoid va lve K 1 -3 5 a
o o o O O O L o c k u p co n tro l s o le n o id va lve K 1 -3 5
z
o
o o o o o 3-2 tim in g s o le n o id va lve K 1 -3 5 CO
o o o o L o c k u p so le n o id va lve K 1 -3 5 (0
o o o o o O O o o o O L in e p re s s u re s o le n o id va lve K 1 -3 5
O
o R e d u c e to rq u e sig n a l 1 K 1 -3 8 X
o R e d u c e to rq u e sig n a l 2 K 1 -3 8 >
o O In h ib ito r signal K 1 -3 8 3J
o O o o o o O o o o O o O O O O O O P o w e rtra in co n tro l m o d u le (E n g in e ) Section F2
o O o o o o O o o o O o O O O O o P o w e rtra in c o n tro l m o d u le (T ra nsa xle ) K 1 -3 8
o o o o o O o o O 0 O O il p u m p K 1 -6 8
o o o o o O o o 0 O o O O O o O O C o n tro l va lve b o d y
1-2 a c c u m u la to r
K 1 -1 0 7
K 1 -1 0 7
oC
2 -3 a c c u m u la to r K 1 -6 6
o
o N -D a c c u m u la to r K 1 -1 0 7 *
o o
o
o o O o
N-R a c c u m u la to r
T o rq u e c o n ve rte r
K 1 -1 0 7
K 1 -6 5 g
o o o o O o o o o O F o rw a rd clu tch K 1 -7 1 >
o o o o O C o a s tin g clu tch K 1 -7 1 D
R e v e rs e clu tch K 1 -7 1 Z
o
o o
o
o o O o o O
o
3-4 c lu tc h K 1 -8 6 o
(/>
o o O o o o O 2 -4 b ra k e band K 1 -9 4
o o o L o w a n d reverse b ra k e K 1 -9 0 0)
o
o
o o o o o o O O n e -w a y clu tc h 1 (S p ra g typ e )
O n e -w a y clu tch 2 (R oller typ e )
K 1 -8 1
K 1 -8 4
o
o o o O z
o P la n e ta ry g e a r K 1 -8 4
o o o o o O >
o O P a rk in g m ech a n ism K 1 -5 1 3J
o o D iffe re n tia l K 1 -1 3 8
| Transaxle overheats
I D, S, L, R ranges
I All ranges
1 No mode changes
I No
I No lo c k u p
I Shift point high
I Frequent shifting
1A b n o rm a l shift
I No shift
[ Excessive
| Lack
Vehicle does not move
When upshifting
When u p sh iftin g
When
Vehicle
Vehicle
Surges
On a c ce le ra tio n
On d e ce le ra tio n
On d e ce le ra tio n
down shifting
and/or down shifting
No engine braking
P, N to R and/or N to D
L and/or R ra n g e s
Poor fuel e c o n o m y
D rive a w a y
|
CO
k ic k d o w n
CD
of p o w e r
^5-
a cce le ra tin g
5'
while
moves
moves
o
ZT
c re e p
CD
cru isin g
E?
and/or
in P ra n g e
in N ra n g e
03
or lo w
“O
03
13
CL
in D, S,
Z
Transaxle
flares u p
acceleration
stalls
shift shock
sp e e d
Poor
E n g in e
noise
Excessive
E n g in e
runs ro u g h
E n g in e
03
3
CQ
CD
CO
46U0K1-332
cn cn U1 cn cn on cn cn cn .ti -b. CO CO CO t\3 ro ro CT> 3

00 -v] o> on -6. CO ro o CD CD CD cn -c*. CO ro O ro O CD cn 4^ CD
K1 SYMPTOM TROUBLESHOOTING
USING THIS SECTION
Introduction
Most of the automatic transaxle control system is electronicaly controlled, often making it difficult to diag
nose problems in the system, especially intermittent problems. Before undertaking actual checks, take
a few minutes to talk with a customer who approaches with a driveability complaint. The customer is often
a good source of information on such problems, especially intermittent ones. Through talks with the cus
tomer, one can find out what the symptoms are and under what conditions they occur.
Work Flow
C H E C K IN
LIS T E N T O C U S T O M E R C O M P L A IN T S
REFER T O T R O U B L E S H O O T IN G P A G E T H A T
C O R R ESPO N D S TO A C T U A L SYM PTO M
•C H E C K FOR W H A T IS B A D IN SYSTEM In sp e ctio n
C H E C K FOR W H A T PART IS B A D A ctio n
R E P A IR / R E P L A C E
■D E T E R M IN E IF T R O U B L E H A S B E E N E L IM IN A T E D
No Y es
CHECK OUT
36UQKX-200
Diagnostic Index
^Description:
Describes each troubleshooting item.
No.:
Each
assigned a number.
Page:
Shows the reference page or section.
Troubleshooting Item:
There are 58 troubleshooting
items. Choose the item that
most closely corresponds to
the actual symptom.
16E0KX-551
SYMPTOM TROUBLESHOOTING K1
49 B 0 1 9 9 A 0
16E0KX-552
D E S C R IP T IO N :
Further describes the symptom. Confirm that the chart addresses the actual symptom before beginning
troubleshooting.
T R O U B L E S H O O T IN G H IN T S :
STEP:
IN S P E C T IO N :
to perform the INSPECTION, refer to the page shown by the " c r " mark.
ACTION
the action is described on the reference page shown by the " c r " mark.
16E0KX-553
K 1-197
DIAGNOSTIC INDEX
D c S C n lP T IO N PAGE
No. TROUBLE
1 M e lts m a in o r o th e r fu se S e ctio n F2
W ill n o t c ra n k o r c ra n k s slo w ly S ta rte r d o e s n o t w o rk
2 S e ctio n F2
S ta rte r c ra n k s e n g in e a t slo w s p e e d
C ra n k s n o r N o c o m b u s tio n S ta rte r c ra n k s e n g in e at no rm a l s p e e d b u t e n g in e
3 S e ctio n F2
m a lly b u t w ill s h o w s no in d ic a tio n o f firin g
n o t s ta rt
Partial c o m b u s tio n S ta rte r c ra n k s e n g in e at no rm a l s p e e d a n d e n g in e
— w h e n e n g in e c o ld s h o w s in d ic a tio n o f firin g b u t w ill n o t run w h e n e n g in e
4 is c o ld o r at initial sta rtin g S e ctio n F2
E n g in e w ill n o t c o n tin u e ru n n in g w h e n c o ld w h e n ig
n itio n sw itch is re tu rn e d fro m STA to IG po sitio n
Partial c o m b u s tio n S ta rte r c ra n k s e n g in e a t no rm a l s p e e d a n d e n g in e
— w h e n e n g in e w a rm s h o w s in d ic a tio n of firin g b u t w ill n o t run w h e n e n g in e
5 is w a rm S e ctio n F2
E n g in e w ill n o t c o n tin u e ru n n in g w h e n w a rm w h e n
IG N sw itch is re tu rn e d fro m STA to IG p o sition
6 W ill s ta rt in o th e r th a n P a n d N ra n g e s E n g in e starts in P, N a n d o th e r ran g e s K 1 -2 0 1

C ra n k s n o r A n y e n g in e te m p . S ta rte r c ra n k s e n g in e at no rm a l s p e e d b u t e n g in e re
m a lly b u t h a rd q u ire s e xce ssive c ra n k in g tim e b e fo re sta rtin g at a n y
7 to start e n g in e te m p e ra tu re S e ctio n F2
E n g in e starts a fte r sta llin g a fe w tim e s at a n y e n g in e
te m p e ra tu re
W h e n e n g in e c o ld S ta rte r c ra n k s e n g in e a t no rm a l sp e e d b u t e n g in e re
q u ire s e xce ssive c ra n k in g tim e b e fo re sta rtin g w h e n
8 e n g in e is c o ld S e ctio n F2
E n g in e starts a fte r sta llin g a fe w tim e s w h e n e n g in e is
co ld
A fte r w a rm -u p S ta rte r c ra n k s e n g in e at no rm a l s p e e d b u t e n g in e re

9 q u ire s e xce ssive c ra n k in g tim e b e fo re sta rtin g after S e ctio n F2
w a rm -u p
E n g in e stalls Id le at a n y e n g in e E n g in e s to p s u n e x p e c te d ly a t a n y e n g in e te m p .
10 S e ctio n F2
te m p .
11 D u rin g fa st id le E n g in e sto p s u n e x p e c te d ly d u rin g fa st-id le o p e ra tio n S e ctio n F2
12 Id le a fte r w a rm -u p E n g in e sto p s u n e x p e c te d ly at id le a fte r w a rm -u p S e ctio n F2

Id le w ith A /C , P/S, E n g in e sto p s u n e x p e c te d ly w h e n A /C , P/S, a n d /o r
13 S e ctio n F2
a n d /o r E /L ON E /L tu rn e d O N at idle
Idle w hen shifted from E n g in e sto p s u n e x p e c te d ly w h e n sh ifte d fro m N o r P S e ctio n F2
*1 4
N or P to other ranges to o th e r ra n g e s at idle K 1 -2 0 1
15 D riv e a w a y E n g in e s to p s u n e x p e c te d ly u p o n d riv e a w a y S e ctio n F2
O n a cc e le ra tio n E n g in e sto p s u n e x p e c te d ly at b e g in n in g of a c c e le ra
16 S e ctio n F2
tio n o r d u rin g a cce le ra tio n
17 W h ile c ru is in g E n g in e s to p s u n e x p e c te d ly w h ile c ru is in g S e ctio n F2
O n d e ce le ra tio n E n g in e sto p s u n e x p e c te d ly at b e g in n in g of d e c e le ra S e ctio n F2
*1 8
tio n o r re c o v e ry fro m d e c e le ra tio n e xh a u st a fte rb u rn K 1 -2 0 3
E n g in e ro u g h Id le a t a n y e n g in e E n g in e s p e e d flu ctu a te s b e tw e e n s p e c ifie d id le sp e e d

te m p . a n d lo w e r sp e e d a n d e xce ssive e n g in e sh a ke a t a n y
19 e n g in e te m p . S e ctio n F2
Idle s p e e d to o slo w a n d e xce ssive e n g in e sh a ke at
a n y e n g in e te m p .
D u rin g fa s t idle Fast id le sp e e d to o slo w a n d e xce ssive e n g in e sh a ke

20 S e ctio n F2
d u rin g fa s t idle, b u t retu rn s to n o rm a l after w a rm -u p
Id le a fte r w a rm -u p E n g in e s p e e d flu c tu a te s b e tw e e n sp e c ifie d id le s p e e d
21 a n d lo w e r s p e e d a n d e xce ssive e n g in e sh a ke at id le S e ctio n F2
a fte r w a rm -u p
R e fe r to S e c tio n F2 b e fo re re fe rrin g to K1 S ection.
DESCRIPTION PAGE
No. TROUBLE
E n g in e ru n s Id le w ith A /C , P/S, E n g in e s p e e d flu c tu a te s b e tw e e n sp e c ifie d id le s p e e d
22 ro u g h a n d /o r E /L O N a n d lo w e r s p e e d a n d e xce ssive e n g in e sh a ke at idle S e ctio n F2
w h e n A /C , P/S, a n d /o r E /L O N
Idle w hen shifted from E n g in e s p e e d flu c tu a te s b e tw e e n sp e c ifie d id le s p e e d
23 N or P to other range a n d lo w e r s p e e d a n d e xce ssive e n g in e sh a ke at idle S e ctio n F2
w h e n sh ifte d fro m P o r N to o th e r ra n g e
O n d e c e le ra tio n E n g in e sh a ke s at b e g in n in g of d e ce le ra tio n , d u rin g
S e ctio n F2
*2 4 d e c e le ra tio n , o r re c o v e ry fro m d e ce le ra tio n
K 1 -2 0 4
E xh a u st a fte rb u rn
Poor ac D riv e a w a y E n g in e s p e e d in cre a se s n o rm a lly b u t v e h ic le sp e e d

*2 5
c e le ra tio n s lo w ly in cre a se s d u rin g d riv e a w a y S e ctio n F2
O n a cc e le ra tio n E n g in e s p e e d in crea se s n o rm a lly b u t v e h ic le s p e e d K 1 -2 0 5
*2 6
slo w ly in cre a se s d u rin g a cce le ra tio n
H ig h id le s p e e d a fte r w a rm -u p Id le s p e e d c o n tin u e s at fast id le a fte r w a rm -u p , e n

27 S e ctio n F2
g in e re tu rn s slo w ly to id le a fte r a c c e le ra to r is relea se d
Id le flu c tu a te s /id le h u n ts E n g in e s p e e d c h a n g e s b a c k a n d fo rth b e tw e e n

28 S e ctio n F2
sp e c ifie d id le s p e e d a n d h ig h e r sp e e d
H e sita te s/S tu m b le s on a c c e le ra tio n M o m e n ta ry p a u se at b e g in n in g of a c c e le ra tio n o r d u r
29 S e ctio n F2
in g a c c e le ra tio n
S u rg e s w h ile c ru is in g M o m e n ta ry m in o r irre g u la rity in e n g in e o u tp u t at S e ctio n F2
*3 0
s te a d y v e h ic le sp e e d K 1 -2 0 8
L ack of pow er P e rfo rm a n c e p o o r u n d e r lo a d (i.e., p o w e r d o w n w h e n S e ctio n F1
*31
c lim b in g hills) K 1 -2 1 9
P o o r fu e l e c o n o m y Fuel e c o n o m y u n sa tisfa cto ry S e ctio n F2
*3 2
K 1 -2 0 9
A /C d o e s n o t w o rk A /C c o m p re s s o r m a g n e tic c lu tc h d o e s n o t e n g a g e
33 S e ctio n F2
w h e n A /C sw itch O N
K n o c k in g /P in g in g S o u n d p ro d u c e d w h e n a ir/fu e l m ixtu re is ig n ite d b y
34 s o m e th in g o th e r th a n s p a rk p lu g (i.e., h o t s p o t in S e ctio n F2
c o m b u s tio n c h a m b e r)
35 Fuel o d o r G a so lin e fu e l sm ell o r v is ib le leaks S e ctio n F2

36 E x h a u st su lfu r sm ell R otten e g g sm ell from e xh a u st S e ctio n F2
37 H ig h oil c o n s u m p tio n Oil c o n s u m p tio n e xce ssive S e ctio n F2
S e lf-D ia g n o sis C h e c k e r fla sh e s 88 M IL a lw a ys O N /S e lf-D ia g n o sis C h e c k e r fla sh e s 88

38 S e ctio n F2
w ith te st c o n n e c to r g ro u n d
M IL n e ve r O N S e lf-D ia g n o sis C h e c k e r in d ic a te s d ia g n o s tic tro u b le
39 S e ctio n F2
c o d e N o. o f in p u t d e v ic e b u t M IL n e ve r O N
V e h icle d o e s n o t m o v e in D, S, L N o c re e p at all
40 a n d /o r R ra n g e s V e h icle d o e s n o t m o v e w h e n a c c e le ra to r pe d al K 1 -2 0 9
d e p re s s e d a fte r sh ifte d to D, S, L a n d /o r R ra n g e
V e h ic le m o v e s in N ra n g e V e h icle c re e p s in N ra n g e
41 K 1 -2 1 0
V e h icle m o v e s w h e n a cce le ra to r p e d a l n o t d e p re sse d
42 V e h ic le m o v e s in P ra n g e V e h icle rolls in P ran g e , a n d d rive tra in n o t lo c k u p K 1 -2 1 0
E x ce ssive c re e p V e h icle m o ve s q u ic k ly in D, S, L a n d R ra n g e (a c
c e le ra to r p e d a l not d e p re sse d ) K 1 -2 1 0
43
E xce ssive N to R ra n g e a n d N to D ra n g e shift s h o c k
fe lt
* R e fe r t S e ctio n F1 b e fo re re fe rrin g to K1 S ection.
K1—199
DESCRIPTION PAGE
No. TROUBLE
N o sh ift S in g le ra n g e sh ift ( 1 - * 2 , 2 -» 3 , o r 3 -» 4 ) o n ly
S o m e tim e s shifts c o rre c tly
44 W ith g e a r p o sitio n in h o ld m o d e : K 1 -2 1 1
S hifts s ig le ra n g e s o n ly (1-2, 2-3, o r 3-4)
S hifts in c o rre c tly a t tim e s
A b n o rm a l sh ift S hifts in c o rre c tly (in c o rre c t sh ift pattern)
(ex) V e h ic le shifts 1 -> 4
45 K 1 -2 1 3
d ire c tly w h e n a cc e le ra tin g w ith a c c e le ra to r p e d a l
d e p re s s e d slig h tly
F re q u e n t sh iftin g D o w n s h ift o c c u rs w h e n a cce le ra to r d e p re s s e d s lig h tly
46 K 1 -2 1 5
in D, S a n d L ra n g e s (e x c e p t h o ld m od e )
S hift p o in t h ig h o r lo w Shift p o in ts d o n o t m a tch shift d ia g ra m
S h ifts d e la y e d w h e n a c c e le ra tin g
47 K 1 -2 1 6
S hifts o c c u r to o fa st w h e n a c c e le ra tin g a n d e n g in e
s p e e d d o e s n o t in cre a se
48 N o lo c k u p N o lo c k u p w h e n v e h ic le s p e e d re a ch e s lo c k u p ra n g e K 1 -2 1 9
N o k ic k d o w n D o e s n o t d o w n s h ift w h e n a c c e le ra to r p e d a l
49 K 1 -2 1 9
d e p re s s e d m o re th a n 7 /8 w ith in k ic k d o w n ra n g e
50 E n g in e s p e e d W h e n a c c e le ra tin g E n g in e s p e e d fla re s u p on a c c e le ra tio n K 1 -2 1 9

fla re s u p W h e n u p s h iftin g E n g in e fla re s u p w h e n a cce le ra to r p e d a l d e p re s s e d
a n d /o r d o w n s h iftin g fo r u p s h iftin g
51 K 1 -2 2 0
E n g in e fla re s u p s u d d e n ly w h e n a c c e le ra to r p e d a l
d e p re s s e d fo r d o w n s h iftin g
E x c e s s iv e P, N to R a n d /o r N to S tro n g sh ift s h o c k fe lt a t id le w h e n sh iftin g fro m N to

52 K 1 -2 2 3
sh ift s h o c k D D o r R ra n g e
W h e n u p s h iftin g E xce ssive shift s h o c k fe lt w h e n a cc e le ra tin g at up-
a n d /o r d o w n s h iftin g sh iftin g
53 K 1 -2 2 6
D u rin g cru is in g , e xce ssive sh ift s h o c k fe lt w h e n a c
c e le ra to r p e d a l d e p re s s e d at d o w n s h iftin g
N o e n g in e b ra k in g E n g in e s p e e d d ro p s to id le b u t v e h ic le d o e s n o t slo w
w h e n a c c e le ra to r p e d a l released d u rin g c ru is in g at
m e d iu m to h ig h s p e e d
54 K 1 -2 2 9
E n g in e s p e e d d ro p s to id le b u t v e h ic le d o e s n o t slo w
w h e n a c c e le ra to r p e d a l relea se d w h e n in L ra n g e at
lo w v e h ic le s p e e d
No m ode change M o d e d o e s n o t c h a n g e to /fro m n o rm a l m o d e in D

55 K 1 -2 3 1
ra n g e H o ld m o d e n o t se le cte d o r not ca n c e lle d
56 T ra n s a x le All ra n g e s T ra n sa xle n o isy in all ra n g e s w h e n v e h ic le is id lin g K 1 -2 3 1

n o ise
57 D, S, L, R ra n g e s A b n o rm a l n o ise fro m tra n sa xle in D, S, L, R K 1 -2 3 1
58 T ra n s a x le o v e rh e a ts AT F sm ells b u rn t a n d /o r is d is c o lo re d K 1 -2 3 1
46U0K1-333
SYMPTOM TROUBLESHOOTING CHART
6 WILL START IN OTHER THAN P AND N RANGES
DESCR
• Engine starts in P, N and other ranges
IPTION
Inspect parts and wiring; repair, adjust, or replace malfunctioning parts as necessary
© Selector lever installation or adjustment incorrect cr page K 1 -1 8 3
@ Park/Neutral switch worn or misadjusted c r page K 1 -3 0
46U0K1-334
14 ENGINE STALLS • IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGES
DESCR
• Engine stops unexpectedly when shifted from N or P to other ranges at idle
IPTION
© Engine idle speed low (3) 1-2 shift and/or lockup control solenoid valve worn
(2) Control valve stuck (Pressure regulator valve, converter ® Inhibitor signal malfunction
relief valve, solenoid reducing valve, lockup shift valve © Park/Neutral switch worn or misadjusted
and/or lockup control valve)
Are ignition timing and idle speed OK? Yes Go to next step
c t Section F2
No Adjust ignition timing and/or idle speed
cr Section F2
49 B 0 1 9 9 A 0
Is problem corrected when 10 pin connector of Yes Go to next step

solenoid valve is disconnected?
No Overhaul control valve body and repair
or replace parts as necessary
If large amounts of material are found,
overhaul transaxle and repair or replace
parts as necessary
K1—201
STEP IN S P E C T IO N AC TIO N
A re m e a s u re m e n ts a t p o w e rtra in c o n tro l m o d u le Yes G o to n e xt step
(tra n sa xle ) te rm in a ls O K ?
No If resista n ce n o t O K, c h e c k fo r m a lfu n c
Term. Unit Spec. Condition Page tio n in g p a rts a n d w irin g
n 1 1 -2 7 Constant (lgn:OFF) — • 1-2 shift s o le n o id va lve
2E 0 S o le n o id O FF cr page K 1 -3 5
V
B+ S o le n o id O N
K 1 -3 8 • L o c k u p co n tro l s o le n o id va lve cr page K 1 -3 5
12 1 1 — 27 Constant (lgn:0FF) — If re sista n ce O K b u t v o lta g e not, re p la ce

2K
V
0 N o lo c k u p
K 1 -3 8
p o w e rtra in co n tro l m o d u le (transaxle) cr page K 1 -4 4
B+ Lockup
U n it: f i -♦ R e sista n ce
V - * V o lta g e
Terminal Function
2E 1-2 sh ift so le n o id v a lve
2K L o cku p control solenoid valve
Is o u tp u t v o lta g e o f in h ib ito r sig n a l at p o w e rtra in Yes C h e c k w irin g a n d c o n n e c to r fro m 1 D

c o n tro l m o d u le (tra n sa xle ) te rm in a l O K ? te rm in a l o f p o w e rtra in co n tro l m o d u le
B + : Battery positive voltage (transaxle) to 1 R te rm in a l o f p o w e rtra in
c o n tro l m o d u le (E ngine)
Term. Unit Spec. Condition Page
1D V K 1 -3 8 No G o to n e xt step
B e lo w 1.0 P and N ranges
U nit: V -> V o lta g e
A re m e a s u re m e n ts a t p o w e rtra in c o n tro l m o d u le Yes R e p la ce p o w e rtra in co n tro l m o d u le

(tra n sa xle ) te rm in a ls O K ? (transaxle)
B + : Battery positive voltage cr page K 1 -4 4
0 P and N ranges No C h e c k p a rk/n e u tra l sw itch
2B V cr page K1-30
\/ B+ R ra n g e
11
0 Other ranges
\/ B+ D ra n g e
2D K 1 -3 8
0 Other ranges
B+ S ra n g e
2F V
0 O th e r ra n g e s
B+ L ra n g e
2H V
U nit: V -> V o lta g e
T erm inal F unction

2 B , 11, 2 D , 2F, 2H P a rk/N e u tra l sw itch
46U0K1-335
K 1-202
18 EN G IN E S TA LLS • O N D EC ELER ATIO N
DESC R
• Engine stalls when brake pedal depressed while driving at low speed or stopping
IPTIO N
© AT F level lo w © C o n tro l v a lve stu ck

Is A T F level O K ? Yes G o to n e xt step
cr page K 1 -2 7
No A d ju s t A T F level cr page K 1 -2 7
Level: Between notches on dipstick
HOT RANGE
ATF TEMPERATURE 60—70°C (140—158°F)
20t6Fc
COOL RANGE
ATF TEMPERATURE 1 5 -2 5 °C (5 9 -7 7 ° F )
Is lin e p re ssu re O K? Yes G o to n e xt step

cr page K 1 -1 5
No R e p la ce co n tro l va lve b o d y a sse m b ly
Specified line pressure kPa {kgf/cm2, psi)
Range Idle Stall
420-530 1,100-1,170
D, S, L
(4.2—5.5, 6 0 -7 8 ] (11.2-12.0, 160-170)
730-1,010 1,910-2,030
R
(7.4-10.3, 110-146) (19.4-20.7, 276-294)
Is s o le n o id re d u c in g p re s s u re O K ? Yes G o to N o .14 “ E N G IN E S T A L L S -ID L E

cr page K 1 -1 7 W H E N S H IF TE D FRO M N OR P TO
O TH E R R A N G E S ” in S e ctio n K1 o f this
Specified solenoid reducing pressure: m anual
360— 400 kPa (3 .6 — 4.1 kgf/cm2, 52— 58
(at P range) No R e p la ce co n tro l va lve b o d y a sse m b ly
46U0K1-336
K 1-203
24 ENGINE RUNS ROUGH •O N DECELERATION

DESCR ’ E n g in e s h a ke s a t b e g in n in g o f d e c e le ra tio n , d u rin g d e c e le ra tio n , o r re c o v e ry fro m d e c e le ra tio n
IPTION • E x h a u s t a fte rb u rn
© A T F level lo w
Is A T F level O K ? Y es G o to N o .14 "E N G IN E S T A L L S -ID L E
cr page K 1 -2 7 W H E N S H IF TE D FR O M N O R P TO
O TH E R R A N G E S " in S e ctio n K1 o f this
Level: Between notches on dipstik m an u a l
No A d ju s t A T F level cr page K 1 -2 7
HOT RANGE
ATF TEM PERATURE 60— 7 0 °C (140— 1 5 8 °F |
ATF TEM PERATURE 15— 2 5 °C (59 —7 7 °F )
46U0k1 -337
2 5 , 26 PO O R A C C E L E R A T IO N • DRIVEAWAY
• ON ACCELERATION
DESCR
• E n g in e s p e e d in c re a s e s n o rm a lly b u t v e h ic le s p e e d slo w ly in cre a se s d u rin g a cce le ra tio n
IPTION
© P a rk /N e u tra l sw itch w o rn o r m is a d ju s te d © C o n tro l v a lv e s tu c k (p re ssu re re g u la to r va lve , p re s s u re
© L o c k u p c o n tro l s o le n o id v a lv e w o rn m o d ifie r valve, s o le n o id re d u c in g valve)
(3) L in e p re s s u re lo w © E n g in e p o w e r low
© P o w e rtra in s lip p a g e © P o w e rtra in co n tro l m o d u le (transaxle) m a lfu n c tio n
D o e s S e lf-D ia g n o sis C h e c k e r d is p la y " 0 0 ” w ith Yes G o to n e xt ste p
ig n itio n sw itch O N ?
cr page K 1 -2 3 2 No D ia g n o s tic tro u b le co d e (s) d is p la y e d
• C h e c k fo r c a u s e o f co d e (s) cr page K 1 -2 3 4
Is lin e p re s s u re O K ? Yes G o to n e xt ste p

cr page K 1 -1 5
No R e p la ce c o n tro l v a lve b o d y a sse m b ly
Specified line pressure kPa {kgf/cm 2, psi)
If p ro b le m rem ains, o ve rh a u l tra n sa xle
Range Idle Stall a n d re p a ir o r re p la c e p a rts as
n e ce ssa ry
420-530 1,100-1,170
D, S, L
{4.2—5.5, 6 0 -7 8 ) {11.2-12.0, 160-170)
730-1,010 1,910-2,030
R
{7.4-10.3, 110-146) {19.4-20.7, 276-294)
Is s o le n o id re d u c in g p re ssu re O K ? Yes G o to n e xt ste p

cr page K 1 -1 7
Specified solenoid reducing pressure: No R e p la ce c o n tro l v a lve b o d y a sse m b ly

360— 400 kPa {3.6— 4.1 Kgf/cm2, 52— 58 psi) If p ro b le m rem ains, o ve rh a u l tra n sa xle
(at P range) a n d re p a ir o r re p la c e p a rts as
n e ce ssary
STEP IN SPEC TIO N A C TIO N

Is e n g in e stall s p e e d O K ? Yes G o to S te p 6
cr page K 1-11
rpm
No O ve rh a u l tra n sa xle a n d re p a ir o r re
Engine Engine stall speed p la ce p a rts as n e ce ssary
KL 2 ,2 7 0 — 2 ,5 0 0
A re re s is ta n c e a n d o u tp u t d u ty o f lo c k u p c o n tro l Yes O ve rh a u l tra n sa xle a n d re p a ir o r re

s o le n o id v a lv e at p o w e rtra in c o n tro l m o d u le p la ce p a rts as n e ce ssary
(tra n sa xle ) O K ?
Term. Unit Spec. Condition Page No If resista n ce n o t O K, c h e c k lo c k u p c o n
n 1 1 — 27 Constant (Ign: OFF) — trol s o le n o id va lve a n d w irin g
2K 0 N o lo c k u p cr page K 1 -3 5
V K 1 -3 8 If resista n ce O K b u t v o lta g e is not, g o
B+ Lockup
to n e xt step
U nit: f i -» R e sista n ce
V -> V o lta g e
D is c o n n e c t s o le n o id 1 0 -p in c o n n e c to r; is ve h icle Yes G o to n e xt step

d riv e n as fo llo w s ?
cr page K 1 -2 6 3
Range Gear position

D ra n g e T h ird g e a r (fixed) No R e p la ce co n tro l v a lve b o d y a sse m b ly
S ra n g e T h ird g e a r (fixed) If p ro b le m rem ains, o v e rh a u l tra n sa xle
L ra n g e 1st g e a r (fixed) a n d re p a ir o r re p la c e p a rts as
R ra n g e R e ve rse (fixed) n e ce ssary
D rive v e h ic le in D, S, a n d L ra n g e s (e x c e p t h o ld Yes O ve rh a u l tra n sa xle a n d re p a ir o r re

m o d e ); d o e s v e h ic le sta rt fro m s to p in 1st gear? p la c e p a rts as n e ce ssary
A re e n g in e rp m (d ru m rpm ) at 2 0 km /h 12
m p h ) a n d th ro ttle o p e n in g O K ?
RPM Approx. 2,100

Throttle opening: 4/8
A re m e a s u re m e n ts at p o w e rtra in c o n tro l m o d u le Yes G o to n e xt ste p
(tra n sa xle ) te rm in a ls O K?
B + : Battery positive voltage No C h e c k p a rk/n e u tra l sw itch a n d w irin g cr page K 1 -3 0
Term. Unit Spec. Condition Page If p ro b le m rem ains, retu rn to S tep 6
0 P and N ranges
2B V
B+ R ra n g e
11 V
B+ D ra n g e
2D V K 1 -3 8
B+ S ra n g e
2F V
B+ L ra n g e
2H V
U n it: V -+ V o lta g e
Terminal Function
R e p la c e w ith k n o w n g o o d p o w e rtra in c o n tro l Yes R e p la ce p o w e rtra in co n tro l m o d u le

m o d u le (tra n sa xle ) is p ro b le m c o rre c te d ? (transaxle)
cr page K 1 -4 4 cr page K 1 -4 4
No R e p la ce to rq u e c o n v e rto r cr page K 1-51
46U0K1-338
D ESC R
• M o m e n ta ry m in o r irre g u la rity in e n g in e o u tp u t at s te a d y v e h ic le sp e e d
IP TIO N
© V e h ic le s p e e d p u ls e g e n e ra to r m a lfu n ctio n © E n g in e rp m sig n a l (N e1) m a lfu n ctio n
© C o n tro l v a lv e s tu c k © P o w e rtra in co n tro l m o d u le (transaxle) m a lfu n ctio n
© T h ro ttle p o s itio n s e n s o r m a lfu n c tio n o r m isa d ju ste d

Is re s is ta n c e o f v e h ic le s p e e d p u lse g e n e ra to r at Y es G o to n e xt ste p
p o w e rtra in c o n tro l m o d u le (transaxle) O K?
Term. Unit Spec. Condition
C o n sta n t
2J«2L n 2 5 3 -6 0 4
(Ian: O FF)
U n it: f i <-*• R e sista n ce No C h e c k v e h ic le s p e e d p u lse g e n e ra to r
a n d w irin g
cr page K 1 -3 3
Terminal Function
2J Vehicle speed pulse genelator
2L G ro u n d (in pu t)
Is lin e p re s s u re O K ? Yes O ve rh a u l tra n sa xle a n d re p a ir o r re

cr page K 1 -1 5 p la c e p a rts as n e ce ssary
Specified line pressure kPa {kgf/cm 2, psi)

Range Idle Stall
420-530 1,100-1,170
D, S, L
{4.2—5.5, 60-78) {11.2-12.0,160-170)
730-1,010 1,910-2,030
R
{7.4-10.3, 110-146) {19.4-20.7, 276-294)
Is s o le n o id re d u c in g p re s s u re O K? Y es G o to n e xt step
cr page K 1 -1 7
Specified solenoid reducing pressure:

360— 400 kPa {3.6—4.1 kgf/cm2, 52—58 psi)
(at P range) No R e p la ce co n tro l v a lve b o d y a s s e m b ly
A re m e a s u re m e n ts a t p o w e rtra in c o n tro l m o d u le Yes C h e c k fo r m a lfu n c tio n in g p a rts a n d

(tra n sa xle ) te rm in a ls O K ? w irin g
Term. Unit Spec. Condition Page • E n g in e rp m sig n a l cr page K 1 -3 8

(Ne1 signal)
0 or Engine stopped • T h ro ttle p o sitio n se n so r cr Section F2
4 .5 — 5 .5 (ignition switch ON)
1N V K 1 -3 8
E n g in e run
2 .0 — 3 .0
n in g at idle
Throttle valve closed p la c e p a rts as n e ce ssary
0 .1 — 1.1
throttle position
2T V K 1 -3 8
Throttle valve wide
3 .1 — 4 .4
open throttle
U nit: V - * V o lta g e
Terminal Function
1N Engine rpm signal (Ne1 signal)
2T T h ro ttle p o sitio n se n so r
46U0K1-339
K1—208
31 LACK OF POWER
DESCR
• P e rfo rm a n c e p o o r u n d e r lo a d (i.e., p o w e r d o w n w h e n c lim b in g hills)
IPTION
In s p e c t p a rts; re p a ir, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssary
© T o rq u e c o n v e rte r w o rn c r page K 1 -6 5
© P o w e rtra in b u rn e d (re ve rse clu tch ) c r page K 1-71
46U0K1-340
DESCR
• Fuel e c o n o m y u n sa tisfa cto ry
IPTION
In s p e c t p a rts a n d w irin g ; rep a ir, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssary
© L o c k u p s o le n o id v a lv e w o rn c r page K 1 -3 5
© L o c k u p c o n tro l so le n o id v a lve w o rn _______ c r page K 1 -3 5
46U0K1-341
40 VEHICLE DOES NOT MOVE IN D, S, L, AND/OR R RANGES
DESCR »N o c re e p at all
IPTION •V e h ic le d o e s n o t m o v e w h e n a c c e le ra to r p e d a l d e p re s s e d a fte r sh ifte d to D, S, L, a n d /o r R ra n g e
© A T F level lo w c r page K 1 -2 7
© S e le c to r le v e r in sta lla tio n o r a d ju s tm e n t in c o rre c t c r page K 1 -1 8 3
© L in e p re s s u re lo w c r page K1 - 1 5
© P o w e rtra in s lip p a g e (fo rw a rd c lu tc h , c o a s tin g c lu tc h , 3-4 c lu tc h , 2-4 b ra k e b a n d , o n e -w a y c lu tc h 1,
2, o r p la n e ta ry g e a r) cr page K 1-51
© C o n tro l v a lv e s tu c k (m a n u a l va lve , so le n o id re d u c in g valve) cr page K 1 -1 0 7
© L in e p re s s u re a n d /o r 1-2 sh ift so le n o id v a lv e w o rn cr page K 1 -3 5
© P a rk in g m e c h a n is m w o rn cr page K 1-51
© P o w e rtra in c o n tro l m o d u le (tra n sa xle ) m a lfu n c tio n cr page K 1 -3 8
46U0K1-342
41 VEHICLE MOVES IN N RANGE

DESCR • V e h ic le c re e p s in N ra n g e
IPTION • V e h ic le m o v e s w h e n a c c e le ra to r p e d a l n o t d e p re s s e d
In s p e c t parts; re p a ir, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssary
© S e le c to r le v e r in sta lla tio n o r a d ju s tm e n t in c o rre c t cr page K 1 -1 8 3
© P o w e rtra in b u rn t (F o rw a rd c lu tc h , co a s tin g clu tch ) cr page K 1-51
© C o n tro l v a lv e s tu c k (m a n u a l valve) cr page K 1 -1 0 7
46U0K1 -343
42 VEHICLE MOVES IN P RANGE

DESCR
• V e h ic le ro lls in P ran g e , a n d d riv e tra in n o t lo c k u p
IPTION
In s p e c t parts; rep a ir, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssa ry
© S e le c to r le v e r in sta lla tio n o r a d ju s tm e n t in c o rre c t cr page K 1 -1 8 3
© P a rk in g m e c h a n is m w o rn cr page K 1-51
46U0K1-344
43 EXCESSIVE CREEP
DESCR • V e h ic le m o v e s q u ic k ly in D, S, L, a n d R ra n g e s (a cce le ra to r p e d a l n o t d e p re sse d )

IPTION
E x c e s s iv e N to R ra n g e a n d N to D ra n g e sh ift s h o c k fe lt
[T R O U B L E S H O O T IN G H IN T S ]
In s p e c t p a rts a n d w irin g ; rep a ir, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssa ry
© E n g in e id le s p e e d m is a d ju s te d cr Section F2
© L in e p re s s u re at id le h ig h cr page K 1 -1 5
© Id le s w itc h m a lfu n c tio n cr Section F2
® P o w e rtra in c o n tro l m o d u le (tra n sa xle ) m a lfu n ctio n cr page K 1 -3 8
46U0K1-345
44 NO S H IF T
DESCR W ith g e a r p o sitio n p o sitio n in h o ld m o d e :

IPTION S hifts in s in g le ra n g e s o n ly (1-2, 2-3, o r 3-4)
S h ifts in c o rre c tly at tim e s
[T R O U B L E S H O O T IN G H IN T S ]
© A T F level lo w © V e h icle s p e e d s e n so r m a lfu n ctio n
© 1-2 shift, 2-3 shift, a n d /o r 3-4 sh ift so le n o id va lve s w orn © P oor g ro u n d
© C o n tro l v a lv e stu ck © P o w e rtra in co n tro l m o d u le (transaxle) m a lfu n c tio n
© H o ld s w itc h m a lfu n c tio n
© V e h ic le s p e e d p u lse g e n e ra to r m a lfu n ctio n

A re A T F level a n d c o n d itio n O K? Y es G o to n e xt step
cr page K 1 -2 7
No P ro b le m w ith in tra n sa xle
G o to n e xt step, a n d c h e c k fo r th e
m ain cause.
W h e n th e p ro b le m is fo u n d a n d c o rre c t
ed, o ve rh a u l th e tra n sa xle a n d re p a ir o r
re p la c e p a rts as n e ce ssry
D o e s S e lf-D ia g n o sis C h e c k e r d is p la y “ 0 0 ” w ith Yes G o to n e xt ste p

ig n itio n s w itc h O N ?
cr page K 1 -2 3 2
No D ia g n o stic tro u b le co d e (s) d is p la y e d
• C h e c k fo r c a u se o f co d e (s) cr page K 1 -2 3 5
49 B 019 9A 0
49 H 018 9A1
D is c o n n e c t s o le n o id 1 0 -p in c o n n e c to r; is v e h ic le Yes G o to n e xt ste p
d riv e n as fo llo w s?
cr page K 1 -2 6 3
Range Gear position No R e p la ce co n tro l va lve b o d y a sse m b ly
D ra n g e T h ird g e a r (fixed) If p ro b le m rem ains, o ve rh a u l tra n sa xle
a n d re p a ir o r re p la c e p a rts as
S ra n g e T h ird g e a r (fixed)
n e ce ssa ry
L ra n g e 1st g e a r (fixed)
R ra n g e R e ve rse (fixed)
D riv e v e h ic le in D, S, a n d L ra n g e s (e x c e p t h o ld Yes G o to S te p 6
m o d e ); d o e s v e h ic le sta rt fro m s to p in 1st g e a r?
A re e n g in e rp m (d ru m rpm ) at 2 0 km /h (1 2
m p h ) a n d th ro ttle o p e n in g O K ?
RPM: Approx. 2,100
Throttle opening: 4/8
K1-211
A re m e a s u re m e n ts at p o w e rtra in c o n tro l m o d u le Yes R e p la ce c o n tro l v a lve b o d y a sse m b ly
(tra n sa xle ) te rm in a ls O K ? If p ro b le m rem ains, o v e rh a u l tra n sa xle
B + : Battery positive voltage a n d re p a ir o r re p la c e p a rts as
Term. Unit Spec. Condition Page n e ce ssa ry
fi 1 1 -2 7 Constant (Ign: OFF) — No If resista n ce not O K, c h e c k fo r m a lfu n c

2E 0 S o le n o id O FF tio n in g p a rts a n d w irin g
V
K 1 -3 8 • 1-2 sh ift s o le n o id va lve cr
page K 1 -3 5
• 2 -3 shift s o le n o id va lve cr
page K 1 -3 5
G 11— 27 Constant (Ign: OFF) — • 3-4 sh ift s o le n o id va lve cr page K 1 -3 5
2G 0 S o le n o id O FF If resista n ce O K b u t v o lta g e is not, g o
V K 1 -3 8
B+ S o le n o id O N to n e xt ste p
12 1 1— 27 Constant (Ign: OFF) —
21 0 S o le n o id O FF
V K 1 -3 8
U n it: f i R e sista n ce
V V o lta g e
Terminal Function
2E 1-2 shift s o le n o id va lve
2G 2-3 sh ift so le n o id va lve
21 3 -4 sh ift so le n o id va lve
A re m e a s u re m e n ts at p o w e rtra in c o n tro l m o d u le Yes G o to n e xt ste p

No C h e c k fo r m a lfu n c tio n in g p a rts a n d

Term. Unit Spec. Condition Page w irin g
0 Switch depressed • H o ld sw itch cr page K 1 -3 3
1H V K 1 -3 8 • V e h icle s p e e d p u lse g e n e ra to r cr page K 1 -3 3
B+ Switch released
• V e h icle s p e e d se n so r cr page K 1 -3 3
C o n sta n t If p ro b le m rem ains, retu rn to S tep 3
2J«2L 253— 604 —
(Ign : O FF)
0 or 4.0—5.0 Vehicle stopped
1P V K 1 -3 8
2 .0 — 3 .0 Vehicle m oving
U n it: V V o lta g e
Q R e sista n ce
Terminal Function
1H H o ld sw itch
1P V e h ic le s p e e d se n so r
2J Vehicle speed pulse generator
2L G ro u n d (input)
Is v o lta g e b e tw e e n 2P te rm in a l of p o w e rtra in Yes G o to n e xt ste p

c o n tro l m o d u le (transaxle) a n d tra n s a x le ca se
O K?
No P ro b le m in g ro u n d c irc u it
R e p a ir w irin g o r re p la c e c o n n e c to r
Specified voltage: OV
R e p la c e w ith k n o w n g o o d p o w e rtra in co n tro l Yes R e p la ce p o w e rtra in co n tro l m o d u le

m o d u le (tra n sa xle ) is p ro b le m c o rre c te d ? (transaxle)

p la c e p a rts as n e ce ssary
46U0K1-346
K 1-212
45 ABNORMAL SHIFT
D ESC R • S hifts in c o rre c tly (in c o rre c t sh ift pa ttern )

IP TIO N (Ex) V e h ic le sh ifts 1 - * 4 d ire c tly w h e n a c c e le ra tin g w ith a cce le ra to r p e d a l d e p re s s e d slig h tly
© A T F level lo w © P a rk/N e u tra l sw itch w o rn
© 1-2 shift, 2-3 shift, a n d /o r 3-4 sh ift so le n o id valves w o rn © P o w e rtra in co n tro l m o d u le (transaxle) m a lfu n c tio n
© P o o r g ro u n d © S tu ck c o n tro l va lve s
@ T h ro ttle p o sitio n s e n so r m a lfu n c tio n o r m isa d ju ste d
© V e h ic le s p e e d p u lse g e n e ra to r m a lfu n ctio n

A re A T F level a n d c o n d itio n O K? Yes G o to n e xt step
C7- page K 1 -2 7
m ain ca u se .
W h e n th e p ro b le m is fo u n d a n d c o rre c t
e d , o v e rh a u l th e tra n sa xle a n d re p a ir or
re p la c e p a rts as n e ce ssry
D o e s S e lf-D ia g n o sis C h e c k e r d is p la y “ 0 0 " w ith Yes G o to n e xt ste p

cr page K 1 -2 3 2 No D ia g n o stic tro u b le co d e (s) d is p la y e d
49 B01 9 9 A 0
49 H 018 9A1
A re m e a s u re m e n ts a t p o w e rtra in c o n tro l m o d u le Yes G o to n e xt ste p

a 1 1 — 27 Constant (Ign: OFF) — No If resista n ce n o t O K, c h e c k fo r m a lfu n c
tio n in g p a rts a n d w irin g
2E 0 S o le n o id O FF
V K 1 -3 8 • 1-2 sh ift s o le n o id va lve cr page K 1 -3 5
• 2-3 sh ift s o le n o id va lve cr page K 1 -3 5
ft 11— 2 7 Constant (Ign: OFF) — • 3-4 sh ift s o le n o id va lve cr page K 1 -3 5
2G 0 S o le n o id O FF
V K 1 -3 8 If resista n ce O K b u t v o lta g e is not, g o
B+ S o le n o id ON
to n e xt ste p
ft 1 1 -2 7 Constant (Ign: OFF) —
V K 1 -3 8
U n it: ft - * R e sista n ce
V - * V o lta g e
Terminal Function
2E 1-2 sh ift s o le n o id va lve
2G 2-3 sh ift so le n o id v a lve
2\ 3-4 sh ift s o le n o id va lve
K 1-213
STEP IN SPEC TIO N AC TIO N

Is v o lta g e b e tw e e n 2 P te rm in a l o f p o w e rtra in Yes G o to n e xt step
c o n tro l m o d u le (tra n sa xle ) a n d tra n sa xle ca se
OK?
C h e c k fo r w irin g
A re m e a s u re m e n ts at p o w e rtra in c o n tro l m o d u le Yes G o to n e xt step

0 .1 -1 .1 Throttle valve closed • T h ro ttle p o sitio n se n so r cr Section F2
w throttle position • V e h icle sp e e d p u lse g e n e ra to r cr page K 1 -3 3
2T K 1 -3 8 • P a rk/N e u tra l sw itch cr page K 1 -3 0
Throttle valve wide
3 .1 — 4 .4
open throttle
C o n s ta n t
2J«2L U 2 5 3 -6 0 4
(Ign : OFF)
—
0 P and N ranges
2B V
B+ R ra n g e
11 V
B+ D ra n g e
2D V K 1 -3 8
B+ S ra n g e
2F V
B+ L ra n g e
2H V
U nit: f i R e sista n ce
V V o lta g e
R e p la c e w ith k n o w n g o o d p o w e rtra in co n tro l Yes R e p la ce p o w e rtra in c o n tro l m o d u le

m o d u le (tra n sa xle ); is p ro b le m c o rre c te d ? (transaxle) cr page K 1 -4 4
cr page K 1 -4 4 No R e p la ce co n tro l va lve b o d y a sse m b ly
If p ro b le m rem ains, o v e rh a u l tra n sa xle
a n d re p a ir o r re p la ce p a rts as
n e ce ssa ry
46U0K1-347
46 FREQUENT SHIFTING
DESCR
• D o w n s h ift o c c u rs w h e n a c c e le ra to r d e p re s s e d slig h tly in D, S, a n d L ra n g e s (e x c e p t h o ld m od e )
IPTION
© P o o r g ro u n d @ V e h icle s p e e d se n so r m a lfu n ctio n
© T h ro ttle p o sitio n s e n s o r m a lfu n c tio n o r m isa d ju ste d © P o w e r tra in b u rn t (2— 4 b ra k e b a n d )
( 3) P o w e rtra in c o n tro l m o d u le (tra n sa xle ) m a lfu n ctio n

A re th e re a n y d ia g n o s tic tro u b le co d e (s) d is Yes D ia g n o stic tro u b le co d e (s) d is p la y e d
p la y e d o n th e S e lf-D ia g n o sis C h e c k e r w h e n th e • C h e c k fo r c a u se of co d e (s) cr page K 1 -2 3 5
ig n itio n sw itch is O N ?
a- page K 1 -2 3 2 No G o to n e xt ste p
Is v o lta g e b e tw e e n 2 P te rm in a l o f p o w e rtra in Y es G o to n e xt ste p

c o n tro l m o d u le (tra n sa xle ) a n d tra n s a x le ca se
OK?
R e p a ir w irin g o r re p la c e c o n n e c to r
Is in p u t v o lta g e o f th ro ttle p o sitio n s e n so r at Yes G o to n e xt ste p

p o w e rtra in c o n tro l m o d u le (tra n sa xle ) O K ?
Term. Unit Spec. Condition Page No C h e c k th ro ttle p o sitio n se n so r and
Throttle valve closed w irin g
0 .1 — 1.1 cr Section F2
throttle position
2T V K 1 -3 8
Throttle valve wide
3 .1 — 4 .4
open throttle
U n it: V -» V o lta g e
Is in p u t v o lta g e o f v e h ic le s p e e d s e n so r at Yes G o to n e xt ste p

p o w e rtra in c o n tro l m o d u le (tra n sa xle ) O K?
Term. Unit Spec. Condition Page No C h e c k v e h ic le s p e e d s e n so r a n d w irin g
0 or 4.0-5.0 Vehicle stopped cr page K 1 -3 3
1P V K 1 -3 8
2 .0 — 3 .0 Vehicle moving
U nit: V -♦ V o lta g e
R e p la c e w ith k n o w n g o o d p o w e rtra in co n tro l Y es R e p la ce p o w e rtra in c o n tro l m o d u le

m o d u le (transaxle); is p ro b le m c o rre c te d ? (transaxle)
If p ro b le m rem ains, o ve rh a u l tra n sa xle
ne ce ssary
46U0K1-348
K 1-215
47 SHIFT POINT HIGH OR LOW

D ESC R • S h ift p o in ts d o n o t m a tc h sh ift d ia g ra m
IP TIO N • S h ifts d e la y e d w h e n a cc e le ra tin g
• S hifts o c c u r to o fa st w h e n a c c e le ra tin g a n d e n g in e s p e e d d o e s n o t in cre a se
© L in e p re s s u re s o le n o id v a lv e w o rn @ V e h icle s p e e d p u lse g e n e ra to r m a lfu n ctio n
© T h ro ttle p o s itio n s e n so r m a lfu n c tio n o r m isa d ju ste d © V e h icle s p e e d s e n so r m a lfu n ctio n
(3) A T F th e rm o s e n s o r m a lfu n c tio n © P a rk/N e u tra l sw itch m a lfu n ctio n
D o e s S e lf-D ia g n o sis C h e c k e r d is p la y “ 0 0 ” w ith Yes G o to n e xt ste p
cr page K 1 -2 3 2
• C h e c k fo r c a u se o f code(s) cr page K 1 -2 3 5
A re re s is ta n c e a n d o u tp u t d u ty o f line p re ssu re Y es G o to n e xt ste p

s o le n o id v a lv e a t p o w e rtra in co n tro l m o d u le
No If resista n ce n o t O K, c h e c k line p re s
Term. Unit Spec. Condition Page s u re so le n o id va lve a n d w irin g
9 -1 8 Constant (Ign: OFF) — cr page K 1 -3 5
Throttle valve closed
A pprox. 67 If resista n ce O K b u t d u ty is not, g o to
2N throttle position
% K 1 -2 6 3 n e xt ste p
Throttle valve wide
A pprox. 23
open throttle
U nit: f i - * R e sista n ce
% -> O N d u ty
Is in p u t v o lta g e o f th ro ttle p o sitio n s e n so r at Y es G o to n e xt step

p o w e rtra in c o n tro l m o d u le (tra n sa xle ) O K ?
Term. Unit Spec. Condition Page No C h e c k th ro ttle p o sitio n se n so r a n d
0 .1 — 1.1 cr Section F2
throttle position
2T V K 1 -3 8
Throttle valve wide
3 .1 — 4 .4
open throttle
U nit: V -» V o lta g e
K 1-216
STEP IN S P E C TIO N AC TIO N
Is in p u t v o lta g e o f A T F th e rm o s e n s o r at p o w e r Yes G o to n e xt ste p
tra in c o n tro l m o d u le (tra n sa xle ) O K ?

A T F te m p .
Approx. 3.5 No C h e c k A T F th e rm o s e n s o r a n d w irin g cr page K 1 -3 2
2 0 °C (6 8 °F )
1G»2P V K 1 -3 8
A T F te m p .
Approx. 0.6
130°C (26 6 °F )
Unit: V -» Voltage
Terminal Function
1G A T F th e rm o s e n s o r
2P G ro u n d (input)

C o n s ta n t No C h e c k fo r m a lfu n c tio n in g p a rts a n d
2J«2L n 2 5 3 — 604 — w irin g
(Ign: O FF)
• V e h icle s p e e d p u lse g e n e ra to r cr page K 1 -3 3
\/ 0 or 4.0—5.0 Vehicle stopped
1P • V e h icle s p e e d se n so r cr page K 1 -3 3
2 .0 — 3 .0 Vehicle moving cr page K 1 -3 0
• P a rk/N e u tra l sw itch
0 P and N ranges
2B V
B+ R ra n g e
11 V
K 1 -3 8
\/ B+ D ra n g e
2D
B+ S ra n g e
2F
B+ L ra n g e
2H V
U n it: n R e sista n ce
V V o lta g e
Terminal Function
1P V e h icle s p e e d se n so r

K 1-217

Is lin e p re s s u re O K? Yes G o to n e xt step
cr page K 1 -1 5
Specified line pressure kPa (kgf/cm 2, psij

Range Idle Stall If p ro b le m rem ains, o v e rh a u l tra n sa xle
420-530 1,100-1,170
D, S, L n e ce ssa ry
(4.2—5.5, 6 0 -7 8 ) (11.2-12.0, 160-170)
730-1,010 1,910-2,030
R
(7.4-10.3, 110-146) (19.4-20.7, 276-294)
Is s o le n o id re d u c in g p re s s u re O K? Yes R e p la ce p o w e rtra in co n tro l m o d u le

cr page K 1 -1 7 (transaxle)
cr page K 1 -4 4
Specified solenoid reducing pressure:
360— 400 kPa (3 .6 —4.1 kgf/cm2, 52— 58 psi) If p ro b le m rem ains, o v e rh a u l tra n sa xle
(at P range) a n d re p a ir o r re p la c e p a rts as
n e ce ssary
No R e p la ce c o n tro l v a lve b o d y a s s e m b ly
46U0K1-349
48 NO LO C K -U P
D ESC R
• N o lo c k u p w h e n v e h ic le s p e e d re a ch e s lo c k u p ra n g e
IP TIO N
© A T F level lo w cr page K 1 -2 7
© 1-2 shift, 2 -3 shift, 3 -4 shift, lo c k u p c o n tro l, 3 -2 tim in g , lo c k u p a n d /o r line p re ssu re s o le n o id va lve w o rn cr page K 1-35
@ H o ld sw itch w o rn cr page K 1-29
© P a rk/N e u tra l sw itch w o rn o r m is a d ju s te d cr page K 1-30
© S to p lig h t sw itch m a lfu n c tio n cr page K 1-35
© C o n tro l va lve s tu c k (lo c k u p sh ift valve, lo c k u p co n tro l valve, so le n o id re d u c in g valve) cr page K1-107
© ATF th e rm o s e n s o r m a lfu n c tio n cr page K 1-32
© T h ro ttle p o sitio n s e n s o r m a lfu n c tio n o r m is a d ju s te d cr Section F2
© E n g in e rp m sig n a l (N e 1 sig n a l) m a lfu n c tio n cr page K 1 -3 8
© V ehicle s p e e d p u lse g e n e ra to r m a lfu n c tio n cr page K 1-33
© V ehicle s p e e d s e n so r m a lfu n c tio n cr page K 1-33
© P ow ertrain c o n tro l m o d u le (transaxle) m a lfu n c tio n cr page K 1 -3 8
© T orque c o n v e rte r w o rn cr page K 1 -6 5
46U0K1-350
49 NO KICKDOWN
DESCR
• D o e s n o t d o w n s h ift w h e n a c c e le ra to r p e d a l d e p re s s e d m o re th a n 7/8 w ith in k ic k d o w n ra n g e
IPTION
In s p e c t p a rts a n d w irin g ; repair, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssary
© T h ro ttle p o sitio n s e n so r m a lfu n c tio n o r m isa d ju ste d cr Section F2
© H o ld sw itch w o rn cr page K 1-2 9
© P a rk /N e u tra l sw itch w o rn o r m is a d ju s te d cr page K 1-30
© L in e p re s s u re s o le n o id valve w o rn cr page K 1-35
© C o n tro l va lve s tu c k (p re ssu re re g u la to r valve, p re ssu re m o d ifie r valve, s o le n o id re d u c in g valve) cr page K1-107
© P ow ertrain c o n tro l m o d u le (tra n sa xle ) m a lfu n c tio n cr page K 1 -3 8
46U0K1-351
50 ENGINE SPEED FLARES UP •W H EN ACCELERATING
DESCR
• E n g in e s p e e d fla re s u p o n a c c e le ra tio n
IPTION
In s p e c t p a rts a n d w irin g ; repair, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as ne ce ssary
© ATF level lo w cr page K 1 -2 7
© S e le c to r lever in sta lla tio n o r a d ju s tm e n t in c o rre c t cr page K 1-183
© T h ro ttle p o sitio n s e n s o r m a lfu n c tio n o r m is a d ju s te d cr Section F2
© L in e p re s s u re lo w cr page K 1-15
© P ow ertrain s lip p a g e (F o rw a rd c lu tc h , 3 -4 clu tch , 2-4 b ra ke b a n d , o ne-w ay c lu tc h 1, 2, p la n e ta ry g e a r) cr page K1-51
© C o n tro l va lve s tu c k (P ressu re re g u la to r valve, s o le n o id re d u c in g valve) cr page K1-107
© L in e p re s s u re so le n o id va lve w o rn cr page K 1-35
© ATF th e rm o s e n s o r m a lfu n c tio n cr page K 1-32
© P ow ertrain c o n tro l m o d u le (tra n sa xle ) m a lfu n c tio n cr page K 1-38
46U0K1-352
51 ENGINE SPEED FLARES UP •W H EN UPSHIFTING AND/OR DOWNSHIFTING

DESCR • E n g in e fla re s u p w h e n a c c e le ra to r p e d a l d e p re s s e d fo r u p sh iftin g
IPTION • E n g in e fla re s u p s u d d e n ly w h e n a c c e le ra to r p e d a l d e p re s s e d fo r d o w n s h iftin g
© A T F level lo w © L in e p re ssu re s o le n o id va lve w o rn
© S e le c to r le v e r in sta lla tio n o r a d ju s tm e n t in c o rre c t © 3-2 tim in g s o le n o id va lve w o rn
© T h ro ttle p o s itio n s e n s o r m a lfu n c tio n o r m isa d ju ste d © V e h icle s p e e d p u lse g e n e ra to r m a lfu n ctio n
© L in e p re s s u re lo w ® A T F th e rm o s e n s o r m a lfu n ctio n
© P ow ertrain s lip p a g e (F o rw a rd c lu tc h , c o a s tin g clu tch , 3-4 © P o w e rtra in co n tro l m o d u le (tra n sa xle ) m a lfu n ctio n
c lu tc h , 2 -4 b ra k e b a n d o O n e -w a y c lu tc h 1, 2, p la n e ta ry
g e a r)
© C o n tro l v a lv e s tu c k (P ressu re re g u la to r va lve , p re ssu re
m o d ifie r va lve , s o le n o id re d u c in g valve)
cr page K 1 -2 7
No P ro b le m w ith in tran sa xle .
m ain ca u se . W h e n th e p ro b le m is fo u n d
a n d c o rre c te d , o v e rh a u l th e tra n sa xle
a n d re p a ir o r re p la c e p a rts as n e ce ssry
D o e s S e lf-D ia g n o sis C h e c k e r d is p la y " 0 0 ” w ith Y es G o to n e xt step

cr page K 1 -2 3 2
No D ia g n o s tic tro u b le co d e (s) d is p la y e d
Is lin e p re s s u re O K ? Yes O ve rh a u l tra n sa xle a n d re p a ir o r re

cr page K 1 -1 5 p la ce p a rts as n e ce ssa ry
No C h e c k se le cto r le ve r o p e ra tio n
Specified line pressure kPa (kgf/cm 2, psi)
cr page K 1 -1 8 3
Range Idle Stall If O K, g o to n e xt ste p
If n o t O K , ad ju st, rep a ir, o r re p la ce
420-530 1,100-1,170
D, S, L se le c to r lever
(4.2—5.5, 60-78) (11.2-12.0,160-170)
cr page K 1 -1 8 3
730-1,010 1,910-2,030
R
[7.4-10.3,110-146) (19.4-20.7, 276-294]
K 1-220
4 A re re s is ta n ce a n d o u tp u t d u ty o f lin e p re ssu re Yes R e p la ce co n tro l v a lv e b o d y a sse m b ly
s o le n o id v a lve a t p o w e rtra in c o n tro l m o d u le If p ro b le m rem ains, o ve rh a u l tra n sa xle
tra n s a x le ) O K ? a n d re p a ir o r re p la c e p a rts as
n e ce ssa ry
n 9 -1 8 Constant (Ign: OFF) — No If resista n ce n o t O K, c h e c k line p re s
Throttle valve closed su re s o le n o id v a lve a n d w irin g
2N Approx. 67
throttle position
cr page K 1 -3 5
[3V ] % K1 If re sista n ce O K b u t d u ty is not, g o to
Throttle valve wide
Approx. 23 n e xt ste p
open throttle
U nit: Q — R e sista n ce
% — O N d u ty
5 A re re s is ta n ce a n d o u tp u t v o lta g e o f 3-2 tim in g Yes G o to n e xt ste p

s o le n o id v a lv e at p o w e rtra in c o n tro l m o d u le
No If resista n ce n o t O K, c h e c k 3-2 tim in g
s o le n o id v a lve a n d w irin g
Term. Unit Spec. Condition Page cr page K 1 -3 5
fi 1 1 -2 7 Constant (Ign: OFF) — If resista n ce O K b u t v o lta g e is not, g o
to n e xt ste p
O th e r th a n
0
above
2M K1 38
V 1 — 2, 2 - 3 ,
B+ 3 - 4 , 3 — 2,
2 — 1 shift
U nit: f i — R e sista n ce
V — V o lta g e
6 Is in p u t v o lta g e o f th ro ttle p o sitio n s e n so r at Yes G o to n e xt ste p

0 .1 — 1.1 No C h e c k th ro ttle p o sitio n s e n so r and
throttle position
2T V K 1 -3 8 w irin g
Throttle valve wide
3 .1 -4 .4
open throttle
cr Section F2
U nit: V — V o lta g e

A re m e a s u re m e n ts a t p o w e rtra in c o n tro l m o d u le Yes R e p la ce p o w e rtra in co n tro l m o d u le
(tra n sa xle ) te rm in a ls O K ? (transaxle)
cr page K 1 -4 4
C o n s ta n t w irin g
2J«2L 0 2 5 3 -6 0 4 —
(Ign: OFF) • V e h icle sp e e d p u lse g e n e ra to r cr page K 1 -3 3
Approx. 3.5
A T F te m p . • A T F th e rm o s e n s o r cr page K 1 -3 2
2 0 ° C |6 8 ° F )
1G«2P V K 1 -3 8
ATF temp.
Approx. 0.6
130°C (26 6 °F )
U nit: f i -» R e sista n ce
V - * V o lta g e
Terminal Function
46U0K1-353
52 EXCESSIVE SHIFT SHOCK • P, N to R and/or N to D
DESCR
• S tro n g sh ift s h o c k fe lt at id le w h e n sh iftin g fro m N to D o r R ra n g e
IPTION
© Id le s p e e d h ig h © 1-2 shift, 2-3 shift, a n d /o r 3-4 shift s o le n o id va lve s
© T h ro ttle p o sitio n s e n s o r m a lfu n c tio n o r m isa d ju ste d © AT F th e rm o s e n s o r m a lfu n ctio n
© L in e p re s s u re h ig h © N-D, o r N-R a c c u m u la to r w o rn
@ C o n tro l v a lv e s tu c k (P re ssu re re g u la to r valve, c u tb a c k © In h ib ito r sig n a l m a lfu n ctio n
va lve , s o le n o id re d u c in g valve) © V e h icle s p e e d p u lse g e n e ra to r m a lfu n ctio n
© P o w e rtra in s lip p a g e © P a rk/N e u tra l sw itch w o rn o r m isa d ju ste d
© L in e p re s s u re so le n o id v a lv e w o rn © P o w e rtra in co n tro l m o d u le (transaxle) m a lfu n c tio n
A re ig n itio n tim in g a n d id le s p e e d O K? Yes G o to n e xt ste p
cr Section F2
No A d ju s t ig n itio n tim in g a n d /o r id le s p e e d
crS ection F2
D o e s S e lf-D ia g n o sis C h e c k e r d is p la y " 0 0 ” w ith Yes G o to n e xt step

cr page K 1 -2 3 2
Is lin e p re s s u re O K ? Y es G o to n e xt ste p
cr page K 1 -1 5
No G o to S te p 6
Specified line pressure kPa (kgf/cm 2, psi)
Range Idle Stall
420-530 1,100-1,170
D, S, L
(4.2—5.5, 6 0 -7 8 ) (11.2-12.0, 160-170)
730-1,010 1,910-2,030
R
(7.4-10.3, 110-146) (19.4-20.7, 276-294)
Is s o le n o id re d u c in g p re ssu re O K? Yes G o to n e xt ste p
cr page K 1 -1 7
If p ro b le m rem ains, o v e rh a u l tra n sa xle
Specified solenoid reducing pressure: a n d re p a ir o r re p la c e p a rts as
360— 400 kPa (3 .6 —4.1 kgf/cm2, 52—58 psi) n e ce ssary
(at P range)
K 1-223
is e n g in e stall s p e e d O K ? Yes G o to S te p 9
cr page K 1-11
rpm p la c e p a rts as n e ce ssa ry
Engine Engine stall speed
KL 2 ,2 7 0 -2 ,5 0 0
A re re s is ta n c e a n d o u tp u t d u ty o f line p re ssu re Yes O ve rh a u l tra n sa xle a n d re p a ir o r re

so le n o id v a lv e at p o w e rtra in c o n tro l m o d u le p la c e p a rts as n e ce ssa ry
Term. Unit Spec. Condition Page No If re sista n ce not O K , c h e c k line p re s
12 9 -1 8 Constant (Ign: OFF) — s u re s o le n o id va lve a n d w irin g
cr page K 1 -3 5
A p p ro x. 67
% K 1 -2 6 2 If resista n ce O K b u t d u ty is not, g o to
Throttle valve wide
A p p ro x. 23 n e xt ste p
open throttle
U nit: 12 -» R e sista n ce
% — O N d u ty
Is in p u t v o lta g e of th ro ttle s e n so r at p o w e rtra in Y es G o to n e xt ste p

c o n tro l m o d u le (tra n sa xle ) O K?
Term. Unit Spec. Condition Page No C h e c k th ro ttle p o sitio n s e n so r a n d
0 .1 — 1.1
throttle position cr Section F2
2T V K 1 -3 8
Throttle valve wide
3 .1 — 4 .4
open throttle
U nit: V -+ V o lta g e
A re m e a s u re m e n ts at p o w e rtra in c o n tro l m o d u le Yes R e p la ce co n tro l va lve b o d y a sse m b ly

(tra n sa xle ) te rm in a ls O K? If p ro b le m rem ains, o ve rh a u l tra n sa xle
B + : Battery positive voltage a n d re p a ir or re p la c e p a rts as
n e ce ssa ry
12 1 1 -2 7 Constant (Ign: OFF) — No If resista n ce not O K, c h e c k fo r m a lfu n c
V K 1 -3 8 • 1-2 shift s o le n o id va lve cr page K 1 -3 5
B+ S o le n o id O N • 2-3 shift s o le n o id va lve cr page K 1 -3 5
12 1 1 — 27 Constant (Ign: OFF) — • 3-4 sh ift s o le n o id va lve cr page K 1 -3 5
V K 1 -3 8
B+ S o le n o id O N If re sista n ce O K b u t v o lta g e is not, g o
to n e xt ste p
12 1 1 — 27 Constant (Ign: OFF) —
V K 1 -3 8
U nit: 12 - * R e sista n ce
V -» V o lta g e
Terminal Function
2E 1-2 sh ift s o le n o id v a lve
2G 2 -3 sh ift so le n o id v a lve
21 3 -4 sh ift so le n o id v a lve
K 1-224
A re m e a s u re m e n ts a t p o w e rtra in c o n tro l m o d u le Yes G o to n e xt ste p

w irin g
Term. Unit Spec. Condition Page • AT F th e rm o s e n s o r cr page K 1 -3 2
C o n s ta n t • In h ib ito r signal cr page K 1 -3 8
2J«2L n 2 5 3 -6 0 4 —
(Ign : O FF) • V e h icle s p e e d pu lse g e n e ra to r cr page K 1 -3 3
A T F te m p .
• P a rk/N e u tra l sw itch cr page K 1 -3 0
Approx. 3.5
W 2 0 °C (6 8 °F )
1G«2P
ATF temp.
Approx. 0.6
130°C (26 6 °F )
w B+ O th e r ra n g e s
1D
B e lo w 1.0 P and N ranges
V 0 P and N ranges
2B
K 1 -3 8
w B+ R ra n g e
11
B+ D ra n g e
2D V
w B+ S ra n g e
2F
w B+ L ra n g e
2H
U nit: V V o lta g e
0 R e sista n ce
Terminal Function
1D In h ib ito r sig n a l
2 B , 21, 2 D , 2F, 2 H P a rk/N e u tra l sw itch
2P G ro u n d (in pu t)
10 R e p la c e w ith k n o w n g o o d p o w e rtra in co n tro l Yes R e p la ce p o w e rtra in co n tro l m o d u le

m o d u le (E n g in e ); is p ro b le m c o rre c te d ? (E ngine)
cr Section F2
No O ve rh a u l tra n s a x le a n d re p a ir o r re
p la c e p a rts as n e ce ssa ry
46U0K1-354
K 1-225
53 EXCESSIVE SHIFT SHOCK •W H EN UPSHIFTING AND/OR DOWNSHIFTING

DESCR • E x c e s s ive sh ift s h o c k fe lt w h e n a c c e le ra tin g at u p sh iftin g
IPTION • D u rin g cru is in g , e xce ssive sh ift s h o c k fe lt w h e n a c c e le ra to r pe d al d e p re s s e d at d o w n s h iftin g
© A T F level lo w © V e h icle s p e e d p u lse g e n e ra to r m a lfu n ctio n
© T h ro ttle p o s itio n s e n s o r m a lfu n c tio n o r m is a d ju s te d © R e d u ce to rq u e sig n a l 1 m a lfu n ctio n
© L in e p re s s u re h ig h © R e d u ce to rq u e sig n a l 2 m a lfu n ctio n
© P o w e rtra in s lip p a g e ® T o rq u e re d u c e d sig n a l/E n g in e c o o la n t te m p e ra tu re s ig
© C o n tro l v a lv e s tu c k (P re ssu re re g u la to r va lve , s o le n o id nal m a lfu n ctio n
re d u c in g v a lve , p re ssu re m o d ifie r valve) © AT F th e rm o s e n s o r m a lfu n ctio n
© 1-2 shift, 2-3 shift, 3 -4 shift, 3 -2 tim in g , a n d /o r line p re s © A tm o s p h e ric p re ssu re s e n so r m a lfu n ctio n
s u re s o le n o id v a lv e w o rn

cr page K 1 -2 7
a n d c o rre c te d , o ve rh a u l th e tra n sa xle
a n d re p a ir or re p la c e parts as n e ce ssry
D o e s S e lf-D ia g n o sis C h e c k e r d is p la y “ 0 0 ” w ith Yes G o to n e xt step

cr page K 1 -2 3 2
No D ia g n o s tic tro u b le co d e (s) d is p la y e d
• C h e c k fo r c a u s e o f code(s) cr page K 1 -2 3 5
Is line p re s s u re O K? Yes G o to n e xt step

cr page K 1 -1 5
No G o to S tep 5
Specified line pressure kPa {kgf/cm 2, psij
Range Idle Stall
420-530 1,100-1,170
D, S, L
(4.2—5.5, 60-78) (11.2-12.0, 160-170)
730-1,010 1,910-2,030
R
(7.4-10.3, 110-146) (19.4-20.7, 276-294)
K1—226
Is e n g in e stall s p e e d O K ? Yes G o to S te p 7
cr page K 1-11
No O ve rh a u l tra n s a x le a n d re p a ir o r re
rp m p la c e p a rt as n e ce ssary
Engine Engine stall speed
KL 2 ,2 7 0 — 2 ,5 0 0
A re re s is ta n ce a n d o u tp u t d u ty o f line p re ssu re Y es O ve rh a u l tra n s a x le a n d re p a ir o r re

s o le n o id v a lv e a t p o w e rtra in c o n tro l m o d u le p la c e p a rts as n e ce ssary
No If resista n ce n o t O K, c h e c k line p re s
Term. Unit Spec. Condition Page s u re s o le n o id va lve a n d w irin g
fi 9 -1 8 Constant (Ign: OFF) — cr page K 1 -3 5
A p p ro x. 67 If resista n ce O K b u t d u ty is not, g o to
% K 1 -2 6 2 n e xt step
Throttle valve wide
A p p ro x. 23
open throttle
U nit: f i - R e sista n ce
°/o ►O N d u ty
Is in p u t v o lta g e o f th ro ttle s e n so r a t p o w e rtra in Yes G o to n e xt ste p

c o n tro l m o d u le (tra n sa xle ) O K?
Term. Unit Spec. Condition Page No C h e c k th ro ttle p o sitio n s e n so r a n d
0 .1 -1 .1 cr Section F2
throttle position
2T V K 1 -3 8
Throttle valve wide
CO
T—
I
open throttle
U nit: V -► V o lta g e
A re m e a s u re m e n ts a t p o w e rtra in c o n tro l m o d u le Yes R e p la ce co n tro l va lve b o d y a sse m b ly

(tra n sa xle ) te rm in a ls O K ? If p ro b le m rem ains, o v e rh a u l tra n sa xle
B + : Battery positive voltage a n d re p a ir o r re p la ce p a rts ne ce ssary

fi 1 1 -2 7 Constant (Ign: OFF) —
V K 1 -3 8 No If resista n ce n o t O K, c h e c k fo r m a lfu n c
fi 11— 27 Constant (Ign: OFF) — • 1-2 sh ift s o le n o id va lve cr page K 1 -3 5
2G 0 S o le n o id O FF • 2-3 sh ift s o le n o id va lve cr page K 1 -3 5
V K 1 —38
B+ S o le n o id O N • 3-4 shift s o le n o id va lve cr page K 1 -3 5
fi 11— 2 7 Constant (Ign: OFF) —
• 3-2 tim in g s o le n o id va lve cr page K 1 -3 5
V K 1 -3 8 If re sista n ce O K b u t v o lta g e not, re
B+ S o le n o id O N p la c e p o w e rtra in co n tro l m o d u le
fi 1 1 -2 7 Constant (Ign: OFF) — (transaxle)
1 -2 , 2 -3 ,
2M B+ 3 -4 , 3 -2 ,
V K 1 -3 8
2 - 1 shift
0 Other than above
V V o lta g e
Terminal Function
2E 1-2 sh ift so le n o id va lve
2G 2 -3 sh ift so le n o id va lve
21 3 -4 sh ift so le n o id va lve
2M 3 -2 sh ift so le n o id va lve
K 1-227
(tra n sa xle ) te rm in la s O K ?
C o n s ta n t V e h icle s p e e d p u lse g e n e ra to r cr page K 1 -3 3
2J«2L 0 2 5 3 -6 0 4 — R e d u c e to rq u e sin g a l 1 cr page K 1 -3 8
(Ig n : O FF)
1 - 2 , 2 - 3 shift R e d u c e to rq u e sig n a l 2 cr page K 1 -3 8
T o rq u e re d u c e d s ig n a l/e n g in e
and throttle
B e lo w 1.0 c o o la n t te m p e ra tu re signal cr page K 1 -3 8
opening 4/8 or
1J V more A T F th e rm o se n so r cr page K 1 -3 2
B a ro m e tric a b s o lu te p re ssu re
O th e r th a n
B+ se n so r cr Section F2
above
4 -2 ,4 —1,3-2,
3 -1 ,2 -1 shift and
B e lo w 1.0
thottle opening 3/8 or
1L V more
O th e r th a n
B+
above
T o rq u e c o n tro l
B e lo w 1 .0
d u rin g s h iftin g
Engine coolant
B+ temperature: more
1K V than 60°C (140°F)
Engine coolant K 1 -3 8
temperature: less than
0
60°C (140°F) or
torque control during
shifting
A T F te m p .
A pprox. 3.5
2 0 ° C [6 8 ° F )
1G«2P V
ATF temp.
A pprox. 0.6
130°C (2 6 6 °F )
Atmospheric pressure
Above more than 89.6 kPa
a p p ro x . (672mmHg, 26.5 in
3 .5 Hg] (below approx.
1,500m [4,921ft])
1M V
Atmospheric pressure
B e lo w less than 89.6kPa
a p p ro x . [672mmHg, 26.5 in
3 .5 Hg] (above approx.
1,500 m [4,921 ft])
U nit: 12 -» R e sista n ce
V - * V o lta g e
Terminal Function
1J R e d u c e to rq u e sig n a l 1
1L R e d u c e to rq u e sig n a l 2
1K T o rq u e re d u c e d sig n a l
1M Barometric absolute pressure sensor

R e p la c e w ith k n o w n g o o d p o w e r tra in co n tro l Yes R e p la ce p o w e rtra in co n tro l m o d u le

m o d u le (E n g in e ) is p ro b le m c o rre c te d ? (E ngine)
cr Section F2
p la c e p a rts as n e ce ssa ry
46U0K1-355
K 1-228
54 NO EN G IN E BR AKING
DESCR * E n g in e s p e e d d ro p s to id le b u t v e h ic le d o e s n o t s lo w w h e n a c c e le ra to r p e d a l re le a se d d u rin g c ru is in g at
IPTION m e d iu m to h ig h s p e e d
►E n g in e s p e e d d ro p s to id le b u t v e h ic le d o e s n o t slo w w h e n a cce le ra to r p e d a l re le a se d w h e n in L ra n g e at
lo w v e h ic le s p e e d
© A T F le ve l lo w ® ISC s o le n o id v a lve w o rn
© P o w e rtra in s lip p a g e © 2-3 sh ift a n d /o r 3-4 shift s o le n o id va lve s w o rn
© C o n tro l v a lv e s tu c k © P o w e rtra in co n tro l m o d u le (transaxle) m a lfu n ctio n
(p re s s u re re g u la to r va lve , s o le n o id re d u c in g va lve
p re s s u re m o d ifie r va lve )
A re A T F level a n d c o n d itio n O K ? Y es G o to n e xt ste p
cr page K 1 -2 9
a n d c o rre c te d , o ve rh a u l th e tra n sa xle
a n d re p a ir o r re p la c e p a rts as n e ce ssry
D o e s S e lf-D ia g n o sis C h e c k e r d is p la y " 0 0 ” w ith Yes G o to n e xt ste p

cr page K 1 -2 3 2 No D ia g n o stic tro u b le co d e (s) d is p la y e d
• C h e c k fo r c a u se of co d e (s) cr page K 1 -2 3 5
Is th e re s lip p a g e w h e n a c c e le ra tin g o r sh iftin g ? Y es G o to No.50 “E N G IN E S P E E D FLA R ES

U P - W H E N A C C E L E R A T IN G " o r No.51
"E N G IN E S P E E D FLA R ES U P - W H E N
U P S H IF T IN G A N D /O R D O W N S H IFT
IN G ” in S e ctio n K1 o f th is m an u a l
No G o to next step
Is e n g in e b ra k in g fe lt in L ra n g e h o ld m o d e ? Y es G o to n e xt step
cr page K 1 -2 3
No R e p la ce co n tro l v a lve b o d y a sse m b ly
If p ro b le m rem ains, o ve rh a u l tra n s a x le
n e ce ssa ry
Is e n g in e stall s p e e d O K ? Yes G o to n e xt ste p
cr page K 1-11
rpm
Engine Engine stall speed p la c e p a rt as n e ce ssary
KL 2 ,2 7 0 -2 ,5 0 0
D o e s ISC s o le n o id v a lv e o p e la te c o rre c tly ? Y es G o to n e xt ste p

cr Section F2
No R e p la ce ISC s o le n o id va lve
cr Section F2
A re m e a s u re m e n ts a t p o w e rtra in co n tro l m o d u le Yes R e p la ce co n tro l v a lv e b o d y a s s e m b ly
(tra n sa xle ) te rm in a ls O K ? If p ro b le m rem ains, o ve rh a u l tra n sa xle
B + : Battery positive voltage a n d re p a ir o r re p la c e p a rts as
n e ce ssa ry
Q 1 1 -2 7 Constant (Ign: OFF) — No If resista n ce n o t O K, c h e c k fo r m a lfu n c
V K 1 -3 8 • 2 -3 shift s o le n o id va lve cr page K 1 -3 5
• 3-4 shift s o le n o id va lve cr page K 1 -3 5
0 1 1 -2 7 Constant (Ign: OFF) —
21 0 S o le n o id O FF If re sista n ce O K b u t v o lta g e is not,
V K 1 -3 8
B+ S o le n o id O N re p la c e p o w e rtra in co n tro l m o d u le
(transaxle)
V V o lta g e
Terminal Function
2G 2-3 sh ift s o le n o id va lve
21 3 -4 sh ift s o le n o id va lve
46U0K1-356
55 NO MODE CHANGE
DESCR • M o d e d o e s n o t c h a n g e to /fro m n o rm a l m o d e in D ra n g e
IPTION • H o ld m o d e n o t se le cte d o r n o t c a n c e lle d
In s p e c t p a rts a n d w irin g ; rep a ir, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssa ry
© T h ro ttle p o sitio n s e n s o r m a lfu n c tio n o r m isa d ju ste d cr Section F2
© P o w e rtra in c o n tro l m o d u le (tra n sa xle ) m a lfu n c tio n cr page K 1 -3 8
46U0K1-357
56 TRANSAXLE NOISE •A L L RANGES
DESCR
•T ra n s a x le n o isy in all ra n g e s w h e n v e h ic le is id lin g
IPTION
In s p e c t p a rts; rep a ir, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssary
© P o w e rtra in b u rn t (d iffe re n tial, 3 -4 c lu tc h ) cr page K 1-51
46U0K1-358
57 TRANSAXLE NOISE •D , S, L, R RANGES
DESCR
• A b n o rm a l n o ise fro m tra n s a x le in D, S, L, R
IPTION
In s p e c t p a rts; re p a ir, a d ju st, o r re p la c e m a lfu n c tio n in g p a rts as n e ce ssary
© T o r q u e c o n v e rte w o rn cr page K 1 -6 5
46U0K1-359
58 TRANSAXLE OVERHEATS
DESCR
• A T F sm e lls b u rn t a n d /o r is d is c o lo re d
IPTION
© P o w e rtra in b u rn t (fo rw a rd c lu tc h , re ve rse c lu tc h , lo w a n d re ve rse b ra ke o n e -w a y c lu tc h 1, 2) cr page K 1-51
© L o c k u p p isto n b u rn t cr page K 1 -6 5
© 1-2 shift, 2 -3 shift, 3 -4 shift, lo c k u p co n tro l, 3-2 tim in g , lo c k u p , a n d /o r line p re ssu re so le n o id va lve
w o rn cr page K 1 -3 6
© T h ro ttle p o sitio n s e n s o r m a lfu n c tio n o r m isa d ju ste d cr Section F2
© V e h ic le s p e e d p u ls e g e n e ra to r m a lfu n ctio n cr page K 1 -3 3
© V e h ic le s p e e d s e n s o r m a lfu n c tio n cr page K 1 -3 3
© E n g in e rp m sig n a l (Ne1 sig n a l) m a lfu n ctio n cr page K 1 -3 8
© A T F th e rm o s e n s o r m a lfu n c tio n cr page K 1 -3 2
® P o w e rtra in c o n tro l m o d u le (transaxle) cr page K 1 -3 8
© Oil c o o le r c irc u it m a lfu n c tio n cr page K 1 -2 8
46U0K1-360
K1 SELF-DIAGNOSIS FUNCTION
SELF-DIAGNOSIS FUNCTION
DESCRIPTION
The self-diagnosis system integrated in the powertrain control module (Transaxle) diagnoses malfunctions
of the main sensors (input) and solenoid valves (output) and the powertrain control module (Transaxle) itself.
Malfunctions or intermittent malfunctions are memorized in the powertrain control module (Transaxle) to
later be output as diagnostic trouble codes.
The Self-Diagnosis Checker can be used to retrieve these diagnostic trouble codes. The Self-Diagnosis
Checker indicates a malfunction by displaying a code number and sounding a buzzer.
When the TAT and GND terminals of the data link connector are shorted with the ignition switch ON, the
powertrain control module (Transaxle) outputs any memorized diagnostic trouble codes by flashing the
hold indicator.
46U0K1 -361
PREPARATION
SST
49 B019 9A0 For 4 9 H 0 1 8 9A1 For

r” — ---
d ia g n o s is of r gg] d ia g n o s is of
S yste m s e le c to r E C -AT S e lf-D ia g n o sis ({ ^ EC-AT
checker y • j'v _
46U0K1 -362
Assembly of SST
16E0KX-581
SELF-DIAGNOSIS FUNCTION K1
nector.
2. Set the SYSTEM SELECT switch A to position 2.
3. Set the TEST SW to SELF TEST position.
49 B 0 19 9A 0
36U0KX-232
4. Connect the SST (Self-Diagnosis Checker) to the SST (Sys
tem Selector) and a ground.
5. Set the SELECT SW to position A.
6. Turn on the ignition switch.
7. Verify that 88 flashes on the digital display and that the
“ ”
buzzer sounds for 3 seconds.

8. If “ 88 ” does not flash, check the main relay and 2S and
2Q terminals of the powertrain control module (transaxle)for
an open or short circuit.
“ ”
than 20 seconds, check the wiring to terminal 1C of the

46U0K1-363 powertrain control module (Transaxle) for an open or short
circuit.
If necessary, replace the powertrain control module (Trans
axle) and repeat from step 2.
10. Note any code number(s) and check for the cause(s).
Repair as necessary. (Refer to page K1-234.)
11. After repairs are made, do the After-Repair Procedure (page
K1-252) to verify that there are no remaining code
numbers.
Troubleshooting
If a diagnostic trouble code number is shown on the SST (Self-Diagnosis Checker), check for cause
by using the chart related to the code number shown.
Diagnostic trouble code number

Code Diagnosed
B u zzer P attern C ondition Point Memorized Page
No. circuit
E n g in e N o in p u t sig n a l fro m d is • D istrib u to r c o n n e c to r
rp m sig n a l trib u to r Ne1 signal w h ile • W irin g fro m d is trib u to r to
01 (Ne1 d riv in g at d ru m s p e e d p o w e rtra in co n tro l m o d u le Yes K 1 -2 3 6
signal) a b o v e 6 0 0 rp m in D, S, (transaxle)
o r L ra n g e s
V e h icle N o in p u t sig n a l fro m ve h i • V e h icle s p e e d s e n so r c o n
speed c le s p e e d se n so r w h ile n e cto r
s e n so r d riv in g at d ru m s p e e d • W irin g fro m v h ic le s p e e d
a b o v e 6 0 0 rp m in D, S, se n so r to in stru m e n t clu ste r
06 o r L ra n g e s • W irin g fro m in stru m e n t c lu s Yes K 1 -2 3 7
te r to p o w e rtra in co n tro l
m o d u le (transaxle)
• V e h ich e s p e e d s e n so r re
sista n ce
T hro ttle O p e n o r s h o rt c irc u it • T h ro ttle p o sitio n s e n so r c o n
p o sitio n n e cto r
se n so r • W irin g fro m th ro ttle p o sitio n
12 s e n so r to p o w e rtra in co n tro l Yes K 1 -2 3 8
• T h ro ttle p o sitio n s e n so r re
sista n ce
B a ro m e tric O p e n o r sh o rt c irc u it • B a ro m e tric a b so lu te
a b so lu te p re ssu re se n so r c o n n e c to r
p re ssu re •W ir in g fro m a tm o s p h e ric
14 Yes K 1 -2 3 9
s e n so r p re ssu re se n so r to p o w e r
tra in co n tro l m o d u le
(Engine)
V e h icle N o in p u t sig n a l fro m ve h i ’ V e h icle s p e e d p u lse
speed c le s p e e d p u lse g e n e ra g e n e ra to r c o n n e c to r
pu lse to r w h ile d riv in g at ’ W irin g fro m v e h ic le sp e e d
g e n e ra to r v e h ic le s p e e d 4 0 km /h p u lse g e n e ra to r to p o w e r
55 Yes K 1 -2 4 0
( 2 5 m p h ) o r h ig h e r in D, train co n tro l m o d u le
S o r L ra n g e (transaxle)
'V e h ic le s p e e d pulse
g e n e ra to r resista n ce
AT F th e r O p e n o r s h o rt c irc u it •A T F th e rm o s e n s o r c o n n e c to r
m osensor W irin g fro m A T F th e rm o s e n
so r to p o w e rtra in c o n tro l
56 Yes K 1 -2 4 1
• ATF th e rm o s e n s o r re
sistance
R e d u ce O p e n o r sh o rt c irc u it of ’ W irin g fro m p o w e rtra in c o n
to rq u e re d u c e to rq u e sig n a l 1 trol m o d u le (E ngine) to
57 Yes K 1 -2 4 2
sig n a l 1 w ire h a rn e ss p o w e rtra in co n tro l m o d u le
(transaxle)
R e d u ce O p e n o r s h o rt c irc u it of ’W irin g fro m p o w e rtra in c o n

to rq u e re d u c e to rq u e sig n a l 2 trol m o d u le (E n g in e ) to
58 Yes K 1 -2 4 3
sig n a l 2 w ire h a rn e ss p o w e rtra in co n tro l m o d u le
(transaxle)
T o rq u e re O p e n o r s h o rt c irc u it of 'W irin g fro m p o w e rtra in c o n

d u c e d s ig to rq u e re d u c e d trol m o d u le (E ngine) to
n a l/e n g in e s ig n a l/e n g in e c o o la n t p o w e rtra in co n tro l m o d u le
59 Y es K 1 -2 4 4
c o o la n t te m p e ra tu re sig n a l w ire (transaxle)
te m p e ra h a rn e ss
tu re sig n a l
K1—234
Code Diagnosed
B u zzer P attern C ondition Point Memorized Page
No. circuit
1-2 shift O p e n o r s h o rt c irc u it of •S o le n o id v a lve c o n n e c to r
s o le n o id s o le n o id va lve a n d /o r •W ir in g fro m s o le n o id va lve
60 v a lve w irin g to p o w e rtra in co n tro l m o d Yes K 1 -2 4 5
ule (transaxle)
•S o le n o id va lve resistance
2-3 shift O p e n o r s h o rt c irc u it of • S o le n o id v a lve c o n n e c to r
s o le n o id so le n o id va lve a n d /o r • W irin g fro m s o le n o id va lve
61 va lve w irin g to p o w e rtra in co n tro l m o d Yes K 1 -2 4 6
ule (transaxle)
•S o le n o id va lve resista n ce
3 -4 shift O p e n o r s h o rt c irc u it of • S o le n o id v a lve c o n n e c to r
so le n o id so le n o id v a lve a n d /o r • W irin g fro m s o le n o id va lve
ule (transaxle)
• S o le n o id v a lve resista n ce
lo c k u p
c o n tro l O p e n o r s h o rt c irc u it of • S o le n o id v a lve c o n n e c to r
63 s o le n o id so le n o id v a lv e a n d /o r • W irin g fro m s o le n o id va lve
va lve w irin g to p o w e rtra in co n tro l m o d Yes K 1 -2 4 8
u le (transaxle)
3-2 tim in g O p e n o r sh o rt c irc u it of • S o le n o id v a lve c o n n e c to r
s o le n o id so le n o id v a lv e a n d /o r • W irin g fro m s o le n o id va lve
u le (transaxle)
Lockup O p e n o r sh o rt c irc u it of • S o le n o id v a lve c o n n e c to r

s o le n o id so le n o id v a lve a n d /o r • W irin g fro m s o le n o id va lve
u le (transaxle)
L in e p re s O p e n o r s h o rt c irc u it of •S o le n o id va lve c o n n e c to r
s u re so le so le n o id v a lve a n d /o r • W irin g fro m s o le n o id va lve
66 n o id va lve w irin g to p o w e rtra in co n tro l m o d Yes K 1 -2 5 1
ule (transaxle)
• S o le n o id va lve resista n ce
46U0K1-364
To cancel malfunction codes from the memory, disconnect the negative battery terminal for 20 seconds
or longer and then depress the brake pedal.
K 1-235
DIAGNOSTIC TROUBLE CODE No.01 ENGINE RPM SIGNAL

1 A re th e re a n y p o o r c o n n e c tio n s a t d is trib u to r Yes R e p a ir o r re p la c e c o n n e c to r
a n d p o w e rtra in c o n tro l m o d u le (tra n sa xle ) c o n
n e c to rs ?
2 C o n n e c t a c irc u it te ste r to te rm in a ls as sh o w n . Yes G o to S te p 6

Is in p u t v o lta g e o f e n g in e rp m sig n a l a t p o w e r
cr page K 1 -3 8 No C h e c k w irin g a n d c o n n e c to rs fro m
(+)term. ( - ) term. Voltage (V) Condition p o w e rtra in co n tro l m o d u le (transaxle)
2 .0 — 3 .0 E n g in e ru n n in g to d is trib u to r
1N G ro u n d If O K, g o to n e xt ste p
0 or 4.5—5.5 E n g in e s to p p e d
If n o t O K , re p a ir w irin g a n d /o r c o n
n e c to r
3 D is c o n n e 3t th e dist rib u to r c o m le c to r. Yes G o to next step
Is v o lta g e at p o w e r tra in c o n tro 1 m o d u le (transax-
le) te rm in al O K ?
(+)term. (- ) term. Voltage (V) Condition

No Replace engine control unit
1N G ro u n d 4 .5 — 5 .5 Ignition switch ON
4 At Step 3 condition, is th e voltage to the distributor Yes R e p la ce d is trib u to r

co n n ecto r (vehicle-side) OK?
(+) term. (- ) term. Voltage (V) Condition No G o to n e xt step
B G ro u n d 4 .5 — 5 .5 Ignition switch ON
5 Is th e re c o n tin u ity b e tw e e n d is trib u to r c o n n e c to r Yes G o to n e xt step

(v e h ic le -s id e ) a n d p o w e rtra in co n tro l m o d u le
(tra n sa xle ) 1N te rm in a l?
No R e p a ir w irin g a n d /o r c o n n e c to r
6 D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r a t least Yes R e p la ce p o w e rtra in co n tro l m o d u le

2 0 s e c o n d s a n d d e p re s s th e b ra k e p e d a l (transaxle) cr page K 1 -4 4
C o n n e c t b a tte ry c a b le a n d re c h e c k fo r se rvice
code
No In te rm itte n t p o o r c o n n e c tio n
Is d ia g n o s tic tro u b le c o d e d is p la y e d ?
C h e c k fo r ca u se
czr page K 1 -2 5 2
46U0K1 -365
POWERTRAIN CONTROL
MODULE (ENGINE)
G NE1
-0 -0 -J POWERTRAIN
CONTROL
MODULE
(TRANSAXLE)
K 1-236
D IA G N O S T IC T R O U B L E C O DE N o .06 V E H IC LE SPEED SENSO R
Are there any poor connections at speedometer Yes Repair or replace connector
sensor and powertrain control module (transaxle)
connectors? No Go to next step
C o n n e c t a c irc u it te ste r to te rm in a ls as sh o w n . Y es G o to S te p 7
Is in p u t v o lta g e o f v e h ic le s p e e d s e n so r at
cr page K 1 -3 8
(+) term. (- ) term. Voltage (V) Condition
2 .0 — 3 .0 V e h ic le m o v in g
1P G ro u n d
0 or 4.0-5.0 V e h icle s to p p e d
R e m o v e in s tru m e n t c lu s te r Yes G o to n e xt ste p

Is th e re c o n tin u ity b e tw e e n 1H te rm in a l o f m e te r
c o n n e c to r a n d 1 P te rm in a l o f p o w e rtra in co n tro l
No R e p a ir o r re p la c e w irin g a n d /o r c o n
m o d u le (transaxle) n e cto r
C o n n e c t c irc u it te s te r to 1B a n d 1F te rm in a ls o f Yes R e p la ce sp e e d o m e te r
m e te r c o n n e c to r
D o e s p o in te r o f c irc u it te s te r m o v e slig h tly w h e n
fro n t w h e e ls a re s lo w ly tu rn e d ?
cr page K 1 -3 3
R e m o v e v e h ic le s p e e d se n so r Yes G o to n e xt ste p
Is re s is ta n ce fe lt w h e n tu rn in g s p e e d o m e te r d riv
en g e a r b y h a n d ?
No R e p la ce v e h ic le s p e e d se n so r
cr page K 1 -3 4
D is c o n n e c t v e h ic le s p e e d s e n s o r c o n n e c to r a n d Y es G o to n e xt step
c o n n e c t c irc u it te ste r
D o e s p o in te r o f c irc u it te ste r m o v e slig h tly w h e n
No R e p la ce v e h ic le s p e e d se n so r
d riv e n g e a r is s lo w ly tu rn e d ?
cy page K 1 -3 4
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r a t least Y es R e p la ce p o w e rtra in c o n tro l m o d u le

C o n n e c t th e b a tte ry c a b le a n d re c h e c k fo r
d ia g n o s tic tro u b le c o d e In te rm itte n t p o o r c o n n e c tio n
No
Is d ia g n o s tic tro u b le c o d e d is p la y e d ? C h e c k fo r ca u se
cr page K 1 -2 5 2
46U0K1-366
INSTRUMENT CLUSTER
K 1-237
DIAGNOSTIC TROUBLE CODE No. 12 THROTTLE POSITION SENSOR

1 A re th e re a n y p o o r c o n n e c tio n s at th ro ttle po si Yes R e p a ir o r re p la c e c o n n e c to r
tio n s e n s o r a n d p o w e rtra in c o n tro l m o d u le (trans
axle) c o n n e c to r o r te rm in a l?
2 C o n n e c t a c irc u it te ste r to te rm in a ls as sh o w n Yes G o to S te p 5

Is in p u t v o lta g e o f th ro ttle p o sitio n s e n s o r (TVO)
a t p o w e rtra in c o n tro l m o d u le (transaxle) O K?
c r page K 1 -3 8
(+) term. (-) term. Voltage (V) Condition
0 .1 — 1.1
throttle position
2T G ro u n d
Throttle valve wide
3 .1 — 4 .4
open throttle
3 C o n n e c t a c irc u it te ste r to te rm in a ls as s h o w n Yes G o to n e xt ste p

Is in p u t v o lta g e o f th ro ttle p o sitio n s e n so r (VREF)
a t p o w e rtra in c o n tro l m o d u le (tra n sa xle ) O K ?
No C h e c k v o lta g e at 21 te rm in a l of e n
cr page K 1 -3 8
g in e co n tro l unit
4 .5 — 5 .5 Ignition switch ON Voltage: 4.5—5.5V (ignition
2A G ro u n d switch ON)
0 Ignition switch OFF
If O K , g o to n e xt ste p
If n o t O K, re p a ir w irin g a n d /o r c o n
n e c to r
4 Is th ro ttle p o s itio n s e n s o r O K ? Yes C h e c k w irin g a n d c o n n e c to rs fro m
cr Section F2 p o w e rtra in co n tro l m o d u le (transaxle)
to th ro ttle p o sitio n se n so r
If O K , g o to n e xt ste p
If n o t O K, re p a ir w irin g a n d /o r c o n
n e cto r
No A d ju s t o r re p la ce th ro ttle po sito n
s e n so r
cr Sections F2
5 D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Yes R e p la ce p o w e rtra in co n tro l m o d u le
2 0 s e c o n d s a n d d p re s s th e b ra ke p e d a l (transaxle) c r page K 1 -4 4
C o n n e c t th e b a tte ry c a b le a n d re c h e c k fo r se rv
ic e c o d e
c r page K 1 -2 5 2
46U0K1-367
K 1-238
D IA G N O S T IC T R O U B L E C O DE No. 14 B A R O M ETR IC A B S O L U T E PRESSURE SENSO R

Are there any poor connections at powertrain Yes Repair or replace connector
control module (Engine) connectors?
No Go to next step
C o n n e c t a c irc u it te ste r to te rm in a ls as sh o w n . Yes G o to S te p 4

Is in p u t v o lta g e o f a tm o s p h e ric p re ssu re s e n so r
a t p o w e rtra in c o n tro l m o d u le (E n g in e ) O K? No G o to n e xt ste p
cr Section F2
( + ) term. (-) term. Voltage (V) C ondition
Atmosheric pressure
more than 89.6 kPa
Above approx. (672 mmHg,
3.5 V 26.5 inHg)
(below approx. 1,500
m (4,921 ft))
2R G ro u n d
Atmosheric pressure
less than 89.6 kPa
Below approx. (672 mmHg,
,3.5 V 26.5 inHg)
(Above approx. 1,500
m (4,921 ft))
D is c o n n e c t p o w e rtra in c o n tro l m o d u le (E n g in e ) Yes G o to n e xt ste p

c o n n e c to r
Is th e re c o n tin u ity b e tw e e n 2 G te rm ia n l of
p o w e rtra in c o n tro l m o d u le (E n g in e ) a n d B a ro No R e p a ir w irin g
m e tric a b s o lu te p re ssu e se n so r?
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Yes R e p la ce o r p o w e rtra in co n tro l m o d u le

2 0 s e c o n d s a n d d e p re s s th e b ra k e p e d a l (E ngine)
C o n n e c t b a tte ry c a b le a n d re c h e c k fo r d ia g n o s cr Section F2
tic tro u b le c o d e
cr page K 1 -2 5 2
46U0k1-368
POWERTRAIN CONTROL
MODULE (ENGINE)
BAROMETRIC
ABSOLUTE
PRESSURE
SENSOR
INPUT
POWERTRAIN CONTROL
MODULE (TRANSAXLE)
K 1-239
D IA G N O S T IC T R O U B L E C O D E N o .55 VE H IC LE SPEED PULSE G ENERATO R
Are there any poor connections at vehicle speed Yes Repair or replace connector
pulse genertor and powertrain control module
(transaxle) connector or connectors?
No Go to next step
C o n n e c t a c irc u it te ste r to te rm in a ls as sh o w n . Yes G o to S te p 5

Is in p u t v o lta g e o f v e h ic le s p e e d p u lse g e n e rto r
cr page K 1 -3 8
Approx. OV
E n g in e s to p p e d No
(AC) G o to n e xt step
2J 2L
0 .1 — 1.0V E n g in e ru n n in g
(AC) (P range)
D is c o n n e c t 2 0 -p in p o w e rtra in co n tro l m o d u le Yes G o to S te p 5

(tra n sa xle ) c o n n e c to r
Is re s is ta n c e b e tw e e n 2 J te rm in a l a n d 2 L te rm i
nal O K ?
Resistance: 253— 60412
D is c o n n e c t v e h ic le s p e e d p u lse g e n e ra to r c o n Yes C h e c k w irin g a n d c o n n e c to rs fro m

n e c to r p o w e rtra in co n tro l m o d u le (transaxle)
Is re s is ta n c e o f v e h ic le s p e e d p u lse g e n e ra to r to v e h ic le sp e e d p u lse g e n e ra to r
OK? If O K, g o to n e xt ste p
Resistance: 253— 60412 n e c to r
cr page K 1 -3 3 No R e p la ce ve h icle s p e e d p u lse
g e n e ra to r
cr page K 1 -3 3
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Y es R e p la ce p o w e rtra in co n tro l m o d u le
C o n n e c t b a tte ry c a b le a n d re c h e c k fo r d ia g n o s
No In te rm itte n t p o o r c o n n c e tio n
ar page K 1 -2 5 2
46U0K1-369
VEHICLE SPEED PULSE GENERATOR
K 1-240
D IA G N O S T IC T R O U B L E C O D E N o .56 A T F TH ER M O SEN SO R
Are there any poor connections at ATF ther Yes Repair or replace connector
mosensor and powertrain control module (trans
axle) connectors or terminals? No Go to next step
C o n n e c t a c irc u it te s te r to te rm in a ls as s h o w n Yes G o to S te p 5
Is in p u t v o lta g e o f A T F th e rm o s e n s o r at p o w e r
cr page K 1 -4 2 3.5V- ± Voltage rather
cr Section F2 than approximately
[ + ) term. ( - ) term. Voltage (V) Condition 3.5 or 0.6V
2.3V-
1G 2R S ee g ra p h at rig h t
0.5V-
--- 1----
68°F 168°F 266°F
D is c o n n e c t p o w e rtra in c o n tro l m o d u le (transaxle) Yes G o to S te p 5

c o n n e c to r
Is re s is ta n ce b e tw e e n 1G te rm in a l a n d 2R te rm i
nal O K ?
Terminal Resistance (ft)
1G ~2R S e e g ra p h a t rig h t
D is c o n n e c t s o le n o id c o n n e c to r Yes C h e c k w irin g a n d c o n n e c to rs from

Is re s is ta n ce b e tw e e n I te rm in a l a n d J te rm in a l p o w e rtra in co n tro l m o d u le (transaxle)
o f A T F th e rm o s e n s o r O K? to AT F th e rm o se n so r
cr page K 1 -3 6 If O K, g o to n e xt ste p
Terminal Resistance (ft) n e cto r
2 . 4 4 1 - 2 . 8 9 4 AT F te m p . 2 0 ° C ( 6 8 ° F ) No R e p la ce A T F th e rm o s e n s o r
l« J 1 .1 9 3 - 1 .3 7 4 ATF tem p. 4 0 °C [1 0 4 ° F ] cr page K 1 -3 7
0 .3 5 2 7 -0 .3 8 6 5 ATF temp. 80°C (17 6 °F )
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Yes R e p la ce p o w e rtra in c o n tro l m o d u le

2 0 s e c o n d s a n d d e p re s s th e b ra k e pe d al (transaxle)
C o n n e c t b a tte ry c a b le a n d re c h e c k fo r d ia g n o s cr page K 1 -4 8
tic tro u b le c o d e cr Section F2
Is d ia g n o s tic tro u b le c o d e d is p la y e d ? In te rm itte n t p o o r co n n e c tio n
No
Note
• " H O L D ’ ' lig h t w ill n o t in d ic a te a failure.
cr page K 1 -2 5 2
46U0K1-370
POWERTRAIN CONTROL MODULE

(TRANSAXLE)
INPUT GND
ATF THERMOSENSOR
SOLENOID CONNECTOR
K1-241
D IA G N O S T IC T R O U B L E C O D E N o .57 REDUCE TO R Q U E SIG N A L 1

control module (Engine) and powertrain control
module (transaxle) connectors?
No Go to next step
C o n n e c t a c irc u it te ste r to te rm in a ls as s h o w n Yes G o to S tep 4

Is in p u t v o lta g e o f re d u c e to rg u e sig n a l 1 at p o w e r
tra in c o n tro l m o d u le (tra n sa xle ) OK?
No G o to next step
c r page K 1-38

(+ )term. (-) term. Voltage (V) Condition
B+ O th e r th a n b e lo w
1-2, 2-3 shift a n d
1J G ro u n d
B e lo w 1.0 th ro ttle o p e n in g
4 /8 o r m o re
D is c o n n e c t 2 0 -p in p o w e rtra in co n tro l m o d u le (trans Yes G o to next step

m issio n ) c o n n e c to r
Is th e re c o n tin u ity b e tw e e n 1J te rm in a l of pow ertrain
c o n tro l m o d u le (transaxle) a n d 1S te rm in a l o f p ow er No R e p a ir w irin g
tra in c o n tro l m o d u le (E ngine)?
D is c o n n e c t th e n e g a tive b a tte ry c a b le fo r at least Yes R e p la ce p o w e rtra in c o n tro l m o d u le

2 0 s e c o n d s a n d d e p re s s th e b ra ke p e d a l (transaxle) o r p o w e rtra in co n tro l m o d
C o n n e c t b a tte ry c a b le a n d re c h e c k fo r d ia g n o s ule (E n g in e ) c r page K 1 -44
tic tro u b le c o d e c r Section F2
Is d ia g n o s tic tro u b le c o d e d isp la ye d ?
No In te rm itte nt p o o r c o n n e c tio n
cr page K 1-252
46U0K1-371
0
REDUCE TORQUE SIGNAL 1
POWERTRAIN
Q POWERTRAIN
CONTROL
CONTROL OUTPUT MODULE
(TRANSAXLE) (ENGINE)
K1-242
D IA G N O S T IC T R O U B L E C O DE N o .58 REDUCE T O R Q U E SIG N A L 2
module (transaxle) connectors? No Go to next step
C o n n e c t a c irc u it te s te r to te rm in a ls as sh o w n Yes G o to S te p 4
Is in p u t v o lta g e o f re d u c e to rq u e sig n a l 2 a t p o w e r
cr page K 1 -3 8

B+ O th e r th a n b e lo w
4 -2 , 4 -1 , 3 -2 ,
1L G ro u n d 3 — 1, 2 — 1 shift
B e lo w 1.0
a n d th ro ttle o p e n
in g 3 /8 o r m o re
D is c o n n e ct 2 0 -p in p o w e rtra in co n tro l m o d u le (trans Yes G o to n e xt ste p

a xle ) c o n n e c to r
Is th e re c o n tin u ity b e tw e e n 1 L te rm in a l of p o w e rtra in
c o n tro l m o d u le (transaxle) a n d 1V te rm in a l of p o w e r No R e p a ir w irin g
tra in c o n tro l m o d u le (E n g in e ) ?
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Yes R e p la ce p o w e rtra in co n tro l m o d u le

2 0 s e c o n d s a n d d e p re s s th e b ra k e p e d a l (transaxle) o r p o w e rtra in c o n tro l m o d
C o n n e c t b a tte ry c a b le a n d re c h e c k fo r d ia g n o s u le (Engine) cr page K 1 -4 4
Is d ia g n o s tic tro u b le c o d e d is p la y e d ? No In te rm itte n t p o o r c o n n e c tio n
cr page K 1 -2 5 2 C h e c k fo r ca u se
46U0K1-372
6
REDUCE
TORQUE SIGNAL 2
POWERTRAIN
CONTROL
OUTPUT © POWERTRAIN
CONTROL
MODULE
MODULE
(ENGINE)
(TRANSAXLE)
K 1-243
D IA G N O S T IC TR O U B L E C O D E N o .59 TORQUE REDUCED SIGNAL/ENGINE COOLANT TEMPERATURE SIGNAL

module (transaxle) connectors? No Go to next step
C o n n e c t a c irc u it te ste r to te rm in a ls as s h o w n Yes G o to S te p 4

Is in p u t v o lta g e o f to rq u e re d u c e d s ig n a l/e n g in e
c o o la n t te m p e ra tu re sig n a l a t p o w e rtra in co n tro l
m o d u le (tra n sa xle ) O K ?
cr page K 1 -3 8

Engine coolant
B+ temperature: more
than 60°C {140°F)
Engine coolant
1K G ro u n d
temperature: less than
B e lo w 1.0 60°C (140°F) or
torque control during
shifting
D is c o n n e c t 2 0 -p in p o w e rtra in co n tro l m o d u le (trans Yes G o to n e xt step

a xle ) c o n n e c to r
Is th e re c o n tin u ity b e tw e e n 1K term inal of pow e rtra in
co n tro l m o d u le (transaxle) a n d 1K te rm in a l o f p o w e r No R e p a ir w irin g
tra in c o n tro l m o d u le (E n g in e )?
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Y es R e p la ce p o w e rtra in c o n tro l m o d u le

2 0 s e c o n d s a n d d e p re s s th e b ra ke p e d a l (transaxle) o r p o w e rtra in c o n tro l m o d
C o n n e c t b a tte ry c a b le a n d re c h e c k fo r d ia g n o s ule (E ngine) cr page K 1 -4 4
No In te rm itte nt p o o r c o n n e c tio n
cr page K 1 -2 5 2
46U0K1-373
K 1-244
D IA G N O S T IC T R O U B L E C O DE N o .60 1-2 S H IF T SO LEN O ID VALVE

Are there any poor connections at solenoid valve Yes Repair or replace connector
and powertrain control module (transaxle) con
nectors? No Go to next step
C o n n e c t a c irc u it te s te r to te rm in a ls as s h o w n Yes C h e c k w irin g a n d g o to S te p 5

Is o u tp u t v o lta g e o f 1-2 sh ift so le n o id va lve at
cr page K 1 -3 8
2 n d , T h ird , F ourth
B+
2E G ro u n d g e a r p o sitio n
0 1st g e a r p o sitio n
Disconnect 20-pin powertrain control module Yes Go to Step 5

Is re s is ta n ce b e tw e e n 2E te rm in a l a n d g ro u d
OK?
Resistance: 11— 27fi

Is re s is ta n ce b e tw e e n g ro u n d a n d te rm in a l A of p o w e rtra in co n tro l m o d u le (transaxle)
1 -2 sh ift s o le n o id v a lv e O K ? to 1 -2 sh ift s o le n o id va lve
cr page K 1 -3 5 If O K, g o to n e xt ste p
Resistance: 11— 271) If n o t O K , re p a ir w irin g a n d /o r c o n
n e ctor
No R e p la ce 1-2 sh ift s o le n o id va lve
cr page K 1 -3 6
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Y es R e p la ce p o w e rtra in c o n tro l m o d u le
2 0 s e c o n d s a n d d e p re s s th e b ra k e pe d al (transaxle) cr page K 1 -4 4
No In te rm itte n t p o o r c o n n e c ito n
C h e c k fo r c a u s e
cr page K 1 -2 5 2
46U0K1-374
K 1-245
D IA G N O S T IC TR O U B L E C O D E No.61 2-3 S H IF T SO LEN O ID VALVE

nectors?
No Go to next step
C o n n e c t a c irc u it te ste r to te rm in a ls as s h o w n Yes C h e c k w irin g a n d g o to S te p 5

Is o u tp u t v o lta g e o f 2-3 sh ift so le n o id v a lv e at
p o w e rtra in c o n tro l m o d u le (transaxle) O K ?
cr page K 1 -3 8

1st, 2 n d g e a r
B+
p o sitio n
2G G ro u n d
T h ird , Fourth
0
g e a r p o sitio n
D is c o n n e c t 2 0 -p in p o w e rtra in co n tro l m o d u le Yes G o to S te p 5

Is re s is ta n c e b e tw e e n 2 G te rm in a l a n d g ro u n d
OK?
Resistance: 11—270
D is c o n n e c t s o le n o id c o n n e c to r Yes C h e c k w irin g a n d c o n n e c to rs fro m

Is re s is ta n c e b e tw e e n g ro u n d a n d te rm in a l B of p o w e rtra in co n tro l m o d u le (transaxle)
2 -3 sh ift s o le n o id v a lv e O K ? to 2-3 sh ift s o le n o id va lve
cr page K 1 -3 5 If O K , g o to n e xt ste p
Resistance: 11— 270 If n o t O K, re p a ir w irin g a n d /o r c o n
n e c to r
No R e p la ce 2-3 shift s o le n o id va lve

cr page K 1 -3 6
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r a t least Y es R e p la ce p o w e rtra in c o n tro l m o d u le
cr page K 1 -2 5 2
46U0K1-375
K 1-246
D IA G N O S T IC T R O U B L E C O DE N o .62 3-4 S H IF T SO LEN O ID VA LVE

C o n n e c t a c irc u it te ste r to te rm in a ls as s h o w n Yes C h e c k w irin g a n d g o to S te p 5

Is o u tp u t v o lta g e o f 3 -4 sh ift so le n o id va lve at
c r page K 1-38
(+)term. (-) term. Voltage (V) Condition
1st, 2 n d , Fourth
B+
21 G ro u n d g e a r p o sitio n
0 Third gear position
D is c o n n e c t 2 0 -p in p o w e rtra in c o n tro l m o d u le Yes G o to S te p 5

Is re s is ta n ce b e tw e e n 21 te rm in a l a n d g ro u n d
OK?
D is c o n n e c t so le n o id c o n n e c to r Yes C h e c k w irin g a n d c o n n e c to rs fro m

Is re s is ta n ce b e tw e e n g ro u n d a n d te rm in a l C of p o w e rtra in c o n tro l m o d u le (transaxle)
3 -4 sh ift so le n o id v a lv e O K? to 3-4 sh ift s o le n o id va lve
c r page K 1-35 If O K, g o to n e xt ste p
Resistance: 11—271) If n o t O K, re p a ir w irin g a n d /o r c o n
n e cto r
No R e p la ce 3 -4 sh ift s o le n o id va lve
c r page K 1-36
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Yes R e p la ce p o w e rtra in c o n tro l m o d u le
2 0 s e c o n d s a n d d e p re s s th e b ra k e pe d al (transaxle) c r page K 1-44
tic tro u b le c o d e No In te rm itte nt p o o r c o n n e c ito n
Is d ia g n o s tic tro u b le c o d e d is p la y e d ? C h e c k fo r ca u se
c r page K1-252
46U0K1-376
K1—247
D IA G N O S T IC T R O U B L E C O D E N o .63 LO C KUP C O N TR O L SO LEN O ID V A LVE
STEP IN S P E C TIO N AC TIO N

nectors?
No Go to next step
C o n n e c t a c irc u it te s te r to te rm in a ls as s h o w n Y es C h e c k w irin g a n d g o to S te p 5
Is o u tp u t v o lta g e o f lo c k u p c o n tro l so le n o id va lve
c r page K 1-38 No G o to n e xt step

B+ Lockup
2K G ro u n d
0 N o n lo c k u p

(transaxle) connector
Is re s is ta n c e b e tw e e n 2 K te rm in a l a n d g ro u n d
OK?

Is re s is ta n c e b e tw e e n g ro u n d a n d te rm in a l D of p o w e rtra in co n tro l m o d u le (transaxle)
lo c k u p c o n tro l s o le n o id v a lv e O K? to lo c k u p co n tro l s o le n o id va lve
c' r page K 1-35 If O K , g o to n e xt ste p
Resistance: 11—270 If n o t O K, re p a ir w irin g a n d /o r c o n
n e cto r
No R e p la ce lo c k u p co n tro l s o le n o id va lve
c r page K 1-36
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r a t least Yes R e p la ce p o w e rtra in c o n tro l m o d u le
2 0 s e c o n d s a n d d e p re s s th e b ra k e p e d a l (transaxle) c r page K 1-44
No In te rm itte nt p o o r c o n n e c ito n •
c r page K1-252
46U0K1-377
K 1-248
D IA G N O S T IC T R O U B L E C O DE N o .64 3-2 T IM IN G SO LEN O ID V A LVE

C o n n e c t a c irc u it te s te r to te rm in a ls as s h o w n Yes C h e c k w irin g a n d g o to S te p 5

Is o u tp u t v o lta g e o f 3 -2 tim in g so le n o id va lve at
c r page K 1-38
(+)term. (-) term. Voltage (V) Condition
1 -2 , 2 -3 , 3 -4
B+
3 - 2 , 2 - 1 shift
2M G ro u n d
0 O th e r th a n a b o v e

Is re s is ta n ce b e tw e e n 2 M te rm in a l a n d g ro u n d
OK?

Is re s is ta n ce b e tw e e n g ro u n d a n d te rm in a l E of p o w e rtra in co n tro l m o d u le (transaxle)
3 -2 tim in g so le n o id v a lv e O K ? to 3-2 tim in g s o le n o id va lve
c r page K 1-35 If O K , g o to n e xt ste p
Resistance: 11— 27Q If n o t O K , re p a ir w irin g a n d /o r c o n
n e ctor
No R e p la ce 3-2 tim in g s o le n o id va lve

c r page K 1-36
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r a t least Yes R e p la ce p o w e rtra in co n tro l m o d u le
20 s e c o n d s a n d d e p re s s th e b ra k e p e d a l (transaxle) c r page K 1-44
tic tro u b le c o d e In te rm itte n t p o o r c o n n e c ito n
No
c r page K1-252
46U0K1-378
POWERTRAIN CONTROL
MODULE (TRANSAXLE)
---------------------2M -----------------
K2>(B><C><DKE>(F)<g><^(j\
3-2 TIMING
SOLENOID
VALVE
SOLENOID CONNECTOR
K 1-249
D IA G N O S T IC T R O U B L E C O DE N o .65 LO C KUP SO LEN O ID VALVE


Is re s is ta n c e b e tw e e n 2 C te rm in a l a n d g ro u n d
O K?
Resistance: 9—180

Is re s is ta n c e b w tw e e n g ro u n d a n d te rm in a l F of p o w e rtra in co n tro l m o d u le (transaxle)
lo c k u p s o le n o id v a lv e O K ? to lo c k u p s o le n o id va lve
cr page K1-35 If O K, g o to n e xt ste p
Resistance: 9—180 If n o t O K , re p a ir w irin g a n d /o r c o n
n e cto r
No R e p la ce lo c k u p s o le n o id va lve
cr page K1-36
C o n n e c t a d w e ll m e te r to te rm in a ls as s h o w n Yes G o to n e xt step
Is o u tp u t d u ty o f lo c k u p so le n o id v a lv e at p o w e r
tra in c o n tro l m o d u le (tra n sa xle ) O K?
No R e p la ce p o w e rtra in c o n tro l m o d u le
c r page K1-263 (transaxle)
(+)term. (-) term. Duty (%) Condition c r page K 1-44
Approx. 65 S lip lo c k u p
2C G ro u n d
Approx. 0 Except slip lockup
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Yes R e p la ce p o w e rtra in co n tro l m o d u le

20 s e c o n d s a n d d e p re s s th e b ra k e p e d a l is (transaxle) cr page K 1-44
d e p re s s e d
cr page K1-252
46U0K1-379
POWERTRAIN CONTROL
MODULE (TRANSAXLE)
[{AKBKcKDXEXEXGXiXj)]
LOCKUP
SOLENOID
VALVE
SOLENOID CONNECTOR
K1—250
D IA G N O S T IC T R O U B L E C O DE N o .66 LIN E PRESSURE SO LEN O ID VALVE


Is re s is ta n ce b e tw e e n 2 N te rm in a l (line p re ssu re
s o le n o id va lve ) a n d g ro u n d O K ?
Resistance: 9— 18Q

Is re s is ta n ce b e tw e e n g ro u n d a n d te rm in a l G of p o w e rtra in c o n tro l m o d u le (transaxle)
lin e p re s s u re so le n o id va lve O K ? line p re ssu re s o le n o id va lve
cr page K 1-35 If O K, g o to n e xt ste p
Resistance: 9—18Q If n o t O K, re p a ir w irin g a n d /o r c o n
n e ctor
No R e p la ce line p re ssu re s o le n o id va lve
cr page K 1-36
C o n n e c t a d w e ll m e te r to te rm in a ls as s h o w n Yes G o to n e xt ste p
Is o u tp u t d u ty o f lin e p re s s u re s o le n o id va lve at
No R e p la ce p o w e rtra in co n tro l m o d u le
cr page K1-262
(transaxle)
(+) term. (-) term. Duty (% ) Condition cr page K 1-44
Approx. 67
throttle position
2N G ro u n d
Throttle valve wide
Approx. 23
open throttle
D is c o n n e c t th e n e g a tiv e b a tte ry c a b le fo r at least Y es R e p la ce p o w e rtra in co n tro l m o d u le

20 s e c o n d s a n d d e p re s s th e b ra k e pe d al (transaxle) cr page K 1-44
cr page K1-252
46U0K1-380
POWERTRAIN CONTROL
MODULE (TRANSAXLE)
|<A><|)<C)<5>(iXF)<G XL)^
LINE PRESSURE
SOLENOID VALVE
SOLENOID CONNECTOR
K1-251
After-Repair Procedure
1. Cancel the memory of diagnostic trouble codes by discon
necting the negative battery cable for at least 20 seconds.
Reconnect the battery cable.
2. Remove the SST (Self-Diagnosis Checker) if connected.
46U0K1-381
3. Drive the vehicle at 50 km/h (31 mph), and depress the
accelerator pedal fully to activate kickdown. Stop the vehi
DRIVE AT 50 km/h {31 mph] cle gradually.
KICKDOWN
STOP VEHICLE
36U0KX-256
4. Connect the SST (Self-Diagnosis Checker) to the data
link connector.
5. Turn on the ignition switch.
6. Verify that no code numbers are displayed.
46U0K1-382
SERVICE POINTS K1
SERVICE POINTS
OUTLINE
Hold Switch
• If there is an open or short circuit in the hold switch or harness, selection to/from hold mode is not possible.
Park/Neutral Switch
• If a malfunciton occurs in the wiring of the Park/Neutral switch, the powertrain control module (Transaxle)
cannot determine the range position, and shifting may be abnormal in D, S, and L ranges. There may
not be a shift to Fourth gear.

• If there is an open or short circuit in the throttle position sensor or harness, diagnostic trouble code No. 12
is displayed by the self-diagnosis function, and hold mode is canceled.
• If a malfunction occurs in the throttle position sensor, the powertrain control module (Transaxle) judges
the throttle opening to be at a constant 4/8 stroke.
Idle Switch
• If there is an open circuit in the idle switch or harness, the powertrain control module (Transaxle) does
not correct throttle characteristics. In case of misadjustment of throttle position sensor, lockup is not can
celed when cruising (throttle fully closed) and vehicle jolts when accelerator pedal is depressed or released.
• If there is a short circuit in the idle switch or harness, the line pressure will be low (does not match throttle
characteristics) and the transaxle may slip when shifting.
Vehicle Speed Pulse Generator

• If there is no input signal from the vehicle speed pulse generator, diagnostic trouble code No.55 is dis
played by the self-diagnosis function and hold mode is canceled.
• If a malfunction occurs in the vehicle speed pulse generator, shifting is made based on signals from
speedometer.
• If a malfunction occurs in the vehicle speed pulse generator and vehicle speed sensor at the same time,
1-2, 2-3 and 3-4 shift solenoid valve go OFF, and D and S ranges go to Third gear position. L range goes
to 1st gear position, and lockup is inhibited.

• If there is no input signal from the vehicle speed sensor, diagnostic trouble code No.06 is displayed by
the self-diagnosis function and hold mode is canceled.
• If a malfunction occurs in the vehicle speed sensor, shifting is made normal based on signals from vehicle
Stoplight Switch
• If there is an open circuit in the stoplight switch or harness, lockup is not canceled when brake pedal
is pressed.
• If there is a short circuit in the stoplight switch or harness, lockup and slip lockup is inhibited, but slip
lockup functions when coasting.
ATF Thermosensor
• If there is an open or short circuit in the ATF thermosensor or harness, diagnostic trouble code No.56
is displayed by the self-diagnosis function but hold mode operates normally.
• If a malfunction occurs in the ATF thermosensor, shift shock will be strong.
• The hold indicator lamp does not flash if there is an open and short circuit in the ATF thermosensor or
harness; however the diagnostic trouble code No. is memorized in the powertrain control module (Trans
axle), and the diagnostic trouble code No. is displayed when TAT terminal is grounded.
K1 SERVICE POINTS
Fourth Gear Inhibit Signal (ASC signal)
• If there is an open circuit in the Fourth gear inhibit circuit, there is no input signal from the cruise control
unit and acceleration feeling (driving performance) will deteriorate when the vehicle speed drops 8 km/h
(5 mph) below the set speed or RESUME/ACCEL switch is operated during cruise control operation.
• If there is a short in the Fourth gear inhibit signal circuit, there is no shift to Fourth gear.
Engine RPM Signal (Ne1 signal)

• If there is no input signal from the engine rpm signal, diagnostic trouble code No.01 is displayed by the
self-diagnosis function, and hold mode is canceled.
Barometric Absolute Pressure Sensor

• If there is an open or short circuit in the barometric absolute pressure sensor circuit, the line pressure
is not controlled correctly at high altitude and shift shock will be strong.
Torque Reduced Signal/Engine Coolant Temperature Signal

• If there is an open or short in the torque reduced signal circuit/engine coolant temperature signal circuit,
diagnostic trouble code No.59 is displayed by the self-diagnosis function but hold mode is normal.
• If a malfunction occurs in the torque reduced signal/engine coolant temperature signal, the torque reduc
tion control function is inhibited and line pressure will be high at shifting. Shift shock may be slightly strong.
• The hold indicator lamp does not flash if there is an open and short circuit in the torque reduced signal/engine
coolant temperature signal circuit; however the service code No. is memorized in the powertrain control
module (Transaxle), and the service code No. is displayed when TAT terminal is grounded.
TAT Terminal (Data Link Connector)

• If there is an open circuit in the TAT terminal or harness, diagnostic trouble code(s) are not displayed by
the self-diagnosis function.
• If there is a short circuit in the TAT terminal or harness, diagnostic trouble code(s) memorized in the powertrain
control module (transaxle) are displayed by hold indicator.
1-2 shift solenoid Valve

• If there is an open or short circuit in the 1-2 shift solenoid valve or harness, diagnostic trouble code No.60
is displayed by the self-diagnosis function and hold mode is canceled.
• If a malfunction occurs in the 1-2 shift solenoid valve, the solenoid valve goes OFF and lockup is canceled.


SERVICE POINTS K1
Lockup control solenoid Valve
• If there is an open or short circuit in the lockup control solenoid valve or harness, diagnostic trouble code
No.63 is displayed by the self-diagnosis function and hold mode is canceled.
• If a malfunction occurs in the lockup control solenoid valve, the solenoid valve goes OFF and lockup is
canceled.
3-2 timing solenoid Valve

• If there is an open or short circuit in the 3-2 timing solenoid valve or harness, diagnostic trouble code
• If a malfunction occurs in the 3-2 timing solenoid valve, the solenoid valve goes OFF and lockup is canceled.
Lockup solenoid Valve

• If there is an open or short circuit in the lockup solenoid valve or harness, diagnostic trouble code No.65
• If a malfunction occurs in the lockup solenoid valve, the solenoid valve goes OFF and lockup is canceled.
Line pressure solenoid Valve

• If there is an open or short circuit in the line pressure solenoid valve or harness, diagnostic trouble code
• If a malfunction occurs in the line pressure solenoid valve, line pressure is set at maximum to make driving
possible.
• If a malfunction occurs in line pressure solenoid valve, lockup is conceled.
Hold Indicator Light

• If there is an open circuit in the hold indicator lamp harness or the bulb is burnt out, the lamp will not illuminate.
• If there is a short circuit in the hold indicator lamp harness, the lamp will remain illuminated.
• If the wiring between the FAT terminal and 1C terminal is open or shorted, diagnostic trouble codes are
not displayed on the Self Diagnosis Checker.
• If the wiring between the FAT terminal and 1B terminal is open or shorted, the hold indicator light does
not display the service code(s).
Reduce Torque Signal 1

• If there is an open or short in the reduce torque signal 1 circuit, diagnostic trouble code No.57 is displayed
by the self-diagnosis function and hold mode is canceled.
• If a malfunction occurs in the reduce torque signal 1, the torque reduction control function is inhibited
and line pressure will be high at shifting. Shift shock may be slightly strong.

• If there is an open or short circuit in the reduce torque signal 2 circuit, diagnostic trouble code No.58
• If a malfunction occurs in the reduce torque signal 2, the torque reduction control function is inhibited
and line pressure will be high at shifting. Shift shock may be slightly strong.
Inhibitor Signal
• If there is an open circuit in the inhibitor signal circuit, the engine speed will be slightly low in P and N ranges.
• If there is a short circuit in the inhibitor signal circuit, the engine speed will be slightly high in R, D, S,
and L ranges.
46U0K1-383
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H -1 KL ■ EC-AT CONTROL SYSTEM 2
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PARK/NEUTRAL
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INSTRUMENT
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(SECTION C-b)
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H -01 POWERTRAIN CONTROL MODULE (TRANSAXLE) (EM) H -0 2 VEHICLE SPEED PULSE GENERATOR(E)
IK II 16 IE 2H 2K 21 2G
1 1 p2S> 20 20 2E 2C 2An
BR GY/R Y / L R /Y GY R /B R Y B/Y B /Y L /R R/W L/W G/B L /B P W/B G/L
G /R LG L BR/W BR/B W/G G /Y BR/Y P/G G /0 B/R R/G R W L /0 Y/B R /L G
U IP IN 1L iJ 1H IF ID IBu U 2T 2fl 2P 2N 2L 2J 2H 2F 2D 2B L*
H -0 3 SOLENOID VALVE (EC-AT) (EM) A -0 3 PARK/NEUTRAL SWITCH(EM) 1 -0 4 HOLD SWITCH (I)
BR/B 0
_X B GY
GY R/G R/W G/B P ; B/Y R /L L / 0 R /Y Y/G ;
B /R * W/B L/W L /B
| 6 | y/ b BR | b/ l
SERVICE POINTS K1
Hold Switch
Condition
Circuit
Powertrain control module (Trans Mode does not change Mode does not change Mode may not change
axle) 1H terminal — hold switch when hold switch is when hold switch is when hold switch is
operated operated operated
Hold switch — ground No symptom
Park/Neutral Switch
Note
• If fuse burns out while driving, powertrain control module (Transaxle) judges condition as the R range.
• When ignition switch is turned from OFF to ON after fuse burns out, powertrain control module (Trans
axle) judges condition as the R range.
R range switch
Condition
Circuit
Powertrain control module (Trans No symptom Meter 15A fuse burns out No symptom
axle) 11terminal — R range switch when R range is selected
R range switch — battery Fuse burns out

Ground — R range switch Selector indicator lamp Meter 15A fuse burns out
does not illuminate when R range is selected
L range switch
Condition
Circuit
Powertrain control module (Trans 1st gear is fixed in L range Meter 15A fuse burns out No symptom
axle) 2H terminal — L range switch (Solenoid pattern same as when L range is selected
R range)
L range switch — battery Fuse burns out
Ground — L range switch Selector indicator lamp Meter 15A fuse burns out
does not illuminate when L range
S range switch
Condition
Circuit
Powertrain control module, (Trans Third gear is fixed in S Meter 15A fuse burns out No symptom
axle) 2F terminal — S range switch range when S range is selected
(Solenoid pattern same as
S range switch — battery R range) Fuse burns out
Ground — S range switch Selector indicator lamp Meter 15A fuse burns out
does not illuminate when S range is selected
D range switch
Condition
Circuit
Powertrain control module (Trans Third gear is fixed in D Meter 15A fuse burns out No symptom
axle) 2D terminal — D range switch range when D range is selected
(Solenoid pattern same as
D range switch — battery R range) Fuse burns out
Ground — D range switch Selector indicator lamp Meter 15A fuse burns out
does not illuminate when D range is selected
K 1-257
K1 SERVICE POINTS
P, N range switch
Condition
Circuit
Powertrain control module (Trans No symptom Meter 15A fuse burns out No symptom
axle) 2B terminal — P, N range when ignition switch
switch turned to START
P, N range switch — starter Starter does not operate

Condition
Circuit
Powertrain control module (Trans Code No. 12 output Code No. 12 output Line pressure will be ab
axle) 2A terminal — throttle sensor Shift point incorrect and Shift point incorrect and normal and clutches may
Powertrain control module (Trans shift shock strong shift shock strong slip if powertrain control
axle) 2T terminal — throttle sensor Lockup will be inhibited Lockup will be inhibited module (Transaxle) does
not judge malfunction
Vehicle may jolt
Idle Switch
Condition
Circuit
Powertrain control module (Trans Vehicle jolts when ac Clutches may slip when Vehicle may jolt
axle) 10 terminal — idle switch celerator pedal depressed shifting
or released
Vehicle Speed Pulse Generator

Condition
Circuit
Powertrain control module (Trans Code No. 55 output Code No.55 output
axle) 2J terminal — vehicle speed Shifting does not match Shifting does not match
pulse generator shift diagram and Fourth shift diagram and Fourth
gear is cancelled gear is cancelled NA
Vehicle speed pulse generator —
NA
ground

Condition
Circuit
Powertrain control module (Trans Code No.06 output Code No.06 output
axle) 1P terminal — vehicle speed NA
NA
sensor
Stoplight Switch
Condition
Circuit
Powertrain control module (Trans Lockup will not be in Lockup will be inhibited
NA
axle) 1F terminal — stoplight switch hibited
ATF Thermosensor
Condition
Circuit
O p e n circ u it S h o r t circu it P oo r grou n d
Powertrain control module (Trans Code No.56 output No Code No.56 output
axle) 1G terminal — ATF thermo Shift shock will be strong Shift shock will be strong
NA
sensor
ATF thermosensor — ground NA
NA: Not applicable
K 1-258
SERVICE POINTS K1
Fourth Gear Inhibit Signal (ASC signal)
Condition
Circuit
Powertrain control m odule Fourth gear not inhibit Does not shift to Fourth
(Transaxle) 1M terminal — ed when Fourth gear gear NA
cruise control unit inhibit signal ON
Engine RPM Signal (Ne1 signal)

Condition
Circuit
Powertrain control module (Transax Code No.01 output Code No.01 output
NA
le) 1N term inal — distributor Lockup is canceled Lockup is canceled
Baromtric Absolute Pressure Sensor

Condition
Circuit
Powertrain control module (Trans Shift shock will be strong Shift shock will be strong
axle) 2R terminal — atmospheric at high altitude at high altitude NA
pressure sensor
Torque Reduced Signal/Engine Coolant Temperature Signal

Condition
Circuit
Powertrain control module (transaxle) Code No.59 output Code No.59 output
1K terminal — powertrain control Shift shock may be slight Shift shock may be slight NA
module (Engine) 1K terminal ly strong ly strong
TAT Terminal (Diagnosis Connector)

Condition
Circuit
Powertrain control module (transax Does not diagnose EC-AT Diagnose EC-AT system
NA
le) 1E terminal — TAT terminal system

Condition
Circuit
Powertrain control module (Trans Code No.60 output Code No.60 output Shifting may be abnormal
axle) 2E terminal — 1-2 shift sole Shifting will be performed Shifting will be performed if powertrain control
noid valve by remaining normal sole by remaining normal sole module (Transaxle) does
noid valve(s), but does noid valve(s), but does not judge malfunction
not match shift diagram not match shift diagram
and lockup is canceled and lockup is canceled
1-2 shift Solenoid valve — ground No symptom

Condition
Circuit
axle) 2G terminal — 2-3 shift sole Shifting will be performed Shifting will be performed if powertrain control
2-3 shift Solenoid valve — ground No symptom
NA: Not applicable
K 1-259
K1 SERVICE POINTS
Condition
Circuit
axle) 21 terminal — 3-4 shift sole Shifting will be performed Shifting will be performed if powertrain control
3-4 shift solenoid valve — ground No symptom
Lockup control solenoid Valve

Condition
Circuit
Powertrain control module (Trans Code No.63 output Code No.63 output Lockup may not be oper
axle) 2K terminal — lockup control Lockup will not operate Lockup will not operate ated in lockup zone
solenoid valve
Lockup control solenoid valve —
No symptom
ground
3-2 Timing solenoid Valve

Condition
Circuit
axle) 2M terminal — 3-2 timing Shift shock may be strong Shift shock may be strong
solenoid valve Lockup is canceled Lockup is canceled
3-2 timing solenoid valve — ground No symptom
Lockup solenoid Valve

Condition
Circuit
Powertrain control module (Trans Code No.65 output Code No.65 output Lockup may not operate
axle) 2C terminal — lockup sole Lockup will not operate Lockup will not operate in lockup zone
noid valve
Lockup solenoid valve — ground No symptom
Line pressure solenoid Valve

Condition
Circuit
Powertrain control module (Trans- Code No.66 output Code No.66 output Shifting may be abnormal
axle) 2N terminal — Line pressure Shift shock and select Shift shock and select if powertrain control
solenoid valve shock will be strong shock will be strong module (Transaxle) does
Line pressure solenoid valve — not judge malfunction
No symptom
ground
Hold Indicator Lamp

Condition
Circuit
Powertrain control module (Trans Hold indicator lamp will Hold indicator lamp will
axle) 1B terminal — hold indicator not illuminate be illuminated NA
lamp

Condition
Circuit
axle) 1J terminal — powertrain con Shift shock may be slight Shift shock may be slight NA
trol module (Engine) 1S terminal ly strong ly strong
NA: Not applicable
K 1-260
SERVICE POINTS K1
Condition
Circuit
axle) 1L terminal — powertrain con Shift shock may be slight Shift shock may be slight NA
trol module (Engine) 1V terminal ly strong ly strong
Inhibitor Signal
Condition
Circuit
Powertrain control module (Trans Engine speed will be Engine speed will be
axle) 1D terminal — powertrain slightly low in P and N slightly high in R, D, S
NA
control module (Engine) 1R ranges and L ranges
terminal
FAT Terminal (Data Link Connector)

Condition
Circuit
Powertrain control module (Trans Diagnostic trouble code(s) Diagnostic trouble code(s)
axle) 1C terminal — FAT Terminal not displayed by self- not displayed by self-
(data link connector) diagnosis function diagnosis function
NA
When using self When using self
diagnostic checker, “ 88” diagnostic checker, “ 88”
flashes after 20 seconds flashes after 20 seconds
Battery Power (Backup)

Condition
Circuit
Powertrain control module (Trans Memory functions that rely ROOM 15A fuse burns
axle) 2 0 terminal — battery on self-diagnosis, such as out
NA
diagnostic trouble code
memory, do not operate
Battery Power
Condition
Circuit
Powertrain control module (Trans No symptom Meter 15A fuse burns out
axle) 2Q terminal — battery when ignition switch is NA
ON
Powertrain control module (Trans- No symptom Meter 15A fuse burns out
axle) 2S terminal — battery Powertrain control module when ignition switch is
(transaxle) ON
NA
D, S range: Third gear
fixed
L range: 1st gear fixed
Powertrain control module (Trans Powertrain control module Meter 15A fuse burns out
axle) 2Q and 2S terminals — (Transaxle) does not when ignition switch is
battery function ON
NA
fixed
Ground
Condition
Circuit
Powertrain control module (Trans Powertrain control module
axle) 2P terminal — ground (Transaxle) does not
function
No symptom Shifting may be abnormal
fixed
NA: Not applicable 46U0K1-384
K1-261
K1 SYSTEM INSPECTION
SYSTEM INSPECTION
LINE PRESSURE SOLENOID VALVE OUTPUT DUTY
Inspection
1. Connect the (+ ) terminal of a dwell meter to terminal 2N
at the powertrain control module (Transaxle) and the (-)
terminal to a ground.
Set the dwell meter selector to the 4 cylinder position.
2. Engage the parking brake and use wheel chocks at the front
and rear of the wheels.
4. Depress the brake pedal firmly.
Note
• The dwell meter indicates the OFF duty ratio.
6. Verify the duty ration by depressing and releasing the ac

celerator pedal.
Throttle opening Duty ratio (ON %)

Fully closed (0/8) Approx. 67
Fully open (8/8) Approx. 23
Dwell angle/Duty ratio relationship
Dwell angle (°) 0 18 36 54 72 90

Duty ratio (%) 0 20 40 60 80 100
7. Depress the accelerator pedal slowly and verify the duty

ratio charges as shown in the graph.
8. If not as specified, check the powertrain control module
(Transaxle) (refer to page K1-38) and line pressure sole
noid (refer to page K1-35).
46U0K1-395
SYSTEM INSPECTION K1
LOCKUP SOLENOID VALVE OUTPUT DUTY
Inspection
1. Connect the ( + ) terminal of a dwell meter to terminal 2C
of the powertrain control module (Transaxle) and the (-)
terminal to a ground.
2. Drive the vehicle.
Note
• The dwell meter indicates the OFF duty ratio.
3. Verify the duty ratio in the lockup condition.

46U0K1-396
Condition Duty ratio (ON %)
Slip lockup Approx. 65
Complete lockup Approx. 0
Dwell angle/Duty ratio relationship
Dwell angle (°) 0 18 36 54 72 90

Duty ratio (%) 0 20 40 60 80 100
4. If not as specified, check the powertrain control module

(Transaxle) (refer to page K1-38) and lockup solenoid
valve (refer to page K1-35).
MANUAL OPERATION TEST

Inspection
1. Disconnect the solenoid connector.
2. Accelerate the vehicle from 0 mph, and determine the gear
position by observing the engine speed (drum speed). 1st
gear is approximately 4,250 rpms. Third gear is approxi
mately 1,500 rpms.
3. Verify the gear position of each range.
Range Gear Position
D range Third, fixed
S range Third, fixed
L range 1st, fixed
R range Reverse
4. If not within the specification, check the oil pressure or

transaxle.
K 1-263
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COASTING CLUTCH PRESSURE- O
FORWARD CLUTCH PRESSURE -
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CONVERTER
RELIEF
VALVE
16E0KX-656
K2
warnings and section J for audio antitheft system alarm conditions._________
AUTOMATIC TRANSAXLE
(LA4A-EL)
INDEX................................................... K ? - 2 QUICK DIAGNOSIS CHART............. K 2 - 62

O U T L IN E ............................................ . K ? - 3 OUTLINE............................................. K 2 - 62
SPECIFICATIONS............................. K ?- 3 QUICK DIAGNOSIS CHART ( I) ...... K 2 - 62
CROSS-SECTIONAL VIEW ............ K ? - 4 QUICK DIAGNOSIS CHART (II).... K 2 - 64
POWER FLOW D IA G R A M ............ K ? - 5 SYMPTOM TROUBLESHOOTING... K 2 - 66
OPERATION OF COMPONENTS .. K 2 - 6 USING THIS SECTION..................... K 2 - 66
FLUID PASSAGE LO C ATIO NS.... K ? - 7 DIAGNOSTIC IN D E X ....................... K 2 - 68
MECHANICAL SYSTEM T E S T ...... K?- 10 SYMPTOM TROUBLESHOOTING
PREPARATION................................. . K ?- 10 CHART.............................................. K 2 - 69
LINE PRESSURE TE S T.................. K ?- 10 ON-BOARD DIAGNOSIS SYSTEM.. K2-135
STALL T E S T ..................................... K ?- 12 DESCRIPTION.................................... K2-135
ROAD T E S T ....................................... K ?- 14 ON-BOARD DIAGNOSTIC TEST ... K2-135
D RANGE TEST................................ K?- 14 SERVICE PO IN TS.............................. K2-158
S RANGE TEST................................ K ?- 17 OUTLINE............................................. K2-158
L RANGE TEST................................ K ?- 18 WIRING DIAGRAM ........................... K2-159
P RANGE TEST................................ K?- 19 HYDRAULIC CIRCUIT....................... K2-162
AUTOMATIC TRANSAXLE FLUID TRANSAXLE OVERHALL................. K2-164
(A T F )................................................. K 2 - 21 TRANSAXLE UNIT
A T F ...................................................... K ? - 21 (DISASSEMBLY).............................. K2-164
ELECTRICAL SYSTEM TORQUE CONVERTER................... K2-189
COMPONENTS................................ . K ? - 23 OIL P U M P .......................................... K2-190
PREPARATION................................. K ? - 16 FORWARD ONE-WAY CLUTCH,
TRANSAXLE TESTER LOW-INTERMEDIATE SUN GEAR
INSTRUCTION................................ . K ? - 24 ASSEMBLY, AND LOW-INTERMEDIATE
MLP TESTER INSTRUCTION ....... K ? - 34 CARRIER ASS E M B LY................... K2-194
TRANSAXLE...................................... K ?- 39 FORWARD/COASTING/DIRECT
TRANSAXLE UNIT (REMOVAL) ... . K 2 - 39 CLUTCH CYLINDER AND
CONTROL VALVE BODY REVERSE CLUTCH D R U M .......... K2-198
(ON-VEHICLE REM O VAL/ LOW ONE-WAY C LU TC H ............... K2-212
INSTALLATIO N)............................. . K?- 44 REVERSE/FOURTH GEAR RING
TRANSAXLE UNIT GEAR, REVERSE/FOURTH GEAR
(INSTALLATION)........................... . K ?- 47 CARRIER ASSEMBLY, AND CHAIN
OIL COOLER...................................... K ? - 54 DRIVE................................................ K2-213
OIL C O O LE R .................................... . K ? - 54 CONTROL VALVE BODY
DRIVE PLATE.................................... K ?- 56 (DISASSEMBLY / INSPECTION)... K 2-215
PREPARATION................................. . K ? - 56 ACCUMULATOR B O D Y .................. K2-219
DRIVE PLATE.................................... . K ?- 56 VALVE BODY ASSEMBLY.............. K2-220
SHIFT MECHANISM......................... K ?- 58 CONTROL VALVE BODY
SELECTOR LEVER.......................... K ? - 58 (ASSEMBLY)..................................... K2-222
TROUBLESHOOTING GUIDE......... K ? - 61 DIFFERENTIAL.................................. K2-225
GENERAL NOTES............................ . K ? - 61 TRANSAXLE UNIT (ASSEMBLY)... K 2-227
46U0K2-515
K2 INDEX
INDEX
HOLD INDICATOR LIGHT SERVICE, SECTION K1
SPEEDOMETER
SERVICE, SECTION K1
INDICATOR LIGHT SERVICE, SECTION K1
STOPLIGHT SWITCH
SERVICE, SECTION K1
HOLD SW ITCH SERVICE,

SECTION K1
POWERTRAIN CONTROL MODULE (PCM) SERVICE, SECTION F3
ATF SPECIFICATION TYPE M -m or MERCON®

CAPACITY 8.3 L (8.8 US qt, 7.3 Imp qt)
THROTTLE POSITION SENSOR AND

IDLE SWITCH SERVICE, SECTION F3
DISTRIBUTOR SERVICE,
SECTION F3
VEHICLE SPEEDOMETER
SENSOR, SECTION K1
16E0KX-002
K 2 -2
INDEX, OUTLINE K2
1. Diagnosis connector 7. Control valve body
On-boad diagnosis system... .. page K 2-22 9 Disassembly / Inspection.... .... page K 2 - 95
2. ATF A ssem bly.............................. .... page K 2-10 2
Inspection................................ .. page K 2 - 21 On-vehicle removal............. .... page K 2-10 5
3. TR sensor On-vehicle installation......... .... page K 2-10 5
MLP tester in stru ction .......... page K 2 - 34 8. Oil cooler
4. Solenoid body Removal / Inspection /
Transaxle tester instruction... .. page K 2 - 24 Installation........................... .... page K 2-14 8
5. TSS 9. Drive plate
Transaxle tester instruction... .. page K 2 - 24 Removal / Inspection /
6. Transaxle Installation........................... .... page K 2-15 0
R e m o val.................................. .. page K 2 - 39 10. Shift m echanism ....................... .... page K 2-15 2
D isassem bly........................... .. page K 2 - 44 46U0K2-002
Assem bly................................. .. page K 2-10 9
Installation................................ .. page K2-141
OUTLINE
SPECIFICATIONS
' -------------____________ T ransaxle/Engi ne LA4A-EL
Item ~—____ ___ FS
1 w
Transaxle control Floor shift
Lockup Mechanism Equipped K2
1st Gear 2.889
2nd Gear 1.571
Gear ratio Third Gear 1.000
Fourth Gear 0.698
Reverse 2.310
I Final gear ratio 3.770
Type M-m or MERCON®
ATF
Capacity L (US qt, Imp qt) 8.3 (8.8, 7.3)
Forward clutch 2/3
Coasting clutch 2/2
Number of drive/
Direct clutch 3/3
driven plates
Reverse clutch 2/2
Low/rev clutch 3/3
46U0K2-003
K 2-3
K2________________ _________OUTLINE
CROSS-SECTIONAL VIEW
46UOK2-004
K 2 -4
OUTLINE K2
POWER FLOW DIAGRAM
©
©
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Vis'
I\JjL
LH
S
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( D O ® ®
T -S
46U0K2-005
1. Torque converter 9. Forward clutch 16. Low one-way clutch

2. Turbine shaft 10. Forward one-way clutch 17. Reverse/fourth gear carrier
3. Oil pump drive shaft 11. Low/intermediate sun gear 18. Reverse/fourth gear ring gear
4. Oil pump 12. Low/intermediate planetary 19. Chain
5. Reverse clutch carrier 20. Drive sprocket
6. 2/4 band 13. Low/intermediate ring gear 21. Differential
7. Direct clutch 14. Reverse/fourth gear sun gear
8. Coasting clutch 15. Low/reverse clutch
DIRECT
CLUTCH
K 2 -5
K2 OUTLINE
OPERATION OF COMPONENTS
Low/reverse clutch
one-way
one-way
Forward
clutch
clutch
Coasting clutch
Forward clutch
Engine braking
Reverse clutch
Low
Direct clutch
Range Mode Gear
2/4 band
Coasting
effect
Coast
Drive
Drive
P — — —
R — Reverse Gear Yes O O
N — — —
1st Gear No 0 O ® 0 ®
Except 2gr Gear No O 0 O ®
hold Third Gear No O o o ®
D Fourth gear Yes O © ® ®
2nd Gear Yes 0 0 0 — 0 — ®
H O LD Third Gear Yes o o o — o © ®
'Fourth Gear Yes o o © ® ®
1st Gear No o o — o o ®
Except 2nd Gear Yes o o o — o ® ®

hold Third Gear Yes o o o — o ® ®
S * Fourth Gear Yes o 0 © ® ® ® ®
2nd Gear Yes o o o — o ® ®
H O LD "Third Gear Yes o o o — — ® ®
'Fourth Gear Yes o o © ® ® ® ®
1st Gear Yes o o — o o o ®
Except 2nd Gear Yes o o o — o ® ®

hold "Third Gear Yes o o o — o ® ®
L
1st Gear Yes o o — o o o —
*2nd Gear Yes o o o — o ® ®
H O LD
'Third Gear Yes 0 0 0 — 0 ® ®
46U0K2-006
O Operating.
® Operating but not contributing to transaxle output. (OVER RUNNING)
© Power is not transmitted.
* Engine overspeed protection.
☆ The Powertrain control module (PCM) switches automatically between power and normal modes corresponding to how
rapidly the accelerator pedal is depressed.
OUTLINE K2
FLUID PASSAGE LOCATIONS
Transaxle Case
CONVERTER CLUTCH BYPASS (CBY)
46U0K2-007
K2 OUTLINE
Converter housing
46U0K2-008
K2—8
_____________________________ OUTLINE________ ________________ K2
Oil Pump
SEAL RINGS
COASTING CLUTCH (CC)
FORWARD CLUTCH (FC)
REAR LUBE
DIRECT CLUTCH (DC) (FROM COOLER TC CIRCUIT)
REVERSE CLUTCH (RQ
BOTTOM VIEW
CONVERTER CLUTCH BYPASS (CBY)
46U0K2-0Q9
MECHANICAL SYSTEM TEST

PREPARATION
SST
49 UN01 128 H I For 49 0378 400A For

line pressure test oil pressure
Adapter to If test
mate hose JsJw V vxZ
49 B019 902 For 49 B019 903 For

line pressure line pressure
Oil pressure test H °se a /ff test
gauge (Part of J fjl)
(Part of "■ 49 0378 400A)
49 0378 400A) ^
46U0K2-010
LINE PRESSURE TEST

This test measures line pressure as a means of checking the hydraulic components and inspecting for
oil leakage.
Preparation
1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
2. Check, and correct as necessary, the engine coolant level.
3. Warm the engine thoroughly to raise the ATF temperature to operating level 66—77°C {150—170°C}.
4. Check, and correct as necessary, the engine oil and ATF levels.
5. Check the idle speed and ignition timing in P range. (Service as Section F3.)
ENGAGE PARKING BRAKE WARM UP ENGINE ENGINE COOLANT LEVEL
ENGINE OIL LEVEL
W HEEL CHOCK
ATF LEVEL
46U0K2-011
K 2-1 0
Procedure
1. Connect the SST to the line pressure inspection port.

2. Start engine
3. Shift the selector to D range and read the line pressure at idle.
Caution
• If the accelerator pedal is pressed for longer than 5 seconds be while the brake pedal is pressed,
4. Depress the brake pedal fimly with the left foot and gradually depress the accelerator pedal with the right foot.
5. When the engine speed no longer incressed, quickly read the line pressure and release the accelerator.
7. Read the line pressure at idle and at the engine stall speed for each range in the same manner.
46U0K2-015
Specified line pressure
LINE PRESSURE SPECIFICATIONS
Line Pressure IDLE kPa {kgf-cm2, psi) STALL kPa {kgf-cm2, psi)
RANGE 441—524 {4.50-5.34, 6 4 -7 6 ) —
P, N 4 4 1 -5 2 4 {4.50—5.34, 6 4 -7 6 ) 1,786-2,027 {18.21-20.66, 2 5 9 -2 9 4 )
D 3 1 0 -3 6 5 {3.16-3.72, 4 5 -5 3 ) 1,158-1,269 {11.80-12.93, 168 -1 84 )
S 3 1 0 -3 6 5 {3.16-3.72, 4 5 -5 3 ) 1,158-1,269 {11.80-12.93, 168 -1 84 )
L 3 1 0 -3 6 5 {3.16-3.72, 4 5 -5 3 ) 1,158—1,269 {11.80—12.93, 168—184)
46U0K2-016
9. Install a new in the inspection port.
Evaluation of Line Pressure Test
Line pressure Possible cause

Fluid level low
Restricted inlet filter
Control valve body, solenoid body or accumulater body is loose
Low pressure in every position Excessive leakage in pump, case control bodies
Sticking main regulator valve
Damaged inlet tube seal or inlet filter
Damaged gaskets separator plate
Higher than specification Problem with main regulator valve, solenoid body and wiring harness
46U0K2-Q17
STALL TEST
This test is performed determine if there is slippage of the friction elements or malfunction of the hydraulic
components.
Preparation
Perform the preparation procedure outlined in LINE PRESSURE TEST. (Refer to page K2-10.)
Procedure

Caution
• If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is pressed,
3. Firmly depress the foot brake with the left foot, and gently depress the accelerator pedal with the right foot.
4. When the engine speed no longer increases, quickly read the engine speed and release the accelerator,
6. Perform stall tests for the remaining ranges in the same manner.
(1) D range
(2) S range
(3) L range
Engine stall speed: 2,200—2,500 rpm
Evalution of Stall Test
Condition Possible source
Above specification in D range Forward clutch

Forward one-way clutch
Low one-way clutch
In R range Reverse clutch

Low and reverse clutch
Below specification Engine

Torque converter one-way clutch
46U0K2-013
K 2-13
K2 ROAD TEST
ROAD TEST
A road test is necessary to inspect for problems in the different gear ranges. If a range or function targeted
by the road test is found to have any problem, refer to the ELECTRONIC SYSTEM COMPONENT seg
ment or the TRANSAXLE, OIL COOLER, DRIVE PLATE, and SHIFT MECHANISM segments of this section.
Do the road test only when the ATF is 66—77°C {150—170 °F).
46U0K2-516
D RANGE TEST
Note
• The power mode and the normal mode are automatically selected by the Powertrain control module
(Transaxle).

2. Accelerate the vehicle with half- and wide open throttle.
3. Verify that 1-2, 2-3, and 3-4 upshifts and downshifts are obtained. The shift points must be as shown
in the D range shift diagram.
4. Drive the vehicle in Fourth, Third, and 2nd gears and verify that kickdown occurs for 4-+3, 4->2, 4—►I,
3->2, 3—>1, 2—>1, and that the shift points are as shown in the D range shift diagram.
5. Decelerate the vehicle and verify that engine braking effect is felt in Fourth and Third gears.
8. Accelerate the vehicle with half- and full-throttle opening, and verify that 2-3 upshift and downshift are
obtained. The shift points must be as shown in the D range (hold mode) shift diagram.
9. Drive the vehicle in Third and 2nd gears and verify that kickdown does not occur.
46U0K2-517
ROAD TEST ________________ K2
D range (power mode) shift diagram
46U0K1-015
D range (normal mode) shift diagram
LOCKUP AVAILABLE WHEN ACCELERATING AND CRUISING

LOCKUP AVAILABLE WHEN COASTING
LOCKUP AVAILABLE DURING BOTH 4GR COASTING AND 3GR ACCEL./CRUISE
A-.AV.’.-.v.v.v.v.v.v-
IA p }A V f.V & X $ £ fri
LOCKUP IN 3GR
LOCKUP..IN 4GR
S H IF T UP
LOCKUP IN 4GR
SHIFT
DOWN
2 0 (1 2 ) 4 0 (2 5 ) 6 0 (3 7 ) 8 0 (5 0 ) 1 0 0 (6 3 ) 1 2 0 (7 5 ) 1 4 0 (8 7 ) 1 6 0 (9 9 )
46U0K1-016
K 2-15
K2 ROAD TEST
D range (hold mode) shift diagram
I 1 LOCKUP AVAILABLE W HEN COASTING

8/8
7/8.
6/ 8 .
o
Z
< 5/8-
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z
; LQCKUP. IN _3GR>:
LOCKUP
z 4 /8 . IN 3GR
LU
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0/8
2 0 |1 2 ) 4 0 (2 5 ) 60 137) 8 0 (5 0 ) 1 0 0 (6 3 ) 1 2 0 (7 5 ) 1 4 0 (8 7 ) 1 6 0 (9 9 )
46U0K2-518
S RANGE TEST
1. Shift the selector lever to S range.
3. Verify that 1-2 and 2-3 upshifts and downshifts are obtained. The shift points must be as shown in the
S range shift diagram.
4. Drive the vehicle in Third and 2nd gears and verify that kickdown occurs for 3->2, 3-+1, 2-»1, and that
the shift points are as shown in the S range shift diagram.
8. Accelerate the vehicle with half- and full-throttle opening, and verify that 2nd gear is held.
____________________________ ROAD TEST________ _______________ K2
S range (normal mode) shift diagram
fc jg x l LOCKUP AVAILABLE WHEN ACCELERATING AND CRUISING
n m LOCKUP AVAILABLE WHEN COASTING
46U0K1-019
S range (hold mode) shift diagram
cm
LOCKUP AVAILABLE WHEN COASTING
8/8 .V .V I
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7/8- •XXI
XXI
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X \v XvXl
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20 (12) 40(25) 60(37) 80(50) 10 0 (6 3 ) 1 2 0 (7 5 ) 1 4 0 (8 7 ) 1 6 0(9 9)
46U0K2-519
K 2-17
K2 ROAD TEST
L RANGE TEST
1. Shift the selector lever to L range.
3. Verify that 1-2 upshift and downshift are obtained. The shift points must be as shown in the L range shift
diagram.
4. Drive the vehicle in 2nd gear and verify that kickdown occurs for 2—»•1, and that the shift point is as shown
in the L range shift diagram.
5. Decelerate the vehicle and verify that engine braking effect is felt in 2nd gear.
7. Accelerate the vehicle with half- and full-throttle opening, and verify that 1st gear is held.
36U0KX-018
L range (normal mode) shift diagram
I 1 LOCKUP AVAILABLE WHEN COASTING
46U0K1-021
ROAD TEST K2
L range (hold mode) shift diagram
[X v /p } LOCKUP a v a il a b l e w h e n ACCELERATING a n d c r u is i n g
□ LOCKUP AVAILABLE W HEN COASTING
o
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cc
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46U0K2-520
P RANGE TEST
Shift into P range on a gentle slope, release the brake, and verify that the vehicle does not roll.
46U0K1-023
K2 ROAD TEST
Vehicle Speed at Shiftpoint Table
Throttle condition
Vehicle speed
Range Mode (throttle position Shift
km/h (mph)
sensor voltage)
D 1-+ D 2 5 0 -5 6 (3 1 -3 5 )
Wide open throttle (3.0—4.4V) D 2 -*D 3 1 00-108 (6 2 -6 7 )
D 3-»D 4 1 55-165 (9 6 -1 0 2 )
Di -»D2 3 5 -4 5 (2 2 -2 8 )
Half throttle D 2->D 3 7 3 -9 1 (4 5 -5 6 )
Power D3->D 4 123-148 (7 6 -9 2 )
D 4 -*D 3 3 7 -4 3 (2 3 -2 7 )
Closed throttle position (0.1—1.1V)
D 3 -D 1 8 -1 4 ( 5 - 9 )
D4-+D 3 147-157 (9 1 -9 7 )
Kickdown D 3-+ D 2 9 2 -1 0 0 (5 7 -6 2 )
D 2- D 1 3 7 -4 3 (2 3 -2 7 )
D 1-+ D 2 5 0 -5 6 (3 1 -3 5 )
D
D2->D 3 100—108 (62—108)
Wide open throttle (3.0—4.4V) D 3 -D 4 155-165 (9 6 -1 0 2 )
Lockup ON (D3) 7 8 -8 6 (4 7 -5 3 )
Lockup ON (D4) 146-156 (9 1 -9 7 )
D 1- D 2 2 8 -3 6 (1 7 -2 2 )
Normal D 2-»D 3 5 5 -7 1 (3 4 -4 4 )
Half throttle D3-+D 4 104-131 (6 4 -8 1 )
Lockup ON (D 3) 4 8 -6 4 (3 0 -4 0 )
Lockup ON (D 4) 9 2 -1 1 7 (5 7 -7 3 )
D4->D3 2 7 -3 3 (1 7 -2 0 )
D 3- D 1 8 -1 4 ( 5 - 9 )
D4->D3 147-157 (9 1 -9 7 )
Kickdown D 3->D 2 9 2 -1 0 0 (5 7 -6 2 )
D 2- + D 1 3 7 -4 3 (2 3 -2 7 )
S1-S2 5 8 -6 4 (36—40)
Wide open throttle (3.0—4.4V) S2-»S3 104-112 (6 4 -6 9 )
Lockup ON (S3) 107-115 (6 6 -7 1 )
S 1- S 2 3 5 -4 5 (2 2 -2 8 )
Half throttle S2-»S3 7 3 -9 1 (4 5 -5 6 )
S
Lockup ON (S3) 107-115 (66—71)
D4 ( S 4 )-S 3 1 62-168 (6 3 -1 0 4 )
S3-»S1 8 -1 4 ( 5 - 9 )
S3->S2 9 4 -1 0 3 (5 8 -6 4 )
Kickdown
S2-S1 4 3 -4 9 (2 7 -3 0 )
Wide open throttle (3.0—4.4V) Li -»L2 5 8 -6 4 (3 6 -4 0 )
Half throttle Li -*L2 3 5 -4 5 (2 2 -2 8 )
L
closed throttle position (0.1—1.1V) L2-»Li 8 -1 4 (5 -9 )
Kickdown L2->Li 4 3 -4 9 (2 7 -3 0 )
D2->D3 1 6 -2 2 (1 0 -1 4 )
Lockup ON (D 3) 104-114 (6 4 -7 1 )
D —
D4-»D 3 162-168 (1 0 0 -1 0 4 )
D 3-»D 2 7 -1 3 ( 4 - 8 )
Hold
Lockup ON (S3) 104-114 (6 4 -7 1 )
S — D4(S4)-»S3 162-168 (1 0 0 -1 0 4 )
S3 -+ S 2 103-109 (6 4 -6 8 )
L — L2-»Li 4 3 -4 9 (2 7 -3 0 )
46U0K2-522
Input the voltages displayed on the engine signal monitor into the following formula to calculate the half
throttle voltage.
Wide open throttle voltage - Closed throttle position voltage

-------------------------------- ------ -------------- -—----------------------- = Half throttle voltage
K 2-2 0
AUTOMATIC TRANSAXLE FLUID (ATF) K2
AUTOMATIC TRANSAXLE FLUID (ATF)
ATF
Inspection
Level
1. Park the vehicle on level ground.
3. Warm up the engine until the ATF reaches 66—77°C
{150—170°F).

5. Shift back to P range.
46U0K2-020
6. Ensure that the ATF level is between max. and min.
DO NOT DRIVE MARK
ATF type: M-m or MERCON®
MIN. MAX. Capacity: 6.95 L {7.3 US qt, 6.0 Imp qt)
I l° DON'T ADD IN THIS AREA
V
FLUID LEVEL AT NORMAL
OPERATING TEMPERATURE
6 6 °C — 77°C { 150°F— 170°F)
46U0K2-021
Condition
Determine whether the automatic transaxle should be disas
sembled by noting:
1. If the ATF is muddy or varnished.
2. If the ATF smells strange or unusual.
46U0K2-022
K2 AUTOMATIC TRANSAXLE FLUID (ATF)
Fluid leaks
Check for ATF leaks of the transaxle at the points shown below and repair or replace as necessary.
1. Gaskets, O-rings, and plugs.
2. Oil hoses, oil pipes, and connections.
3. Oil cooler.
16E0KX-055
K 2-22
ELECTRICAL SYSTEM COMPONENTS
PREPARATION
SST
49 UN01 086 For 49 UN01 071 For

Alignment of check of
MLPS alignment TR sensor Transaxle tester electrical system
tool components
■ oT □
» 1
» t*u».lira
49 UN01 089 For 49 UN01 090 For

check of check of
Transaxle electrical system Transaxle overlay electrical system
diagnostic components components
harness
49 UN01 091 For 49 UN01 092 For

check of chek of
MLPS harness TR sensor MLPS overlay TR sensor
adapter
49 UN01 128 For

ATF oil pressure
Adapter tester
46U0k2-023
K 2-23
TRANSMISSION TESTER INSTRUCTION
The transmission tester allows a technician to operate the electrical portion of the transaxle independent of
the vehicle electronics. The transmission tester usage is divided into five step:
1. Preliminary testing and diagnosis.
2. Installing the transmission tester.
3. Static testing-vehicle OFF.
4. Dynamic testing-vehicle running.
5. Removing the transmission tester and clearing Diagnostic Trouble Codes (DTCs).
Preliminary Testing and Diagnosis

Before any diagnostic testing is done on a vehicle some preliminary checks must be performed, as out
lined below. Be sure to write down your findings, especially any DTC, for future reference.
• Check ATF level and condition.
• Check for add-on items (phones, computers, CB radio etc).
• Visually inspect wiring harness and connectors.
• Check for vehicle modifications.
• Verify that the shift linkage is properly adjusted.
• Verify customer concern.
- Upshift, Downshift, Coasting, Engagement, Noise/Vibration
• Vehicle must be at a normal operating temperature.
• Perform vehicle On-Board Diagnostic Test. (Procedue Section F3.)
• Record all DTCs.
• Repair all non-transaxle DTCs.
Installing the Transmission Tester (set up procedures)

Installing the transmission tester at the solenoid body connector allows the separation of the vehicle elec
tronics from the transmission electronics. Disconnecting the normal vehicle electronics will in itself set ad
ditional DTCs and cause firm shifts. (Disconnecting the solenoid body connector defaults the transmission
to maximum line pressure).
Note
• During tester usage additional DTC may be set.
• Therefore, it is important that all DTCs are erased after repairs have been made. To verify elimination
of all DTCs rerun On-Board Diagnostic Test (Procedure, Section F3.)
46U0K2-034
Caution
• Do not attempt to pry off connectors with a screw
driver.
This will damage the connector and could result in
a transaxle concern.
1. Disconnect emission harness at solenoid body connector

and at TSS connector on the oil pump body in LH wheel
arch.
46U0K2-035
2. Turn tester solenoid select switch to the “ OHMS CHECK”

position.
46U0K2-036
Caution
• Route all cables away from HEAT SOURCE.
3. Install SST onto tester.

Connect SST to transaxle tester and then to the appropri
ate solenoid body connector and TSS connector.
46U0K2-037
Caution
• Route all gage line away from heat sources.
4. Connect the SST to the line pressure inspection port.
46U0K2-038
5. Plug transmaxle tester power supply plug into cigarette ligh
ter receptacle. At this time, all LED’s should illuminate for
a short period and them turn off. This is the tester internal
circuit check.
46U0K2-039
K 2-25
6. Bench/Drive switch set to “ BENCH” mode.
[ | SOELNOID SELECT
I___ _ OHMS
BENCH U -V CHEC K x
1 MODE
J '
u
“ 1
© ® ® ® ® ®
+ + +
46UOK2-040
Static Testing-Vehicle “ OFF”

Static testing procedures allow for shop testing of the transaxle in the vehicle or on the bench. Completion
of these tests prove out the transaxle electronically.
Caution
• For resistance checks, be sure that the tester solenoid select switch is set to the “ OHMS
CHECK” position or damage to the ohmmeter may result.
Resistance/Continuity Tests
• Refer to Pinpoint Test (Refer to page K2-135.) to be performed “ On Boad Diagnostics"* based on the
DTC displayed.
• Using a volt-ohmeter and the transmission tester perform the Pinpoint Tests as indicated in “ On Boad
Diagnostics” (Refer to page K2-135) based on the DTC which were displayed.
• Perform repairs as indicated by the Pinpoint Tests (Refer to page K2-135.) Always retest and road test
vehicle after a repair. (Refer to page K2-14.)
46U0K2-041
Transaxle Solenoid and Sensors Resistance Tests

Solenoids (EPC, SS1, SS2, TCC, 3-2T/CCS)
1. Set ohmmeter to 100-200 ohm renge.
2. Connect the position lead of the ohmmeter to the appropri
ate VPWR jack for the solenoid being tested.
3. Connect the negative lead of the ohmmeter to the appropri
ate solenoid (EPC, SS1, SS2, TCC, 3-2T/CCS) jack.
4. Record resistance.
5. Refer to chart for valves.
SOLENOID SOLENOID RESISTANCE (Q)

SS1 1 2 -2 2
SS2 1 2 -2 2
TCC 1 .0 -2 .0
EPC 3.7-5.92
3-2T/CCS 3.7-5.92
K 2-2 6
6. If out of range refer to the following pinpoint tests.
• Pinpoint test E (EPC) (Refer to page K2-149.)
• Pinpoint test A (SS1, SS2) (Refer to page K2-138.)
• Pinpoint test C (TCC) (Refer to page K2-144.)
• Pinpoint test G (3-2T/CCS) (Refer to page K2-154.)
46U0K2-043
Transaxle Fluid Temperature (TFT)

1. Set ohmmeter to 1,000 ohm range.
2. Connect ohmmeter positive lead to +TFT jack.
3. Connect ohmmeter negative lead to -TFT jack.
46U0K2-044
4. Record resistace. Resistance will vary with temperature.
5. Refer to chart for valves.
Temperature °C (°F ) Resistance kft

0—20 (3 2 -6 8 ) 108-33
2 0 -4 0 (6 9 -1 0 4 ) 3 7 -1 4
4 0 -7 0 (10 5-15 9) 1 6 -4 .5
7 0 -9 0 (15 9-19 4) 5 -2 .3
9 0 -1 1 0 (1 9 5 -2 3 0 ) 2 .7 -1 .3
110-130 (23 0-26 6) 1.5-0.7
6. If out of range refer to Pinpoint test B.

46U0K2-045
Turbine Shaft Speed (TSS) Sensor

1. Set ohmmeter to 1,000 ohm range.
2. Connect the postive lead of the ohmmeter to the +TSS jack.
3. Connect the negative lead of the ohmmeter to the -TSS
jack.
4. Recoad the resistance.
5. TSS should be 140—290 ohm.
If out of range refer to Pinpoint test F.
46U0K2-046
K 2-27
Short to Ground and Solenoid Voltage Tests
Note
• LED will turn “ GREEN” when solenoid activates and turn
"OFF” when deactivated. LED will turn “ RED” if an ac
tivated solenoid/harness is shorted to BAT +. LED will
remain "OFF” if an activated solenoid/harness is short
ed to ground or no continuity.
46U0K2-047
1. Tester Bench/Drive switch set to “ BENCH” mode.
2. Set voltmeter to 20 volt D.C. range.
3. Connect voltmeter positive lead to the appropriate solenoid
VPWR.
4. Connect voltmeter negative lead to the appropriate solenoid.
5. Using voltmeter check for voltage across each solenoid by
activating the solenoid switch. Select the appropriate sole
noid with the rotary switch and depress the corresponding
solenoid switch. The “ LED” should illuminate, the voltage
should change and an audible click may be heard. If “ LED”
does not illuminate, a short to ground condition exists.
6. Observe and record values.
Dynamic Testing-Vehicle Running

Dynamic testing is the final step in the transmission tester usage. It allows the transaxle to be proven out
electronically and hydraulically.
46U0K2-049
Transaxle Solenoid Cycling and Drive Test Procedures

Preliminary set up
1. Bench/Drive switch set to DRIVE mode.
2. Rotate gear select switch on tester to GEAR SELECT “ 1”
position.
3. Vehicle in PARK.
4. Start vehicle.
46U0K2-Q50
K 2 -2 8
EPC solenoid
.2 .
Caution
• Do not attempt to hold the EPC switch depress
EPC
(minimum line pressure) and stall the transaxle
® o (holding the vehicle with the brake while depress
VPW R/EPC STATUS ing the throttle with the transaxle in gear), transax
□ □ le damage will result.

PWR ACTIVATE
® ®
EPC 5. Observe line pressure. Record value. Line pressure should
go to maxmum. If not, refer to SYMPTOM TROUBLESHOOT
46U0K2-051 ING (refer to page K2-66) or Pinpoint test “E” concerning
EPC solenoid (refer to page K2-149.)
6. Depress EPC switch. Line pressure should drop to a mini
mum value. Record value. If not, refer to SYMPTOM
TROUBLESHOOTING (refer to page K2-66) or Pinpoint
Test “ E” . (refer to page K2-149.)
Engagement
Note
• For reverse operation gear select switch must be in "3/R” .
7. Set Bench/Drive switch is in the "DRIVE” mode.

8. Rotate gear select switch to GEAR SELECT “ 1” .
9. Start vehicle, rotate gear select switch to GEAR SELECT
“ 3/R". Depress EPC switch. Line pressure should drop to
idle pressure. While holding the EPC switch down, shift ve
hicle from PARK to REVERSE.
• Does vehicle shift into REVERSE?

• Was engagement smooth?
Shift vehicle from REVERSE to PARK.
10. Rotate gear select switch to GEAR SELECT “ 1 Depress

EPC switch. Line pressure should drop to idle pressure.
While holding the EPC switch down, shift vehicle from PARK
to DRIVE.
• Does vehicle shift into DRIVE?

• Was engagement smooth?
Shift vehicle from DRIVE to PARK.

Release the EPC switch, pressure should return to maxi
mum. Repeat step 9 and 10 for engagements, with the EPC
switch released engagements should be firm.
K 2-29
Upshift/Downshift
Note
• GEAR SELECT SWITCH must be in GEAR SELECT
“ 3/R” to get REVERSE gear.
• Upshifts and downshifts will be FIRM during this
procedure.
• Pressure gauges may be removed from vehicle during
these tests.
• These tests should be performed on the road. If per
formed on the hoist the technician may not feel all of the
shifts when they are engaged.
• LED’s will turn "green” when solenoids are activated and
turn "off” when deactivated. Refer to the appropriate
overlay for the proper status/shift sequence of the shift
solenoids during upshift and downshift.
Caution
• Selector lever must be in the D range positon or in
ternal damage could result.
Do not shift to S or L range position.
46U0K2-054
11. Verify that the gear select switch is in 1st gear position. Move
the selector lever into the D range. Depress the 3-2 T/CCS
button and accelerate the vehicle. If there is no vehicle move
ment, inspect the forward one-way clutch. If movement oc
curs proceed to step 12 and continue diagnosis.
12. Verify that the gear select switch is in “ 1’ position. More the
selector shift lever into D range and accelerate to 5 km/h
{15 mph), select 2nd gear by rotating the gear selector
to “ 2” position.
• Did the vehicle upshift to 2nd gear?

• Did the appropriate shift solenoids activate/deactivate?
46U0K2-055
13. Accelerate to 40 km/h {25 mph) and select "3 ” position.
• Did the vehicle upshift to third gear?

14. Accelerate to 56—72 km/h (35—45 mph) and select “ 4”

position.
• Did the vehicle upshift to fourth gear?

Caution
• The vehicel must below 56 km/h (35 mph} before
selecting gear select “ 1” position, or the transax
le could overrun.
15. Reverse the order to downshift.
Note
• 4-3 downshift will be barsh using transmission tester.
• Does the vehicle down shift from forth gear to third gear,
third gear to 2nd gear and 2nd gear to 1st gear?.
K 2-30
Torque converter clutch (TCC) engagement
Note
• This test should be performed on the road. If performed
on a hoist the technician may not feel the torque con
verter clutch engage.
Caution
• Do not depress TCC switch with transaxle in gear
and the vehicle at a stop. Damage to converter
clutch may result.
16. Accelerate and shift vehicle up into third gear. Hold speed
steady and depress the TCC switch.
• Does the converter engage?

• Does the engine rpm drop?
• Did the TCC solenoid activate?
3-2 Timing/Coasting clutch (3-2T/CCS)

Engagement
Note
CCS
• This test should be performed on the road. If performed
©
on the hoist the technician may not feel the 3-2 tim
°
D o ® o I
VPWR STATUE ing/coasting clutching disengage.
ACTIVAT
□
©
® □ 17. Accelerate and upshift the vehicle into 2nd gear. Go to

^ □
CCS '--------’ closed throttle. Depress the 3-2T/CCS switch.
46U0K2-057 • Does the 3-2 timing/coasting clutch disengage?

• Did the 3-2T/CCS solenoid deactivate (light on)?
18. Remain at closed throttle, then release 3-2T/CCS switch.
• Does the 3-2 timing/coasting clutch engage?

• Did the 3-2 T/CCS solenoid activate (light off)?
• Did engine braking occuring when the throttle is released?
46U0K2-058
K2—31
Turbine Shaft Speed Sensor Function Check.
Note
• This test may be performed on the hoist or on the road.
19. Set voltmeter to 20 bolt A.C.

Connect voltmeter positive lead to the (+ ) TSS jack.
Connect voltmeter negative lead to the (-) TSS jack.
Slowly accelerate vehicle and monitor voltmeter.
• Does the voltage increase with vehicle speed?

46U0K2-Q59
Removing the Transaxle Tester and Clearing DTC
Caution
driver. This will damage to connector and could re
sult in a transaxle concern.
1. Disconnect transaxle tester from the solenoid body connec

tor and TSS connector.
2. Reinstall emission harnesses. Verify connection by pulling

up on the harness.
46U0K2-061
K 2-3 2
3. Disconnect transaxle tester power lead from vehicle.
4. Erase all DTCs will be from continuous test using the proce
dures in Section F3.
5. Rerun On-Board Diagnostic Test to receive a pass code
(111). (Procedure, Section F3.)
6. Based on transmission tester testing results, proceed to the
appropriate segment of this section for transmision or elec
trical/wiring service.
7. Confirm service by repeating transmission tester test.
K 2-33
MLP TESTER INSTRUCTION
The transmission tester allows technician to operate the electrical portion of the TR sensor. The MLP tester
usage divided into five step:
1. Preliminary testing and diagnosis.
2. Installing the transmission tester.
3. Testing the TR sensor.
4. Testing the Park/Neutral and backup circuits.
5. Removing the transmission tester and clearing DTCs.
Preliminary Testing and Diagnosis

Before any diagnostic testing is done on a vehicle some preliminary checks must be performed, as out
lined below. Be sure to write down your findings, especially any DTCs found, for future referece.
• Check ATF level and condition.
• Check for add-on items (phones, computers, CB radio etc).
• Visually inspect wiring harness and connector.
• Check for vehicle modifications.
• Verify that the shift linkage is properly adjusted in “ OVERDRIVE” .
• Verify that TR sensor is properly adjusted in "NEUTRAL” .
• Verify customer concern.
- Upshift, Downshift, Coasting, Engagement, Noise/Vibration
• Vehicle must be at a normal operating temperature.
• Perform vehicele On-Board Diagnostic Test. (Procedure Section F3.)
• Record all DTCs.
• Repair all non-transmission DTCs.
Installing the Transmission Tester (Set Up Procedures)

Installing the transmission tester at the TR sensor connector allows the separation of the vehicle electron
ics from the TR sensor electronics.
Note
• During testere usage additional DTCs may be set. Therefore, it is important that all DTCs are erased
after repairs have been made. To verify elimination of all DTCs rerun On-Board Diagnostic Test.
46U0K2-067
Caution
driver. This will damage the connector and could
result in a transmission concern.
1. Disconnect emission harness at transmission TR sensor con

nector. 46U0K2-068
Note
49 UN01 092 ^ B 49 UN01 091 • For in vehicle testing use the SST.
Caution
• Route all cables away from heat sources.
2. Set Bench/Drive switch to "DRIVE” mode. Install SST onto

tester. Connect interface cable (cable I.D. "D ” ) to transmi-
sion tester and then to the TR sensor connector.
46U0K2-069
3. Turn test select switch to the "MLP SENSOR TEST” position.
SENSOR TEST
□
MLP SENSOR
TEST POSITION
□ << 3 □
46U0K2-070
4. Plug transmission tester power supply plug into cigarette
lighter receptacle.
AT this time, all LED’s should illuminate for a short period
and then turn off. This is the tister internal circuit check.
46U0K2-071
K 2-35
Testing the TR Sensor
Static testing procedures allow for shop testing of the transmission in the vehicle or on the bench. Comple
tion of these tests prove out the TR sensor electronically.
Caution
• For resistance checks, be sure that the tester select switch is set to the “ MLP SENSOR TEST”
position or damage to the ohmmeter may result.
Resistance/Continuity Tests
• Using a digital volt-ohmmeter and the transmission tester perform the pinpoint test “ D” as indicated in
pege K2-147 besed on the DTCs which were displayed.
• Perform repairs as indicated by the pinpoint test. Always retest and road test vehicel after a repair.
TR Sensor resistance tests

TR Sensor - Set ohmmeter to 1,000 ohm range.
- Connect the positive lead of the ohmmeter to the MLP jack.
- Connect the negative lead of the ohmmeter to the SIGRTN jack.
- Move selector lever into each range position.
- Record resistance at each position.
- Refer to chart for values.
If out of range refer to pinpoint test “ D” in page K2-147.
Resistance (ohms)
Selector lever position
Minimum Maximum
P 3,770 4,607
R 1,304 1,593
N 660 807
D 361 442
S 190 232
L 78 95
46U0K2-072
Park/Neutral backup lamp and optional circuit voltage
tests
SENSOR TEST
Note
• LED will turn "RED” when the circuti closed and turn
□ "OFF” when the circuit is open.
MLP SENSOR
TEST POSITION
1. Tester select switch to the “ MLP SENSOR TEST” position.
□ <• c ) □
46U0K2-073
2. Press and hold each button while moving the selector le
ver through each range position.
3. Monitor each “ LED” .
PARK/NEUTRAL.' BACKUP LAMPS
-------- p o s i t i o n H
LED RED o LED RED
O
IN PARK STATU IN
REVERSE STAT
a
AND
NEUTRAL ONLY O NLY
HOLD TO TESiT
H HOLD TO
SWITCH TEST
46U0K2-074
4. The status "LED” should indicate “ RED” only in the indi
cated position. Refer to overlay.
5. If the LED does not indicate “ RED” in the desired position,
or indcated “ RED” in another position, first verify MLP align
ment and then retest. If the sensor fails them replace.
46U0K2-075
Removing the transmission tester and clearning DTC

49 UN01 092 49 UN01 091
Caution
driver. This will damage the connector and could
result in a transmission concern.
1. Disconnect transmission tester from TR sensor connector.
49 UN01 071
46U0K2-076
2. Reinstall emission harness. Verify connection by puling up
on the harness.
46U0K2-077
K 2-37
3. Disconnect transmission tester power lead from vehicle.
4. Erase all DTCs using the procedures in Section F3. (Un
latch center button of star tester while codes are being dis
played on a KOEO on-boad diagnostic test)
5. Return on-boad diagnostic test to receive a pass code (111).
6. Verify that the customer concern has been eliminated.
46U0K2-078
Transmission range sensor replacement
2. Remove the resonance chamber,fresh air duct, and air
cleaner assembly.
3. Disconnect the TR sensor connector.
4. Remove the TR sensor.
46U0K2-Q26
5. Install the TR sensor on the manual lever shaft.
6. Loosely tighten the two mounting bolts.
7. Use SST to aline the sensor on the shaft and case.
8. Tighten the two mounting bolts.
Tighten torque: 9.8 N-m (100 kgf-m, 86.8 in-lbf}
46U0K2-027
TRANSAXLE K2
TRANSAXLE
TRANSAXLE UNIT (REMOVAL)
Preparation
SST
49 G017 5A0 For 49 G017 503 For

support of engine support of engine
Support, engine Hook
V (Part of
49 G017 5A0)
49 G017 501 For 49 G017 502 For

Bar Support \
(Part of (Part of V v^
49 G017 5A0) 49 G017 5A0) ^
46U0K2-082
49 0118 850C For

m itt removal of tie rod
Puller, ball joint end
Removal
2. Raise the vehicle on a vehicle hoist.
3. Drain the ATF into a suitable container.
46U0K2-083
K2 TRANSAXLE
HOSE CLAMP,
v REPLACE
K 2 -4 0
TRANSAXLE K2
46U0K2-Q84
1. Battery 22. Turbine speed sensor connector

2. Battery carrier 23. Transverse member
3. Resonance chamber 24. Mount member
4. Fresh air duct 25. Heated oxygen sensor connector
5. Air cleaner assembly 26. Front exhaust pipe
6. Ground and bracket 27. Tie rod end
7. Solenoid body connector Removal Note.......................... page K2-42
8. Manual lever position sensor connector 28. Stabilizer control link
9. Vehicle speedometer sensor connector 29. Lower arm
10. Oil filler tube Removal Note.......................... page K2-42
11. Ignition coil 30. Drive shaft
12. Ignition coil bracket Removal Note.......................... page K2-42
13. Fuel filter mounting nut 31. Joint shaft
14. Emission harness protector nuts 32. Intake manifold bracket
15. No.1 engine mount nut 33. Starter
16. No.1 engine mount rubber 34. Torque converter nut
17. No.1 engine mount bracket 35. No.5 engine mount
18. No.4 engine mount 36. No.2 engine mount
Removal Note...........................page K2-42 37. Oil hose
19. Shift control cable 38. Transaxle
20. Wheel and tire Removal Note.......................... page K2-43
21. Splash shield
K2-41
K2 TRANSAXLE
Removal Note
No.4 engine mount
1. Support the engine by using the SST before removing the
engine mount member.
2. Remove the No.4 engine mount.
46U0K2-085
Tie rod end
Caution
are between the dust boot and the tie rod.

SST.
Lower arm
1. Remove the clinch bolt from the lower arm ball joint.
36U0KX-322
Caution
• Wrap a rag around the ball joint dust seal to pro
tect it from damage.

46U0K2-087
Drive shaft
1. Remove the clip.
nuts.
16E0KX-109
TRANSAXLE K2
3. Separate the drive shaft (right side) from the joint shaft by
using a brass bar and a hammer.
36U0KX-294
Caution
slice or puncture the oil seal. Be careful when
removing the drive shaft from the transaxle.
Note
• Do not pry on seal surface.
4. Separate the left side drive shaft from the transaxle by pry
Transaxle
1. Loosen the SST (engine support) and lean the engine to
ward the transaxle.
16E0KX-118
46U0K2-089
K 2-43
K2 TRANSAXLE
CONTROL VALVE BODY
(ON-VEHICLE REMOVAL / INSTALLATION)
On-vehicle Removal
Caution
• Clean the transaxle exterior thoroghly with a steam
cleaner or cleaning solvents before removal.
1. Remove the follow items. (Refer to page K2-39.)

• Battery
• Battery carrier
• Fresh air duct
• Resence chamber
2. Disconnect the TR sensor connector.
46U0K2-322
3. Drain the ATF.

4. Remove the splash sheiald.
5. Remove the oil cooler hose.
6. Remove the control valve body cover.
46U0K2-323
Caution
ELECTRICAL
• Do not pull on the connector wires or use a ham
mer on the connector.
7. Remove the control valve body assembly.
46U0K2-324
On-vehicle Installation
Caution
• Be sure to align the Z-link in the manual valve.
1. Install the main control assembly.
Tightening torque: 9.8 N-m (100 kgf m, 86.8 ft Ibf}
46U0K2-325
K 2-4 4
TRANSAXLE K2
2. Install the control valve body cover and new gasket.
Tightening torque: 11.8 N-m {120 kgf-cm , 104.2 in lb f}
C aution
• If reusing th e hose clam p , p osition it in th e o rig inal
location on th e hose and s q u eeze th e c lam p lig h tly
w ith large pliers to en su re a tig h t fit.
16E0KX-393
£ i i
& parts.
6. Slide the radiator hose onto the radiator pipe until it is fully
seated.
7. Install the hose clamp on the hose.
8. Squeeze it lightly with large pliers to ensure a good fit.
9. Cnnect the TR sensor connector.
46U0K2-327 10. Install the follow items. (Refer to page K2-39.)
• Battery
• Battery carrier
• Fresh air duct
• Resonance chamber
K2—45
K2 TRANSAXLE
MEMO
'
TRANSAXLE K2
T R A N S A X L E U N IT (IN S T A L L A T IO N )
P re p a ra tio n
SST
49 G017 5A0 For 49 G017 503 For

Support, engine
49G017 5A0)
49 G017 501 For 49 G017 502 For

x support of engine support of engine
Support m
Bar
(Part of (part0f 1J Y \
49 G017 5A0) 49 G017 5A0) ^ |J
46U0K2-445
In s ta lla tio n
1. Install in the order shown in the figure, referring to In stallatio n Note.
2. Fill the transaxle with the specified ATF after installation.
16E0KX-498
K 2-47
K2 TRANSAXLE
19—25 (1.9—2.6, 1 4 -1 8 )
7.9—10.7 N m
(80—110 kgf-cm, 7 0 -9 5 in-lbf)
7.9—10.7 N m
(80—110 kgf cm,
70—95 in-lbf)
7 .9 -1 0 .7 N m
(80—110 kgf cm,
70—95 in-lbf)
7.9—10.7 N-m
(80—110 kgf-cm,
70—95 in Ibf)
COTTER PIN, NEW
38—51
(3.8—5.3, 28—38)
/ 86—116
/ (8.7-11.9,
/© 6 3 -8 6 )
67—93
(6.8—9.5,
50—68)
44—60 (4.4—6.2, 32—4 4 1

94—131 (9.5—13.4,69—96)
75 -1 0 4 ( 7 .6-10.7, 5 5 -7 7 )
67—93 (6.B—9.5, 50—68)
N-m (kgf-m, ft lbf)
K 2 -4 8
TRANSAXLE K2
46U0K2-446
1. Transaxle 19. Engine mount member

Installation Note...................... page K2-50 Installation Note...................... page K2-52
2. Engine mount No.2 20. Front exaust pipe
3. Torque converter nut 2 1 . Heated oxygen sensor connector
4. Starter 22. Transverse member
5. Intake manifold bracket 23. Terbine speed sensor connector
6. Engine mount No.1 bracket 24. Splash sheald
7. Engine mount No.1 rubber 25. Oil hose
8. Engine mount No.1 nut Installation Note...................... page K2-53
9. Emission harness protector nuts 26. Wheel and tire
10. Shift control cable 27. Oil filler tube
11. Engine mount No.4 28. Ground and bracket
12. Drive shaft 29. Fuel filter m o u n tin g nut
Installation Note...................... page K2-50 30. Ignition coil bracket
13. Joint shaft 31. Ignition coil
Installation Note...................... page K2-51 32. Transmission range sensor connector
14. Lower arm 33. Solenoid body connector
Installation Note...................... page K2-51 34. Air cleaner
15. Stabilizer control link 35. Flesh air duct
16. Tie rod end 36. Resonance chamber
Installation Note...................... page K2-52 37. Battery carrier
17. Engine mount No.5 38. Battery
18. Vehicle speed sensor connector
K 2-49
K2 TRANSAXLE
In stallatio n N ote
Tran saxle
W arning
• Do not a llo w th e tran saxle to fall fro m th e jack.
1. Set the transaxle on a jack and lift it into place.
16E0KX-501
T ig h te n in g to rq u e
(A): 9 0 — 116 N m (9 .1 — 11.9 kg f cm , 6 6 — 8 6 ft Ib f)
( D : 3 8 — 51 N m {3 .8 — 5 .3 kg f m , 2 8 — 3 8 ft lb f)
© : 19— 25 N m {1 .9 — 2 .6 kgf-m , 14— 18 ft lb f)
3. Install the torque converter nuts.
T ig h te n in g torque:
4 3 .1 — 6 3 .7 N-m {4 .4 — 6 .2 kgf-m , 3 2 — 44 ft lb f)
46U0K2-447
4. Loosely tighten engine mount No.4 nuts.
D rive shaft
C aution
• In sp ect th e oil seal fo r d am ag e.
• Do not d am ag e th e oil seal w ith th e s h aft splin es.
1. Install the clip with the gap upward.
46U0K2-523
2. A p p ly A T F into the oil se a l lip. Install the d rive shaft.
the shaft. It must not slide out.
TRANSAXLE K2
J o in t sh aft
C autio n
• In sp ect th e oil seal fo r d am ag e.
• Do not d am ag e th e oil seal w ith th e sh aft splines.
1. Insert the joint shaft into the transaxle.

2. Install the joint shaft to the cylinder block in the order shown.
T ig h ten in g to rq u e:
4 3 — 61 N m { 4 .3 — 6 .3 kg f m , 3 2 — 45 ft-lb f)
46U0K2-525
L o w e r arm
bolt.
3 7 — 53 N-m { 3 .7 — 5 .5 kgf m, 2 7 — 39 ft-lb f}
46U0K2-448
7 .9 — 1 0 .7 N m {8 0 — 110 kgf cm , 6 9 .5 — 9 5 .4 in-lbf}
3. Install the clip.
36U0KX-320
K2 TRANSAXLE
T ie rod end
3 2 — 4 4 N m (3 .2 — 4 .5 kgf m , 2 4 — 32 ft-lb f}
46U0K2-449
E ng ine m o u n t m em b er
FRONTSIDE
N o te
• Verify that the engine mount rubbers are installed as
0 shown.
• Put the engine mount No.2 stud bolts in the installing holes
when installing the engine mount member.
16E0KX-504
1. Install the bolts and nuts ® as shown.
A: 6 7 — 93 N m (6 .8 — 9 .5 kg f m , 5 0 — 6 8 ft-lb f}
2. Loosely tighten the nuts (§) as shown.
36U0KX-158
3. Tighten engine mount No.4 nuts.
6 7 — 93 N-m (6 .8 — 9 .5 kgf m , 5 0 — 68 ft-lb f}
4. Remove the S S T (engine support).
16E0KX-506
5. Tighten the nuts (§) as shown.
B: 7 5 — 104 N m ( 7 .6 — 1 0 .7 kg f m , 5 5 .0 — 7 7 .3 ft-lb f}
36U0KX-159
K2—52
TRANSAXLE K2
Oil hose
C aution
• If reusing th e h ose clam p , position it in th e original
lo cation on th e hose and s q u eeze th e clam p lightly
w ith larg e pliers to en su re a tig h t fit.
16E0KX-516
nlfc=3 parts.
16E0KX-517
K 2-5 3
K2 OIL COOLER
OIL COOLER
O IL C O O L E R
R em o val / In s p e c tio n / In s ta lla tio n
4. Install in the reverse order of removal, referring to In stallatio n Note.
5. Add ATF to the specified level.
7. Inspect for oil leakage from the oil pipes and oil hoses.
8. Inspect the ATF level and condition. (Refer to page K-21.)
N m {kgf.m, ftlb f)
~ 46U0K2-450
1. Connector bolts 4. Oil pipe

Inspect for damage and clogging Inspect for damage and cracks
2. Washers 5. Radiator
3. Oil hose Service......................................Section E1
Inspect for damage and cracks
Installation Note...................... page K2-55
K 2-5 4
OIL COOLER K2
In stallatio n note
Oil hose
C autio n
• If reusing th e hose clam p , position it in th e original
lo cation on th e hose, and s q u eeze th e clam p lig h t
ly w ith large pliers to en su re a tig h t fit.
mark and at the angle shown.
parts.
16E0KX-523
K 2-55
K2 DRIVE PLATE
DRIVE PLATE
SST
49 E011 1AO For 49 E011 103 For

holding holding
drive plate Shaft drive plate
(Part of ©
49 E011 1A0)
49 E011 104 For 49 E011 105 For

holding (6 ) holding
c ° iiar / drive plate Stopper \ drive plate
(Part of I / jr jJ (Part of \
49 E011 1AO) 49 E011 1A0) \L
16E0KX-524
D R IV E P L A T E
R em o va l / In s p ec tio n / In s ta lla tio n
46U0K2-451
1. Drive plate mounting bolts 3. Drive plate

Removal Note......................... page K2-57 Inspect for cracks and for ring gear wear
Installation Note...................... page K2-57 and damage
2. Backing plate 4. Adapter
K 2-5 6
DRIVE PLATE K2
R em oval note
D rive plate m ounting bolts
1. Set the S S T or equivalent against
the drive plate.
2. Remove the bolts and the drive plate.
36U0KX-165
In stallatio n note
D rive plate m ounting bolts
1. Remove any old locking compound from the bolt threads
and bolt holes, and apply new locking compound to the
bolt threads.
2. Set the S S T or equivalent against the drive plate.
3. Tighten the drive plate mounting bolts in two or three steps
in the order shown.
9 7 — 102 N m { 9 .8 — 1 0 .5 kgf m , 7 0 .9 — 7 5 .9 ft-lb f)
46U0K2-452
K 2-5 7
K2 SHIFT MECHANISM
SHIFT MECHANISM
S E L E C T O R LE V ER
R em o va l / In s p ec tio n / In stalla tio n
46U0K2-453
1. Steering column cover 6. Selector lever

2. Front console Installation Note...................... page K2-59
3. Side wall 7. Insulator
4. Indicator panel 8. Clip
Service.................. Section K1 9. Selector cable
5. Clip 10. Interlock cable
K 2-5 8
SHIFT MECHANISM K2
LOCKCOVER S e le c to r lever
1. Install the selector lever.
16— 22 N m ( 1 .6 — 2 .3 kg f m , 12— 16 ft-lb f}
2. Install the selector cable to the selector lever.

3. Push the selector lever adjust D range.
SETBUTTON 4. Connect the set button.
36U0KX-188
6. Install the interlock cable to the selector lever.
9 .8 — 1 4 .7 N m {1 0 0 — 150 kg f cm , 8 7 — 13 0 in lb f }
36U0KX-189
.
OW3W
IAISINVH03IAI IdlHS g>|

TROUBLESHOOTING GUIDE K2
GENERAL NOTES
A problem with the EC-AT may be caused by the engine, the EC-AT powertrain, the hydraulic control
system, or the electronic control system; therefore, when troubleshooting begin with those points which
can be inspected quickly and easily. The recommended troubleshooting sequence is described below.
C au tio n
• Be a w a re th a t th is s ec tio n d e als w ith th e p o w ertrain co n tro l m o d u le. It is in te rc o n n e c te d fo r
th e FS e n g in e .
46U0K2-454
S te p 1: O n-B oad D iag n o stic S ystem In sp ectio n

Check for diagnostic trouble code(s) memorized in the
powertrain control module (PCM) with the s u p e r s ta rn
tester.
(Service Section F3.)
N ote
• Diagnostic trouble code(s) can also be checked for by
the flashing sequence of the hold indicator light.
S tep 2: E lectrical Signal In sp ectio n

Check the signals to/from the powertrain control module
(PCM) with the voltmeter and th e b reako u t box.
(Service Section F3.)
S tep 3: M echanical S ystem T est

Check the engine stall speed, line pressure.
S tep 4: Road T est

Check the shift point, shift schedule, and shift shock.
46U0K2-458
K2-61
O U T L IN E
The Quick diagnosis Chart shows various problems and the various components that might be the cause
of the problem.
1. Components indicated in the “ Self-diagnosis” line of the QUICK DIAGNOSIS CHART (I) are diagnosed
by the powertrain control module (PCM) self-diagnosis function. SUPER STAR II can be used for easy
retrieval of the diagnostic trouble code numbers.
2. Components indicated in the “ Adjustment” line of the QUICK DIAGNOSIS CHART (I) indicate that there
is a possibility that the problem may be the result of an incorrect adjustment.
Check the adjustment of each component, and readjust if necessary.
3. Input and output signals of the powertrain control module (PCM) for the components indicated in the SU
PER STAR II line of the QUICK DIAGNOSIS CHART (I) can be easily checked by using the SUPER STAR n.
4. Components indicated in the “ Line Pressure Test” line of the QUICK DIAGNOSIS CHART (I) can be checked
for malfunction by observing the results of the line pressure test.
5. Components indicated in the “ Stall Test” line of the QUICK DIAGNOSIS CHART (I) can be checked for
malfunction by observing the results of the stall test.
6. Components indicated in the “ Road Test” line of the QUICK DIAGNOSIS CHART (I) can be checked
for malfunction by observing the results of the road test.
7. QUICK DIAGNOSIS CHART (II) shows the relationship between the troubleshooting item and inspection
point.
46U0K2-459
Q U IC K D IA G N O S IS C H A R T ( I)
Emission
N-x part s and reference page Preliminary control system
EC-AT
control system
Hydraulic
control system
Electronic pressure control solenoid

I Engine coolant temperature sensor
Transaxle fluid temperature sensor
3-2 timing/coasting clutch solenoid
Thermostatic oil level control valve

Torque converter clutch solenoid
Turbine shaft speed sensor
Vehicle speedmeter sensor
Electronic ignition system
ATF level and condition
I Throttle position sensor

I Power control module
| Mass air flow sensor
Control valve body

Line pressure test
Torque converter
Oil filter and seal
Magnetic clutch
Shift solenoid 1
Stoplight switch
Shift solenoid 2
I Selector lever
Hold switch
Chain pan
I Road test
Oil cooler
Oil pump
I Stall test
Item
On Boad Diagnosis OO ooOOOOooOOOoOOO
Adjustment oO O
Super Star n OO ooOOOoOO0
Testers Transaxle tester 0 O 0 Oo0 o0
Braeak out box oo OOOO o o OOOo Oo O
Stall test oO O
Line pressure test O 00
Road test 0 o o O0 O0 o o OOOo Oo O
K 2-62
oOO Forward clutch
o Coasting clutch
oo Direct clutch
oo Reverse clutch
ooo 2/4 band and servo
ooo Low/reverse clutch
Chain and sprocket
Powertrain
Forward/coasting/direct clutch cylinder
REV/4GR carrier
REV/4GR sun gear and shell
o o Forward one-way clutch
o Low one-way clutch
o Converter one-way clutch
Low-intermediate carrier
Planetaly gearsets (Differential)
o Parking mechanism
Turbine shaft
Final drive and differential

Transaxle case m
CD
Converter housing OS
Joint shaft
Other
Engine mount
Drive plate
o O Tire size
Stall test
Transaxle tester
Road test
Line pressure test
Super Star II
Adjustment
Break out box
On Boad Diagnosis
Possible parts and reference page o

g
>
o
z
O
CO
{/)
Testers
o
X
7s
to c >
o 33
I <5
Item
O) *
CO
IN5
Q U IC K D IA G N O S IS C H A R T ( I I )
Emission
\ Possible parts and reference page Preliminary control system Electronic system Hydraulic
control system
3-2 timing/coasting clutch solenoid I
Thermostatic oil level control valve I

'
Transaxle fluid temperature sensor
Electronic pressure control solenoid

Torque converter clutch solenoid

Vehicle speedometer sensor
Turbine shaft speed sensor
Electronic ignition system
I ATF level and condition
[Throttle position sensor

Power control module
Mass air flow sensor
Control valve body

I Line pressure test
Oil filter and seal

Torque converter
Magnetic clutch
Shift solenoid 1
Stoplight switch
Shift solenoid 2
I Selector lever
Hold switch
Chain pan
Road test
Oil cooler
Oil pump
Stall test
Item
1 No forward engagement only O 0 0
2 No reverse engagement only 0 0 o 0 0 0 o
3 Harsh engagement o o O o 0 O o O
4 Delayed/soft engagement o o o o o O
5 No forward and no reverse engagements o o o o o O0
6 Some or all shift missing o o o o o O OO
7 Timing-early/late o o O O
8 Erratic o 0 0 0 0 0 O0 O0 o o
9 Feel-soft/slipping oo o o oo o O o o O
10 Feel harsh o o o o o o o o O O0 o o 0
No 1st gear engages in higher
11 o o o OOo 0
gear ("D " range)
No 1st gear in “L” range
12
(1st gear in "D ” range O.K.)
o o o oo o
13 No 1-2 shift o o o o oo o
14 No 2-3 shift 0 o o oo o o o
15 No 3-4 shift o o o o o0 o
16 Soft/slipping 1-2 shift o o o o
17 Shift concern Soft/slipping 2-3 shift 0 o o oo
18 Soft/slipping 3-4 shift o o o o
Soft/slipping 4-3 shift
19
(Automatic)
0 oo o o 0
20
(Automatic)
o oo o o ooo
21
(Automatic or kickdown)
o oo o o o
22 Harsh 1-2 shift o oo o0 oo 0O o o
23 Harsh 2-3 shift o o oo oo oo oo
24 Harsh 3-4 shift o oo 0o o 0 ooooo
25 Harsh 4-3 shift (Automatic) o oo oo oo ooooo
26 Harsh 3-2 shift (Automatic) o oo oo oo ooooo
27 Torque No apply o o O o o o o
converter Always applied/may stall
28 clutch
engine
o o ooo o
29 Poor vehicle acceleration/performance o o o o o o
30 Engine will not crank o o o
31 No “ P" range o
32 Transaxle overheating o o o o o o 0 O o OO
33 No engine braking in 1st gear ("L ” range) o 0o o
34 No engine braking in “ D” range (Hold sw ON) o o ooo
Vehicle movement with gear selector in the “ N" o
35
range
o
36 Shift efforts high o o
37 External leaks o
38 Noise/vibration—forward/reverse oo o o oO
K 2-6 4
QUICK DIAGNOSIS CHART K2
Powertrain Exteria Other Possible parts and reference page
Forward/coasting/direct clutch cylinder |
Low-intermediate carrier assembly

Planetaly gearsets Differential
REV/4GR sun gear and shell
REV/4GR carrier assembly
I Final drive and differential

Converter one-way clutch
Forward one-way clutch
Low one-way clutch
2/4 band and servo
Chain and sprocket
I Parking mechanism
Low/reverse clutch
I Converter housing
Coasting clutch
1Transaxle case
Forward clutch
Reverse clutch
I Engine mount
Turbine shaft
Direct clutch
Drive plate
Joint shaft
I Tire size
Item
OO Oo O No forward engagement only 1
O o 0O o No reverse engagement 2
O oo o oo Harsh engagement 3
o 0 0 0 Delayed/soft engagement 4
O O Oo o o No forward and no reverse engagements 5
Some or all shift missing 6
O Timing-early/late 7
Erratic 8
Feel-soft/slipping 9
oo Feel harsh 10
No 1st gear engages in higher gear
o O ("D ” range)
11
No 1st gear in “ L” range
12
(1st gear in “ D” range O.K.)
o O o o No 1-2 shift 13
o o o No 2-3 shift 14
o o O o No 3-4 shift 15
o oo oo o Soft/slipping 1-2 shift 16
o o o o Shift concern Soft/slipping 2-3 shift 17
o 0 Soft/slipping 3-4 shift 18
ooo o (Automatic)
19
o o o (Automatic)
20
o o o (Automatic or kickdown)
21
o o 0 Harsh 1-2 shift 22

o o 0 Harsh 2-3 shift 23
oo o 0 Harsh 3-4 shift 24
o o o Harsh 4-3 shift (Automatic) 25
o o o Harsh 3-2 shift (Automatic) 26
Torque No apply 27
converter Always applied/may
0 clutch stall engine
28
o Poor vehicle acceleration/performance 29

Engine will not crank 30
O No “ P” range 31
oO Transaxle overheating 32
o o No engine braking in 1st gear (“ L” range) 33
o o No engine braking in “ D” range (Hold sw ON) 34
Vehicle movement with gear selector
oo in the “ N” range
35
O Shift efforts high 36

External leaks 37
O o O o ooO Noise/vibration—forward/reverse 38
K 2-65
U S IN G T H IS S E C T IO N
In tro d u c tio n
• Most of the automatic transaxle control system is electronicaly controlled, often making it difficult to diag
nose problems in the system, especially intermittent problems. Before undertaking actual checks, take
a few minutes to talk with a customer who approaches with a driveability complaint. The customer is often
a good source of information on such problems, especially intermittent ones. Through talks with the cus
tomer, one can find out what the symptoms are and under what conditions they occur.
• If the problem is related to any part of the automatic transaxle unit, repair or replace the automatic transax
le unit as necessary.
W o rk F lo w
CHECK IN
REFER TO TROUBLESHOOTING PAGE THAT

CORRESPONDS TO ACTUAL SYMPTOM
-CHECK FOR WHAT IS BAD IN SYSTEM Inspection
CHECK FOR WHAT PART IS BAD Action
REPAIR / REPLACE
■DETERMINE IF TROUBLE HAS BEEN ELIMINATED

No Yes 46U0K2-530
CHECK OUT
K 2-66
T ro u b le s h o o tin g c h a rt
1 NO FORWARD ENGAGEMENT ONLY

© Internal or external shift linkages © Low one way clutch assembly
(2 ) Oil pump © Forward one way clutch assembly
@ Control valve body © Low intermediate carrier assembly
© Forward clutch and coasting clutch assembly
1 Internal or External Shift Linkages Yes Service as required
— Do any of the following problems exist?
• Damaged
No Go to next step
• Misadjusted
• Misassembled
c r page K 2-58
2 Control Valve Body Yes Service as required

• Bolts not torqued to specification
No Go to next step
• Gaskets damaged or leaking
• Pressure Tap Plate/Gasket leaking or
damaged
• Separator Plates damaged
• Hydraulic Passages damaged
• Main Regulator Valve stuck, damaged or mis
assembled
• Forward Accumulator leaking
46U0K2-526
T R O U B L E S H O O T IN G H IN T S :
S TE P :
IN S P E C T IO N :
to perform the INSPECTION, refer to the page shown by the “ c r” mark.
A C T IO N
the action is described on the reference page shown by the "cr" mark.
46U0K2-463
K 2-67
DIAGNOSTIC INDEX
PAGE
No. TROUBLE
1 No forward engagement only K 2 - 69
2 No reverse engagement only (No movement) K 2 - 71
3 Harsh engagement K2— 74
4 Delayed/soft engagement K 2 - 77
5 No forward and no reverse engagements (No vehicle movement) K 2 - 80
6 Some or all shift missing K 2 - 84
7 Timing-early/late K 2 - 85
8 Erratic K 2 - 86
9 Feel-soft/slipping K 2 - 88
10 Feel harsh K 2 - 90
11 No 1st gear engages in higher gear (“ D” range) K 2 - 92
12 No 1st gear in "L ” range (1st gear in "D " range O.K.) K 2 - 93
13 No 1-2 shift K 2 - 94
14 No 2-3 shift K 2 - 96
15 No 3-4 shift K 2 - 98
16 Soft/slipping 1-2 shift K2-100
Shift concern
19 Soft/slipping 4-3 shift (Automatic) K2-106
20 Soft/slipping 3-2 shift (Automatic) K2-108
21 Soft/slipping 2-1 shift (Automatic or kickdown) K2-110
22 Harsh 1-2 shift K2-111
25 Harsh 4-3 shift (Automatic) K2-117
26 Harsh 3-2 shift (Automatic) K2-119
27 Torque converter No apply K2-121
28 clutch Always applied/may stall engine K2-122
29 Poor vehicle acceleration/performance K2-124
30 Engine will not crank K2-125
31 No "P ” range K2-126
32 Transaxle overheating K2-127
33 No engine braking in 1st gear (“ L” range) K2-129
34 No engine braking in "D " range (Hold sw ON) K2-130
35 Vehicle movement with gear selector in the “ N" range K2-131
36 Shift efforts high K2-132
37 External leaks K2-133
38 Noise/vibration—forward/reverse K2-134
46U0K2-464
S Y M P T O M T R O U B L E S H O O T IN G C H A R T
1 NO FORWARD ENGAGEMENT ONLY

© Internal or external shift linkages © Low one way clutch assembly
© Oil pump © Forward one way clutch assembly
© Control valve body © Low intermediate carrier assembly
© Forward clutch and coasting clutch assembly
• Damaged No Go to next step
• Misadjusted
• Misassembled
c r page K 2-58

No Go to next step
• Gaskets damaged or leaking
• Pressure Tap Plate/Gasket leaking or
damaged
• Main Regulator Valve stuck, damaged or mis
assembled
• Forward Accumulator leaking
3 Oil Pump Yes Service as required

• Bolts not torqued to spec No Go to next step
• Gaskets damaged
• Porosity/cross leaks and/or ball plug missing
or leaking or a plugged hole
• Pump support seal rings, # 3 and # 4
damaged
K 2-69

4 Forward Clutch and Coasting Clutch Assembly Yes Service as required
• Seals or Pistons damaged No Go to next step
• Return Spring damaged
• Ball Check Valve damaged
• Friction Elements severely damaged or worn
• F/C/D Clutch Cylinder damaged, leaking,
misassembled or binding
• Welding between Cylinder and Hub broken
or Splines damaged
5 Low One Way Clutch Assembly Yes Service as required

• Worn No Go to next step
• Damaged
• Misassembled
6 Forward One Way Clutch Assembly Yes Service as required

• Worn No Go to next step
• Damaged
• Misassembled
7 Low Intermediate Carrier Yes Service as required

• Damaged No The problem is fixed
• Misassembled
46U0K2-465
K 2-7 0
2 NO REVERSE ENGAGEMENT (NO MOVEMENT)
© Powertrain control system © Reverse clutch assembly
© Improper pressures © Low/reverse clutch assembly
© Internal or external shift linkages © Forward/coasting/direct clutch cylinder assembly
® Control valve body © Case
© Oil pump ® Reverse/fourth gear carrier assembly
1 Powertrain Control System Yes Run OBD Tests
— Are there any problems with the following? Perform Pinpoint Tests “ A and D”
• Electrical Input/Outputs cr page K2-135
• Vehicle Wiring Harnesses No Go to next step
• PCM
• SS1 (ON)
• TR Sensor
c r page K 2-23
2 Improper Pressures Yes Check the following possible components

— Is there low line pressure? Control Valve Body, Oil Pump, Reverse
cr page K 2-10 Clutch Assembly, Low/Reverse Clutch
Assembly
No Go to next step

• Damaged No Go to Step 9
• Misadjusted
c r page K 2-58

No Go to next step
• Gasket damaged
• 1-2 Shift Valve, SS1, Main Regulator Valve,
Low/Reverse Modulator Valve, Low/Reverse
Accumulator Piston, Pressure Tap Plate
damaged, missing, stuck, misassembled

• Bolts not torqued to specification Go to next step
No
• Gasket damaged
• Porosity/cross leaks/ball plug missing or leak
ing, plugged hole
• Pump Support Seal Rings, # 6 and #7,
damaged
6 Reverse Clutch Assembly Yes Service as required

• Seals-Piston damaged No Go to next step
• Ball Check Valve damaged
• Friction Elements worn, severely damaged or
misassebled
• Piston Return Spring damaged
• Reverse Clutch Hub to F/C/D cluch Hub
Splines damaged
K 2-72
7 Low/Reverse Clutch Assembly Yes Service as required
• Seals or Piston damaged No Go to Step 3
• Friction Elements worn or severely damaged
• Piston Return Spring damaged
• Wave Spring missing
• Piston Bore damaged
8 Forward/Coasting/Direct Clutch Cylinder Yes Service as required

— Are any of the reverse seal rings damaged,
missing, or misassembled? No Go to next step
9 Reverse/fourth Carrier Assembly Yes Service as required

— Is there any damaged?
No Go to next step
10 Case
— Is there any serer cross leakage from the re Yes Service as required
verse clutch to low/reverse clutch feeds?
No The problem is fixed
46U0K2-466
K2—73
3 HARSH ENGAGEMENT
© ATF © Joint shafts
© Powertrain control system ® Engine mounts
© Improper pressure © Forward clutch assembly (Forward only)
© Control valve body ® Reverse clutch assembly (Reverse only)
© Oil filter and seal (fi) Low/reverse clutch assembly (Reverse only)
© Internal and external linkages © Direct clutch assembly (Reverse only)
1 ATF Yes Service as required
— Are there any problems with the following?
• Level
No Go to next step
• Condition
c r page K2-21
2 Powertrain Control System Yes R un O B D Tests

— Are there any problems with the following? Perform Pinpoint Tests “ B and E”
• Electrical Input/Outputs c r page K2-135
• PCM
• EPC Solenoid
• TFT Sensor
c r page K 2-23
3 Improper Pressure Yes Verify engagements at minimum EPC

— Is line pressure higher them normal? using the Transaxle Tester
c r page K 2-10 If line remains high, check the following
components: Control valve body, oil Filter
and Seal assembly
No Go to next step

• Bolts not torqued to specification No Go to next step
• Gaskets damaged
• Low/Reverse Accumulator Piston and Spring
(Reverse), Main Regulator Valve, Forward
• Accumulator Piston and Spring
misassembled, stuck or damaged
• EPC Solenoid stuck or damaged
K 2-7 4
5 Oil Filter and Seal Assembly Yes Replace as reguired
• Filter/Seal damaged, plugged No Go to next step
• Recirculation Seal damaged plugged or out
of position

• Misadjusted
c r page K 2-58
7 Joint Shafts Yes Service as required

— Is there splines damage?
c r page K 2-39 No Go to next step
8 Engine Mounts Yes Service as required

• Loose, broken, missing or misaligned No Go to next step
• Powertrain contacting with other vehicle com
ponents
c r page K2-39
9 F/C/D Clutch Assembly (Forward Only) Yes Service as required

• F/C/D Clutch Cylinder damaged No Go to next step
• Friction Elements damaged worn
• Forward Clutch Return Spring damaged or
missing
• Ball Check damaged
• Piston or Seals damaged
K 2-75

10 Reverse Clutch Assembly (Reverse Only) Yes Service as required
• Seals or Piston damaged
No Go to next step
• Reverse Piston damaged
• Friction Elements damaged, worn, misas
sembled
• Return Spring Assy, damaged, worn
• Ball Check damaged, missing

(Reverse Only)
No Go to next step
• Seals or Piston damaged
• Wave Spring damaged
• Friction Elements damaged, worn,
misassembled
• Return Spring Assembly damaged, worn or
misassembled
12 Direct Clutch Assembly (Reverse Only) Yes Service as required

— Are any of the friction elements severely
damaged? No The problem is fixed
46U0K2-467
4 DELAYED/SOFT ENGAGEMENT
(T) ATF © Oil pump
© Improper pressure © Forward clutch assembly
© Internal or external shift linkages ® Reverse clutch assembly
© Control valve body © Low/reverse clutch assembly
© Oil filter and seal assembly ® Forward/coasting/direct clutch cylinder assembly
• Level No Go to next step
• Condition
c r page K2-21
2 Improper Pressure Yes Check the following possible components;

— Is line pressure lower than nomal? Control valve body, oil pump, oil filter and
c r page K 2-10 seal assembly, recirculating seal, clutch
assemblies
No Go to next step

• Damaged No The problem is fixed
• Misadjusted
• Misassembled
c r page K 2-58
K 2-7 7

No Go to next step
• Gaskets damaged
• Manual Valve, Main Regulator Valve, Low/Re
verse Modulator Regulator Valve stuck,
damaged or misassembled
• Pressure Tap Plate/Gasket leaks, damaged,
misassembled
5 Oil Filter and Seal Assembly Yes Service as required

• Filter/Seal damaged, plugged No Go to next step
• Recirculating Seal damaged or out of position

• Gaskets damaged
• Porosity/cross leaks/ball plug missing or leak
ing, or passage blockage
• Pump Support Seal Rings, # 3 and # 4 (For
ward), or # 6 and # 7 (Reverse), damaged
• Pump Gear/Pocket damaged
• Separator Plate damaged
7 Forward Clutch Assembly (Forward Only) Yes Service as required

• Seals or Piston damaged No Go to next step
• Ball Check damaged, missing or not seating
properly
• Friction Elements damaged, worn or
excessive end clearance
K 2-7 8
8 Reverse Clutch Assembly (Reverse Only) Yes Service as required
• Check Ball damaged
• Friction Elements damaged, worn
• Return Spring worn, damaged
• Excessive Clutch Pack End Clearance

(Reverse Only)
— Do any of the following problems exist? No Go to next step
• Piston or Seals damaged
• Friction Elements damaged, worn
• Excessive Clutch Pack End Clearance
10 Forward/Coasting/Direct Clutch Cylinder Yes Service as required

Assembly
— Do any of the following problems exist? No Go to Step 3
• Reverse Seal Ring damaged or missing
• Cylinder damaged or leaking
46U0K2-468
5 NO FORWARD AND NO REVERSE ENGAGEMENTS (NO VEHICLE MOVEMENT)

© ATF ® Turbine shaft to forward/coasting/direct clutch cylinder
© Improper pressure © Torque converter
® Internal or external linkages © Chain and sprocket assembly
© Control valve body © Park mechanism
© Oil filter and seal assembly © Joint shafts
© Oil pump © Final drive and differential assembly
© Drive plate © Planetaly gearsets (Differential)
• Condition
c r page K2-21
2 Improper Pressures Yes If pressure is low, check the following

— Do any of the following problems exist? possible components:
• Low Line Pressure Control Valve Body, Oil Filter and Seal
• No Line Pressure Assembly, Oil Pump
c r page K 2-10 Go to Step 4
If OK, proceed to Turbine Shaft
Check Torque Converter Pump Shaft and
Assembly
Go to Step 7
No Go to next step
• Damaged No Go to Step 10
• Misadjusted
• Misassembled
c r page K 2-58

• Gaskets damaged
• Pressure Plate/Gasket damaged or missing
• Main Regulator Valve, Manual Valve stuck,
damaged, plugged, missing, "Z " Link not
connected

• Filter/Seal damaged, plugged, or missing No Go to next step

• Bolts not torqued to spec
No Go to Step 3
• Gasket damaged, missing
• Porosity/cross leaks or passage(s) blocked
• Pump Support Seal Rings missing
• Oil Pump Shaft broken, damaged
7 Drive plate Yes Service as required

• Damaged
No Go to next step
• Broken
c r page K 2-56
8 Turbine Shaft to Forward/Coasting/Direct Yes Service as required

Clutch Cylinder Housing
— Is there Splines damaged? No Go to next step
9 Torque Converter Assembly Yes Service as required

• Oil Pump Shaft Insert damaged No Go to Step 3
• Studs broken or damaged
• Splines damaged
• Internal Blades damaged, broken
10 Chain and Sprocket Assembly Yes Service as required

• Broken No Go to next step
• Damaged
K 2-82
11 Park Mechanism Yes Service as required
— Are any of the Parking Pawl Return Spring
damaged, missing or misassembled? No Go to next step
12 Joint shaft Yes Service as required

• Broken No Go to next step
• Splines damaged
c r page K 2-39
13 Final Drive and Differential Assembly Yes Service as required

• Splines damaged No Go to next step
• Gearset damaged
14 Planetaly Gearsets (Differential) Yes Service as required

• Gear Teeth No The problem is fixed
• Carriers
• Splines
46U0K2-469
K 2-83
6 SOME OR ALL SHIFTS MISSING

© ATF (3 ) Internal and external shift linkages
© Powertrain control system @ Speed input
1 ATF Yes Adjust fluid to proper level
— Is there improper level?
c r page K2-21
No Go to next step

• Electrical Inputs/Outputs c r page K2-135
• PCM
• Shift Solenoids
• TR Sensor
• TP Sensor
• VSS
• Hold switch
c r page K 2-23
3 Internal and External Shift Linkages Yes Service as required

• Misadjusted
• Misassembled
c r page K 2-58
4 Speed Input Yes Service as required

— Is speedometer drive gear damage?
No For further diagnosis, refer to the appropriate
shift routine(s):
Shifts No Shift
1-2 13
2-3 14
3-4 15
46U0K2-470
7 SHIFT CONCERN: TIMING-EARLY/LATE
© Powertrain control system
( 2) Tire size
© Speed input
— Are there any problems with the following? Perform Pinpoint Test "B "
• Electrical Input/Outputs c r page K2-135
• PCM
• TP Sensor
• VSS
• TFT Sensor
c r page K 2-23
2 Possible Components Yes Service as required

• Tire Size change No The problem is not in the automatic transaxle
c r Section U
Go to Section F3
• Speedometer drive gear damaged
46U0K2-471
8 SHIFT CONCERN: ERRATIC

© ATF 0 Control valve body
© Powertrain control system © Torque converter clutch
© Vehicle speed input
— Are there any problems with the followings?
• Condition
c r page K2-21
2 Powertrain Control System Yes Run OBD tests

— Are there any problems with the following? Perform Pinpoint Test “ A, C, D, F and G”
• Vehicle wiring harness 1 No Go to next step
• PCM
• SS1, SS2
• TR sensor
• TCC solenoid
• VSS
• TP sensor
• TSS
• EPC solenoid
• 3-2T/CCS
c r page K 2-23
3 Vehicle Speed Input Yes Service as required

— Is speedometer drive gear damaged?
No Go to next step
Control Valve Body Yes Service as required
• Bolt not torque to spec
No Refer to the appropriate shift for further diagnosis
• Gaskets damaged
• 3-2 timing valve, Pull in valve, 2-4 accumula Shifts No Shift Soft/Slip Harsh
tor valve, Servo release shuttle valve, 3-2 con
trol valve stuck, damaged, misassembled 1-2 13 16 22
• Solenoid screen brocked 2-3 14 17 23
• Separator plates damaged, blocked 3-4 15 18 24
• Pressure tap plate/gasket damaged 4-3 — 19 25
• SS1, SS2, 3-2T/CCS solenoid malfunction, 3-2 — 20 26
stuck, damaged 2-1 — 21 —
46U0K2-472
9 SHIFT CONCERN: FEEL-SOFT/SLIPPING

©ATF © Control valve body
© Powertrain control system © Oil pump
© Internal or external shift linkages © Oil filter and seal assembly
@ Improper pressure
ATF Yes Service as required
• Condition
c r page K2-21
Powertrain Control System Yes Run OBD Tests, Perform Pinpoint Tests “ B and E”
— Are there any problems with the following? c r page K 2-1 35
• Electrical Inputs/Outputs
No Go to next step
• Vehicle wiring harness
• PCM
• EPC solenoid
• TFT sensor
• TP sensor
• MAF sensor
c r page K 2-23
Internal External Shift Linkage Yes Service as required

• Misadjusted
• Misassembled
c r page K 2-58
Improper Pressure Yes Check the line pressure

— Is there low line pressure? If pressures are low or all shifts are soft/slipping, go to
c r page K 2-10 step 6
If pressures are OK and a specific shift is soft/slipping, re
fer to the following chart: '
Shift Soft/Slip
1-2 16
2-3 17
3-4 18
4-3 19
3-2 20
2-1 21
No Go to next step
No Go to next step
• Gaskets damaged
• Main Regulator Valve, Line Modulator Valve
stuck, damage or misassembled or springs
missing, tangled or damaged
• EPC Solenoid stuck or damaged
• Separator Plates damaged, blocked
• Pressure Tap Plate/Gasket damaged or
missing

• Bolts not torqued to spec
No Go to next step
• Gaskets damaged
• Porosity/cross leaks

• Filter/Seal damaged, plugged or missing
No The problem is not in the automatic transaxle
Go to Section F3
46U0K2-473
10 SHIFT CONCERN: FEEL—HARSH

© ATF (D Improper pressure
© Powertrain control system © Control valve body
© Joint shafts © Torque converter assembly
© Engine mounts
• Condition
c r page K2-21

— Are there any problems with the following? Perform Pinpoint Tests “ B, C, D, E, F and G”
• Electric Inputs/Outputs c r page K2-135
• Vehicle wiring harnesses No Go to next step
• PCM
• EPC solenoid
• TFT sensor
• TSS
• TP sensor
• VSS
• MAF sensor
• TCC solenoid
• TR sensor
• 3-2T/CCS
c r page K 2-23
3 Joint Shafts Yes Service as required

• Loose
• Splines damaged
c r page K 2-39
4 Engine Mounts Yes Service as required

• Loose
• Missing
c r page K 2-39
K 2-9 0
STEP IN S P E C TIO N A C TIO N
Improper Pressure Yes Check the line pressure
— Is there high line pressure? Service as required
c r page K 2-10 If pressures are OK and a specific shift is harsh, refer to
the following chart:
Shift Harsh
1-2 22
2-3 23
3-4 24
4-3 25
3-2 26
2-1 —
No Go to next step
Control Valve Bodys Yes Service as required

• Gaskets damaged
• Main Regulator Valve, By-Pass Valve, Line
Modulator Valve stuck damaged or misas
sembled
Springs tangled, missing, damaged
• EPC solenoid stuck or damaged
• Separator plate damaged, blocked
Torque Converter Assembly Yes Service as required

If heat stained, replace converter
Note No The problem is not in the automatic transaxle
• TCC applied during shifts Go to Section F3
• Piston damaged
• Pump Support Seal #1 (CBY) leaking, miss
ing or damaged
• Case leakage
• Converter Assembly damaged
46U0K2-474
11 SHIFT CONCERNS: NO 1ST GEAR ENGAGES IN HIGHER GEAR (“ D” RANGE)

© Powertrain control system © Seals
© Internal or external shift linkage © Direct clutch
© Control valve body © 2/4 band and servo
• Vehicle wiring harneses No Go to next step
• PCM
• SS1, SS2
• TR sensor
• Hold switch
c r page K 2-23

— Do any of the following problems exist? After servicing linkage, verify that the TR sensor is
• Damaged properly adjusted
• Misadjusted c r page K 2-34
• Misassembled No Go to next step
c r page K 2-58

• Gaskets damaged
• Pull In Valve, Solenoid Regulator Valve, Shift
Valves stuck, damaged, misassembled
• Solenoid Filter Gasket damaged or misas
sembled
• SS1, SS2 Solenoid malfunction
4 Mechanical Yes Service as required

• Seals, Clutches damaged, worn No Refer to the appropriate shift for further diagnosis
• Direct Clutch, 2/4 Band, 2/4 Servo damaged,
stuck on Shifts No Shift
1-2 13
2-3 14
3-4 15
46U0K2-475
12 SHIFT CONCERNS: NO 1ST GEAR IN “ L” RANGE (1ST GEAR IN “ D" RANGE O.K.)
© Powertrain control system
d ) Internal or external shift linkages
® Control valve body
• PCM
• SS1, SS2
• TR sensor
c r page K 2-23
2 Internal or External Shift Linkage Yes Service as required

— Do any of the following problems exist? After servicing linkage, verify that the TR sensor is
• Damaged properly adjusted
• Misadjusted c r page K 2-34
• Misassembled No Go to next step
c r page K 2-58

• Bolts not torqued to specification No The problem is not in the automatic transaxle
• Gaskets damaged
Go to Section F3
• Pullin Valve stuck, damaged
• SS2 stuck “ ON"
46U0K2-476
K 2-93
13 SHIFT CONCERNS: NO 1-2 SHIFT

© Powertrain control system (D Low OWC assembly
(D Improper pressure (§) Reverse/fourth gear sun gear and shell
(D Control valve body © Case
© 2/4 band and servo
— Do any of the following problems exist? Perform Pinpoint Tests “ A and D”
• PCM
• SS1, SS2
• TR sensor
• Hold switch
c r page K 2-23
2 Improper Pressure Yes Go to next step

• High line pressure No Go to Step 4
• Low line pressure
c r page K 2-10

• Gaskets damaged
• 1-2 Shift Valve, 2-4 Accumulator, Main Regu
lator Valve stuck damaged or misassembled
• SS1 malfunction
• Pressure Tap Plate/Gasket damaged
4 2/4 Band and Servo Assembly Yes Service as required
Note No Go to next step

• Also no fourth gear

• Seals damaged, missing
• Piston damaged
• Band damaged, worn
• Springs damaged
• Servo Rod or Rod Bore damaged
5 Low OWC Assembly Yes Service as required

— Is there damaged?
No Go to next step
6 Reverse/fourth gear Sun Gear and Shell Yes Service as required

• Damaged, weld broken
No Go to next step
• Lugs damaged
7 Case Yes Service or replace case as required

— Do any of the following problem exist?
• Band anchor area damaged
No The problem is not in the automatic transaxle
• Porosity/leakage in servo apply, servo release
Go to Section F3
circuits
46U0K2-477
K 2-95

© Powertrain control system (D Direct clutch assembly
© Improper pressure © 2/4 servo
(D Control valve body © Case
@ Oil pump
— Do any of the following problems exist? Perform Pinpoint Tests "A and D”
• PCM
• SS1, SS2
• TR sensor
• Hold switch
c r page K 2-23

c r page K 2-10

• Bolts not torque to specification No Go to next step
• Gasket leaks
• 2-3 Shift Valve (also No 4th), Main Regulator
Valve stuck, damaged, misassembled
• SS2 malfunction (also No 4th)
• Pressure Tap Plate/Gasket leaks
• Bolts not torqued to spec No Go to next step
• Gaskets damaged
• Porosity/cross leaks
• Pump Support Seal Rings, # 4 and # 5,
damaged
5 Direct Clutch Assembly Yes Service as required

• Friction severely damaged, worn
• Ball Check not seating properly
• Return Spring Assy, damaged
• Cylinder Bore/Splines damaged
• Shell/Hub damaged
6 2/4 Servo Yes Service as required

• Piston or Piston Bore damaged No Go to next step
• Rod Bore or Rod damaged leaking
7 Case Yes Service or replace case as required

• Leakage in the Servo Apply, Servo Release No The problem is not in the automatic transaxle
or Direct Clutch Circuits Go to Section F3
46U0K2-478
K 2-97

© Powertrain control system © Coasting clutch assembly
© Improper pressures © Forward OWC assembly
© Control valve body © Case
@ 2/4 band and servo assembly
— Do any of the following problems exist? Perform Pinpoint Tests “ A and D”
• Vehicle wiring harness No Go to next step
• PCM
• SS1, SS2
• TR sensor
• Hold switch
c r page K 2-23

c r page K 2-10

• Gasket leaks
• 3-4 Shift Valve, Main Regulator Valve stuck,
• SS1 malfunction (Also No 1st gear)
• Separator Plates damaged or Orifice blocked

• Also no 2nd gear

• 2/4 Band damaged, worn
• Servo Piston or Cover damaged or leaking
• Springs damaged
5 Coasting Clutch Assembly Yes Service as required

• Piston damaged No Go to next step
• Friction severely damaged, worn
• Check Ball severely damaged
6 Forward OWC Assembly Yes Service as required

— Is there damage?
No Go to next step
7 Case Yes Service as required

• Also no 2nd gear

• Band Anchor damaged
• Servo Apply and Servo Release circuits
leaking
46U0K2-479
K2—99
16 SHIFT CONCERNS: SOFT/SLIPPING 1-2 SHIFT

© Powertrain control system © Forward clutch assembly
© Control valve body © Low OWC assembly
© 2/4 Band and servo assembly © Low/reverse clutch assembly
@ Forward OWC assembly © Case
— Do any of the following problems exist? Perform Pinpoint Tests "B and E”
• PCM
• EPC solenoid
• TFT sensor
c r page K 2-23

• Gaskets damaged
• 2-4 Accumulator Piston Plug and Seal (also
soft 3-4 shift), Main Regulator Valve, Line
Modulator Valve (also soft 3-4 shift) stuck,
• Pressure Tap Plate/Gasket damaged

• Piston, Seals or Piston Bore damaged, No Go to next step
missing
• 2/4 Band and/or Reverse Clutch Drum As
sembly worn, damaged or misassembled
• Springs damaged
• Servo Cover and Seal damaged
4 Forward OWC Assembly (Slips In 1st gear) Yes Service as required
— Is there the forward OWC assembly damaged
or not holding? No Go to next step
5 Forward Clutch Assembly (Slip In 1st gear) Yes Service as required

• Seals damaged No Go to next step
• Friction Elements damaged
• Pump Support Seals # 3, # 4 damaged
6 Low OWC Assembly Yes Service as required

— Is there the low OWC assembly damaged or
not overrunning? No Go to next step

— Is there friction severely damaged?
No Go to next step

• Band Anchor damaged No The problem is not in the automatic transaxle
• Porosity/Leakage in servo Apply Servo Go to Section F3
Release circuits
46U0K2-480
K2-101

© Powertrain control system © 2/4 servo
© Control valve body © Forward OWC assembly
© Oil pump © Case
© Direct clutch assembly
— Do any of the following problems exist? Perform Pinpoint Tests "B and D"
• PCM
• EPC solenoid
• TFT sensor
c r page K 2-23

No Go to next step
• Gasket leaks
• Line Modulator Valve (also soft 1-2 and 3-4
shifts), Servo Release Shuttle Valve stuck

• Gaskets damaged
• Pump Support Seals # 4 and # 5 damaged,
missing
4 Direct Clutch Assembly Yes Service as required
• Seals or Pistin damaged No Go to next step
• Friction damaged, worn or excessive end
clearance
• Check Ball not seating properly
• Return Spring Assy, damaged
5 2/4 Servo Yes Service as required

• Piston or Piston Bore damaged No Go to next step
6 Forward OWC Assembly Yes Service as required

— Is there the toward OWC assembly damaged
or not holding No Go to next step

• Leakage in the Servo Apply, Servo Release No The problem is not in the automatic transaxle
or Direct Clutch circuits Go to Section F3
46U0K2-481

© Powertrain control system @ Direct clutch assembly
© Control valve body © Case
© 2/4 band and servo assembly
— Do any of the following problems exist? Perform Pinpoint Tests “ B and E”
• Vehicle wiring harnesses
No Go to next step
• PCM
• EPC solenoid
• TFT sensor
c r page K 2-23

No Go to next step
• Gasket leaks
• Line Modulator Valve, 2-4 Accumulator Valve
Plug and Seal (also soft 1-2 shift), stuck,
damaged, misassembled
• Separator Plates damaged or Orifice blocked

• 2/4 Band and/or Reverse Clutch Drum Assy No Go to next step
worn, damaged or misassembled
• Piston, Seals or Piston Bore damaged,
missing
• Servo Cover or Seal damaged
• Springs damaged
Direct Clutch Assembly Yes Service as required

• May also have third gear slip

• Piston damaged
• Check Ball damaged, missing or leaking
• Friction Elements damaged
Case Yes Service as required

• Band Anchor damaged No The problem is not in the automatic transaxle
• Servo Apply and Servo Release circuits
Go to Section F3
leaking
46U0K2-482
K 2-105
19 SHIFT CONCERNS: SOFT/SLIPPING 4-3 SHIFT (AUTOMATIC)

© Powertrain control system 0 Direct clutch assembly
© Control valve body © Forward/Coasting clutch assembly
© 2/4 band and servo assembly
— Do any of the following problems exist? Perform Pinpoint Tests "E ”
• Vehicle wiring harnesses
No Go to next step
• PCM
• EPC solenoid
• VSS
• MAF
• TP sensor
c r page K 2-23

No Go to next step
• Gasket leaks
• Servo Release Shuttle Valve, Main Regulator
Valve stuck, damaged, or misassembled
• Pressure Tap Plate/Gasket leaks, or damaged

• 2/4 Band and/or Reverse Clutch Drum As No Go to next step
sembly damaged/worn/misassembled
• Servo Return Spring broken
• Servo Rod damaged
• Piston Seal damaged
4 Direct Clutch Assembly Yes S e rvice as re q u ire d
— D o a n y o f th e fo llo w in g p ro b le m s exists?
• S e a ls d a m a g e d , m issin g
• P iston d a m a g e d
• C h e c k Ball d a m a g e d , m issin g o r le a kin g
• R e tu rn S p rin g d a m a g e d
• F rictio n E le m e n ts d a m a g e d
5 Forward/Coasting Clutch Assembly

— D o a n y o f th e fo llo w in g p ro b le m s exist? Yes S e rvice as re q u ire d
• S eals d a m a g e d , m issin g
• P iston d a m a g e d No G o to n e xt ste p
• F rictio n E le m e n ts w o rn , d a m a g e d
• C h e c k Ball n o t fu n c tio n in g
• F o rw a rd C lu tch . P iston a n d R e tu rn S p rin g
dam aged
6 Case Yes S e rvice as re q u ire d

• P ro s ity /c ro s s le a ks in S e rvo A p p ly , S e rv o R e
No T he p ro b le m is not in th e a u to m a tic tra n sa xle
lease, D ire ct C lu tc h c irc u its
G o to S e ctio n F3
46U0K2-483
K 2-107
20 SHIFT CONCERNS: SOFT/SLIPPING 3-2 SHIFT (AUTOMATIC)

© P o w e rtra in c o n tro l syste m © 2 /4 b a n d a n d se rv o a sse m b ly
© C o n tro l v a lv e b o d y © D ire c t c lu tch a sse m b ly
© Oil p u m p © C a se
1 Powertrain Control System Yes Run O B D Tests
— D o a n y o f th e fo llo w in g p ro b le m s exist? P e rfo rm P in p o in t T ests " E a n d G ”
• E le ctrica l In p u ts /O u tp u ts cr page K2-135
• V e h ic le w irin g h a rn e sse s
• PC M
• E P C s o le n o id
• TP s e n s o r
• VSS
• MAF
• 3 -2 T /C C S
cr page K 2-23
2 Control Valve Body Yes S e rvice as re q u ire d

— D o a n y o f th e fo llo w in g p ro b le m s exist?
• B o lts n o t to rq u e d to s p e c ific a tio n
• G asket d a m aged
• 3 -2 T im in g V alve, S o le n o id R e g u la to r Valve,
3 -2 C o n tro l V a lve S tuck, d a m a g e d o r m isas-
s e m b le d
• 3 -2 T /C C S S o le n o id m a lfu n c tio n
• P re s s u re T a p P la te /G a ske t le a ks o r d a m a g e d
• S e p a ra to r P lates d a m a g e d , b lo c k e d
3 Oil Pump Y es S e rvice as re q u ire d

• B o lts n o t to rq u e d to sp e c ific a tio n
• G a s k e ts d a m a g e d
• P o ro s ity /C ro s s le a ks
• P u m p S u p p o rt Seal R in g s # 4 , 5, 6 d a m a g e d
o r m is a s s e m b le d
• F o rw a rd to D ire ct p a s s a g e le a ks
K 2-108
4 2/4 Band and Servo Assembly Yes S e rvice as re q u ire d
• 2/4 B a n d a n d /o r R e ve rse C lu tc h D ru m A s No G o to n e xt ste p
s e m b ly d a m a g e d , w o rn o r m is a sse m b le d
• S e rv o P iston d a m a g e d
• S e rv o R e tu rn a n d C u s h io n S p rin g s d a m a g e d ,
m is a s s e m b le d
• S p rin g s d a m a g e d , m is a sse m b le d
• S e rvo R o d b e n t, d a m a g e d

• R e tu rn S p rin g d a m a g e d , b ro k e n
• F rictio n E le m e n ts d a m a g e d , w o rn
• Ball C h e c k n o t re le a sin g
• P iston o r Seal d a m a g e d

• Band A nchor dam aged
No T h e p ro b le m is n o t in th e a u to m a tic tra n sa xle
• L e a k a g e in S e rvo A p p ly /R e le a s e circ u its
• C a se B o re d a m a g e d (S e rvo R od)
46U0K2-484
21 SHIFT CONCERNS: SOFT/SLIPPING 2-1 SHIFT (AUTOMATIC OR KICKDOWN)

© P o w e rtra in c o n tro l syste m © F o rw a rd c lu tc h a sse m b ly
( 2) O il p u m p (D L o w O W C a sse m b ly
© 2 /4 b a n d a n d s e rv o a s s e m b ly

— D o a n y o f th e fo llo w n g p ro b le m s exist? P e rfo rm P in p o in t T ests " B a n d E ”
• PCM
• EPC s o le n o id
• TFT s e n s o r
• TP s e n s o r
• MAF
cr page K 2-23
2 Oil Pump Yes S e rvice as re q u ire d

• P o ro s ity /c ro s s le a ks
• P u m p S u p p o rt Seals # 3 a n d 4 le a kin g , m is
a s s e m b le d , d a m a g e d

4 Forward Clutch Assembly Yes S e rvice as re q u ire d

• P iston o r S eals d a m a g e d
• F rictio n E le m e n ts d a m a g e d
5 Low OWC Assembly Yes S e rvice as re q u ire d

— Is th e re th e lo w O W C d a m a g e d o r not
h o ld in g ?
No T he p ro b le m is n o t in th e a u to m a tic tra n sa xle
G o to S ectin F3
46U0K2-485
22 SHIFT CONCERNS: HARSH 1-2 SHIFT
© P o w e rtra in c o n tro l syste m © 2/4 b a n d a n d se rvo a sse m b ly
© C o n tro l v a lv e b o d y © F o rw a rd c lu tc h a sse m b ly
© Oil p u m p © C ase

— D o a n y o f th e fo llo w in g p ro b le m s exist? P e rfo rm P in p o in t Tests “ B, C, D, E, a n d F ”
• E le ctrica l In p u ts /O u tp u ts c r page K2-135
• PCM
• EP C so le n o id
• T F T s e n so r
• TSS
• TP s e n so r
• VSS
• M AF
• TCC
• TR s e n so r
zrc page K 2-23

• G a s k e t le a ks
• 2-4 A c c u m u la to r V alve, 3-2 C o n tro l V a lve
(also h a rsh 3-4 shift) stu ck, d a m a g e d o r
• S e p a ra to r P lates d a m a g e d
• H y d ra u lic P a ssa g e s d a m a g e d

• B o lts n o t to rq u e d to s p e c ific a tio n No G o to n e xt ste p
• G asket dam a g e d
• P u m p S u p p o rt Seal R in g s #3, a n d #4
dam aged
K2-111

• C u s h io n R e tu rn S p rin g s d a m a g e d
• B a n d d a m a g e d , w o rn
• 2 /4 B a n d a n d /o r R e ve rse C lu tch D ru m A s
s e m b ly w o rn , d a m a g e d o r m is a sse m b le d
5 Forward Clutch Assembly Yes S e rvice as re q u ire d

• S e a ls d a m a g e d
• F ric tio n E le m e n ts d a m a g e d

— Is th e re th e b a n d a n c h o r a re a d a m a g e d ?
46U0K2-486
K 2-112
© P o w e rtra in c o n tro l syste m 0 D ire ct c lu tc h a sse m b ly
© C o n tro l v a lv e b o d y © 2/4 se rvo
© O il p u m p © C a se

1 Powertrain Control System Yes R un O B D T ests
— D o a n y o f th e fo llo w in g p ro b le m s exist? P e rfo rm P in p o in t Tests “ B, C, D, E, a n d F "
• E le ctrica l In p u ts /O u tp u ts cr page K 2 -1 3 5
• PCM
• E P C so le n o id
• TR s e n s o r
• VSS
• TFT sensor
• M AF
• T C C so le n o id
• TSS
cr page K 2-23

— D o a n y o f fo llo w in g p ro b le m s exist?
• B o lts n o t to rq u e d to s p e c
• L in e M o d u la to r V a lve (also 1-2 a n d 3-4 ha rsh
shift), S e rv o R e le a se S h u ttle V a lve stu ck,
d a m a g e d , m isa s s e m b le d
• S e p a ra to r P lates d a m a g e d

• B o lts n o t to rq u e d to s p e c
• G asket dam a g e d
• P u m p S u p p o rt Seal R in g s # 4 a n d # 5
dam aged
K 2-113

• P iston o r P iston B o re d a m a g e d
• Ball C h e c k n o t s e a tin g p ro p e rly
• R e tu rn S p rin g A s s e m b ly d a m a g e d
• F /C /D C lu tc h C y lin d e r S p lin e s d a m a g e d
5 2/4 Band Servo Yes S e rvice as re q u ire d

• P iston o r P iston B o re d a m a g e d
• S e rv o R o d d a m a g e d
6 Case Y es S e rvice as re q u ire d

• L e a k a g e in th e S e rv o A p p ly , S e rvo R elease
o r D ire c t C lu tc h c irc u its
• S e rv o R o d B o re d a m a g e d
46U0K2-487
K 2-114
© P o w e rtra in c o n tro l syste m © C o a stin g c lu tc h a sse m b ly
© C o n tro l v a lv e b o d y © D ire ct c lu tch a sse m b ly
@ 2 /4 b a n d a n d s e rv o a s s e m b ly

— D o a n y o f th e fo llo w in g p ro b le m s exist? P e rfo rm P in p o in t T ests " B , C, D, E, F, a n d G ”
• E le ctrica l In p u ts /O u tp u ts C7~ page K2-135
• V e h ic le w irin g h a rn e sse s No G o to n e xt ste p
• PCM
• EP C so le n o id
• TR s e n so r
• VSS
• 3 -2 T /C C S
• TFT se n so r
• TSS
• T P s e n so r
• MAF
c r page K 2-23

• L in e M o d u la to r V a lve (also h a rsh 1-2 a n d 2-3
shifts), 3 -2 C o n tro l V alve, 2-4 A c c u m u la to r
V alve, C o a stin g C lu tc h V alve, stu ck, d a m a g e d
o r m is a sse m b le d
• H y d ra u lic P a ssa g e d d a m a g e d

• B o lts n o t to rq u e d to sp e c No G o to n e xt ste p
• G asket dam aged
• C o a s tin g C lu tc h T eflo n S eals d a m a g e d
K 2-115

• 2 /4 B a n d a n d /o r R e ve rse C lu tc h D ru m A s
s e m b ly d a m a g e d /w o rn /m is a s s e m b le d
• S e rv o P isto n o r C o v e r d a m a g e d o r le a kin g
• S p rin g s d a m a g e d
5 Coasting Clutch Assembly Yes S e rvice as re q u ire d

• P iston o r S e a ls d a m a g e d , m issin g
• F ric tio n d a m a g e d , w o rn

• P iston o r S e a ls d a m a g e d , m issin g
• C h e c k Ball d a m a g e d , m is s in g o r le a kin g
• F ric tio n E le m e n ts d a m a g e d
• F /C /D C lu tc h C y lin d e r S p lin e s d a m a g e d
7 Case Y es S e rvice a s re q u ire d

— Is th e re th e b a n d a n c h o r d a m a g e d ?
No T h e p ro b le m s is n o t in th e a u to m a tic tra n sa xle
46U0K2-488
K 2-116
25 SHIFT CONCERNS: HARSH 4-3 SHIFT (AUTOMATIC)
© P o w e rtra in c o n tro l syste m © 2 /4 b a n d a n d se rv o a sse m b ly
© C o n tro l v a lv e b o d y © C o a stin g c lu tc h a sse m b ly
© Oil p u m p © C a se
1 Powertrain Control System Y es R un O B D Tests
— D o a n y o f th e fo llo w in g p ro b le m s exist? P e rfo rm P in p o in t T ests " B , C, D, E, F a n d G ”
• E le c trica l In p u ts /O u tp u ts cr page K2-135
• PCM
• TR s e n s o r
• VSS
• TP s e n so r
• T FT s e n so r
• MAF
• TSS
• 3 -2 T /C C S
cr page K 2-23
2 Control Valve Body Y es S e rvice as re q u ire d

No G o to nest ste p
• S e rv o R e le a se S h u ttle V alve, 3 -2 T im in g /C o a s t
C lu tc h V a lve stu c k , d a m a g e d , m is a sse m b le d

• P o ro s ity /c ro s s leak, Seal R in g s d a m a g e d ,
m is s in g o r le a k in g ball p lu g
• G asket da m a g e d
• P u m p S u p p o rt Seal R in g s # 2 , 3, 4, a n d # 5
(C o ast a n d D ire ct circ u its ) d a m a g e d

• S e rv o R o d ben t, d a m a g e d
• S e rv o R e tu rn S p rin g b ro k e n
5 Coasting Clutch Assembly Yes S e rvice as re q u ire d

• Seals d a m a g e d , m issin g
• F ric tio n E le m e n ts w o rn , d a m a g e d
• F o rw a rd C lu tc h P istion a n d R e tu rn s p rin g
dam aged

• P o ro s ity /c ro s s le a ks in S e rvo A p p ly , S e rvo
No T he p ro b le m is n o t in th e a u to m a tic tra n sa xle
Release, D ire c t C lu tch , C o a stin g C lu tch
c irc u its
46U0K2-489
K 2-118
26 SHIFT CONCERNS: HARSH 3-2 SHIFT (AUTOMATIC)
© P o w e rtra in c o n tro l syste m © D ire ct c lu tc h a s s e m b ly
© C o n tro l v a lv e b o d y © 2 /4 b a n d a n d se rvo a sse m b ly

— D o a n y o f th e fo llo w in g p ro b le m s exist? P e rfo rm P in p o in t T ests " B , C, D, E, F, a n d G ”
• PCM
• TR se n so r
• VSS
• 3 -2 T /C C S
• TFT s e n so r
• MAF
• T P s e n so r
• TSS
cr page K 2-23

• G asket d a m aged
• 3 -2 T im in g V alve, S o le n o id R e g u la to r Valve,
3 -2 C o n tro l V a lve stu ck, d a m a g e d , m isas-
s e m b le d
• 3 -2 T /C C S S o le n o id m a lfu n c tio n
3 Oil Pump Y es S e rvice as re q u ire d

• G a s ke ts d a m a g e d
• P o ro s ity /C ro s s le a ks
• P u m p S u p p o rt Seal R in g s d a m a g e d o r (Disas
s e m b le d

• R e tu rn S p rin g d a m a g e d , b ro k e n
• C h e c k Ball n o t e x h a u s tin g
• S e rv o R o d b e n t o r d a m a g e d

• 2/4 B a n d a n d /o r R e ve rse C lu tch D ru m A s
s e m b ly d a m a g e d , w o rn o r m is a sse m b le d
• S e rv o P iston d a m a g e d
• S e rv o R e tu rn a n d C u s h io n S p rin g s d a m a g e d ,
• S p rin g s d a m a g e d , m isa s s e m b le d
6 Case Y es S e rvice as re q u ire d

• Band A n ch o r dam aged
• L e a ks
• S e rv o R o d B o re d a m a g e d
46U0K2-490
K 2-120
27 TORQUE CONVERTER CLUTCH: NO APPLY
© P o w e rtra in c o n tro l syste m
© C o n tro l v a lv e b o d y
© T o rq u e c o n v e rte r a s s e m b ly
1 Powertrain Control System Yes Run O B D T ests
— D o a n y o f th e fo llo w in g p ro b le m s exist? P e rfo rm P in p o in t Tests “ B, C, a n d F ”
• PCM
• T F T s e n so r
• S to p lig h t sw itch
• TSS
cr page K 2-23

• C a s ke ts d a m a g e d
• S o le n o id P re ssu re R e g u la to r V alve, B yp a ss
C lu tc h C o n tro l V a lv e a n d P lu n g e r, C o n v e rte r
R e g u la to r V a lve stu ck, d a m a g e d o r m isa s
s e m b le d
• T C C S o le n o id m a lfu n c tio n , s tu c k
3 Torque Convertor Assembly Yes P e rfo rm T o rq u e c o n v e rte r test

• Leakage
No R e p la ce th e to rq u e c o n v e rte r a sse m b ly
• In te rn a l d a m a g e
46U0K2-491
28 TORQUE CONVERTER CLUTCH;

ALWAYS APPLIED/MAY STALL ENGINE
© P o w e rtra in c o n tro l syste m © T o r q u e c o n v e rte r a sse m b ly
© C o n tro l v a lv e b o d y © C a se
© Oil p u m p

— D o a n y o f th e fo llo w in g p ro b le m s exist? P e rfo rm P in p o in t T ests “ B a n d C ”
• E le ctrica l In p u ts /O u tp u ts c r page K2-135
• PC M
• TFT s e n s o r
• T C C s o le n o id
C7- page K2-23

• B y p a s s C lu tc h C o n tro l V a lve a n d P lu n g e r (al
w a y s a p p lie d ), C o n v e rte r R e g u la to r V a lve
stu ck, d a m a g e d , m is a sse m b le d
• S e p a ra to r P lates d a m a g e d , b la c k e d
Note
• C o n v e rte r n o t a p p lie d in 1st g e a r o r re
v e rs e g e a r
• T C C S o le n o id m a lfu n c tio n
• P re s s u re T a p P la te /G a ske t d a m a g e d

• B o lts n o t to rq u e d to sp e c ific a tio n No G o to n e xt step
• P u m p S u p p o rt # 1 , Seal R ing d a m a g e d ,
m issin g , m is a s s e m b le d
4 Torque Converter Assembly Yes S e rvice as re q u ire d
• In te rn a l S e a ls d a m a g e d
• P isto n P la te d a m a g e /s tu c k to C o ve r

• P o ro s itly /c ro s s le a ks fro m th e C B Y c irc u it
No T h e p ro b le m is fixe d
46U0K2-492
K 2-123
29 OTHER: POOR VEHICLE ACCELERATION/PERFORMANCE

( 2) In te rn a l o r e x te rn a l sh ift lin k a g e s
(3) T o rq u e c o n v e rte r c lu tc h
@ C o n v e rte r O W C
— A re th e re a n y p ro b le m s w ith th e fo llo w in g ? If th e p ro b le m is e n g in e related, g o to S e ctio n F3
• E n g in e If th e p ro b le m is n o t e n g in e related, p e rfo rm P in p o in t
• E le ctrica l In p u ts /O u tp u ts T ests “ B, C a n d D "
• V e h ic le w irin g h a rn e sse s cr page K2-135
• PCM
• TFT s e n s o r
• TP s e n s o r
• H o ld s w itc h
cr page K 2-23
2 Internal and External Shift Linkages Y es S e rvice as re q u ire d

• D am aged
• M is a d ju s te d
• M is a s s e m b le d
cr page K 2-58
3 Torque Converter Clutch Yes P e rfo rm S y m p to m T ro u b le s h o o tin g N o .2 8

— Is th e re th e to rq u e c o n v e rte r c lu tc h a lw a ys cr page K2-122
a p p lie d ?
4 Converter OWC Yes S e rvice as re q u ire d

— Is th e re th e c o n v e rte r O W C d a m a g e d ?
No P e rfo rm R o a d T est a n d ve rify p ro p e r sh ift s c h e d u le a n d
e n g a g e m e n ts
S e rvice as re q u ire d
cr page K2-14
46U0K2-493
30 OTHER: ENGINE WILL NOT CRANK
© In te rn a l o r e xte rn a l sh ift lin k a g e s
© TR s e n s o r

1 Powertrain Control System Y es Run O B D Tests
— A re th e re a n y p ro b le m s w ith th e fo llo w in g ? If th e p ro b le m is e n g in e related, g o to S ection F3
• E n g in e If th e p ro b le m is n o t e n g in e related, p e rfo rm P in p o in t
• E le ctrica l In p u ts /O u tp u ts T ests “ D ”
• V e h ic le w irin g h a rn e sse s cr page K2-135
• PCM
• TR se n so r
cr page K 2-23
2 Internal and External Shift Linkage or TR Yes S e rvice as re q u ire d

Sensor
• D am aged
cr page K 2-58
cr page K 2-34
3 Starter/Drive plate Y es S e rvice as re q u ire d

• D am aged
cr Section G
cr page K 2-56
46U0K2-494
K 2-125
31 OTHER: NO “ P” RANGE
© In te rn a l o r e x te rn a l sh ift lin k a g e s
©P a rk m e c h a n is m
1 Internal or External Shift Linkages Yes S e rvice as re q u ire d
• D a m a g e d , m is a d ju s te d o r m is a sse m b le d
cr page K 2-58
2 Park Mechanism Y es S e rvice as re q u ire d

— D o a n y o f fo llo w in g p ro b le m s exist?
• P a rk g e a r o n d riv e n s p ro c k e t a sse m b ly, P a rk
in g p a w l re tu rn s p rin g , P a rk p a w l ra tch e tin g
sp rin g s , P a rk p a w l sh a ft
• M a n u a l le ve r, C a m a p p ly lever
• M a n u a l le v e r d e te n t s p rin g
• M L P s e n so r, P a rkin g p a w l a p p ly ca m
• M a n u a l s h a ft n u t d a m a g e d
• M is s in g o r m is a s s e m b le d
46U0K2-495
32 OTHER: TRANSAXLE OVERHEATING
© ATF © Oil p u m p
© P o w e rtra in c o n tro l syste m © C h a in p an
© Oil c o o le r © T h e rm o sta tic oil level co n tro l va lve
@ C o n tro l v a lv e b o d y ®C a s e /c o n v e rte r
h o u sin g /S ta rto r s u p p o rt
© T o rq u e c o n v e rte r c lu tc h
1 Fluid Yes S e rvice as re q u ire d
— A re th e re a n y p ro b le m s w ith th e fo llo w in g ?
• L e ve l
• C o n d itio n
cr page K2-21
2 Powertrain Control System Y es Run O B D Tests

— A re th e re a n y p ro b le m s w ith th e fo llo w in g ? P e rfo rm P in p o in t Tests " B , C a n d F ”
• E le ctrica l In p u ts /O u tp u ts o-page K2-135
• PCM
• T C C s o le n o id
• T FT s e n so r
• TSS
cr page K2-23
3 Oil cooler Yes S e rvice as re q u ire d

• D am aged
• B lo c k e d
• R e ve rse d
• R e stricte d
• L e a k in g
cr page K 2-54

— D o a n y of th e fo llo w in g p ro b le m s exist?
• M a in R e g u la to r V alve, B y p a s s C lu tch C o n tro l
V a lve , C o n v e rte r R e g u la to r V a lve stuck,
d a m a g e d , m isa s s e m b le d
• S e p a ra to r P la te s/G a ske ts d a m a g e d
• T C C S o le n o id m a lfu n c tio n (OFF)
5 Torque Converter Clutch Yes P e rfo rm S ym p to m T ro u b le s h o o tin g N o .2 7

— Is th e re th e to rq u e c o n v e rte r c lu tc h no a p p ly ? crpage K2-121
K 2-127

• G asket d a m a g e d
• R e a r L u b e P a ssa g e b lo c k e d
7 Chain Pan Yes Install th e c h a in p an

— Is th e re m issin g ?
8 Thermostatic Oil Level Control Valve Yes S e rvice as re q u ire d

• S tu c k o p e n o r d a m a g e d
• G a s k e t d a m a g e d o r m issin g
• B o lt o r b ra c k e t d a m a g e d , m issin g , o r im
p ro p e rly in sta lle d
9 Case/Converter Housing/Stator Support Yes S e rvice as re q u ire d

• F ro n t L u b e P a ssa g e b lo c k e d o r re stricte d
• T C , C l, C T P a ssa g e s b lo c k e d o r re stricte d
G o to S ctio n E
46U0K2-496
33 OTHER: NO ENGINE BRAKING IN 1ST GEAR (“ L” RANGE)
© P o w e rtra in c o n tro l syste m © C o a stin g c lu tc h a sse m b ly
© C o n tro l v a lv e b o d y © L o w /re v e rs e c lu tc h a sse m b ly
© O il p u m p

1 Powertrain Control System Yes Run O B D T ests
— A re th e re a n y p ro b le m s w ith th e fo llo w in g ? P e rfo rm P in p o in t T ests “ G "
• V e h ic le w irin g h a rn e sse s G o to n e xt ste p
No
• PCM
• 3 -2 T /C C S
cr page K 2-23

No G o to nest step
• G a ske ts d a m a g e d
• L o w /R e v e rs e M o d u la to r V alve, C o a stin g
C lu tc h V a lve s tu c k d a m a g e d o r m isa s
s e m b le d
• 3 -2 T /C C S s tu c k o r d a m a g e d
• P re ssu re T a p P la te /G a ske t d a m a g e d
• S e p a ra to r P la te /G a ske t d a m a g e d

• P u m p S u p p o rt # 2 a n d # 3 Seal R in g s fo r
th e C o a st C lu tc h c irc u it d a m a g e d , m issin g
4 Coasting Clutch Assembly Y es S e rvice as re q u ire d

• A s s e m b ly m is a s s e m b le d , d a m a g e d
• F o rw a rd C lu tc h H u b Seal d a m a g e d
• Ball C h e c k d a m a g e d , m issin g
5 Low/Reverse Clutch Assembly Yes S e rvice as re q u ire d

• D am aged
• P iston o r se a ls d a m a g e d
46U0K2-497
K 2-129
34 OTHER: NO ENGINE BRAKING IN “ D” RANGE (HOLD SW ON)

© P o w e rtra in c o n tro l syste m © Oil p u m p
© In te rn a l o r e x te rn a l sh ift lin k a g e s (§) F o rw a rd O W C a sse m b ly
© C o n tro l v a lv e b o d y © C o a stin g c lu tc h a sse m b ly
1 Powertrain Control System Y es R un O B D Tests
— A re th e re a n y p ro b le m s w ith th e fo llo w in g ? P e rfo rm P in p o in t T ests “ G ”
• PCM
• 3 -2 T /C C S
cr page K 2-23

• D am aged
cr page K 2-58

• 3-4 S h ift V alve, 1-2 S h ift V alve, P ullin Valve,
C o a s tin g C lu tc h C o n tro l V a lve stu ck,
dam aged
• 3 -2 T /C C S s tu c k o r d a m a g e d

♦ P u m p S u p p o rt # 2 a n d # 3 Seal R in g s fo r
th e C o a s tin g C lu tch c irc u it d a m a g e d , m issin g
5 Forward OWC Assembly Y es S e rvice as re q u ire d

— Do a n y o f th e fo llo w in g p ro b le m s exist?
• D am aged
6 Coasting Clutch Assembly Y es S e rvice as re q u ire d

• A s s e m b ly m is a s s e m b le d , d a m a g e d
• F o rw a rd C lu tc h H u b Seal d a m a g e d
G o to S e ctio n B1 o r F3
46U0K2-498
K 2-130
35 OTHER: VEHICLE MOVEMENT WITH GEAR SELECTOR IN “ N” RANGE
© Internal o r e xte rn a l sh ift lin ka g e s
( 2) Oil p u m p
(3) F o rw a rd /c o a s tin g c lu tc h a s s e m b ly

• D am aged
cr page K 2-58

• G a ske ts S e ve re ly d a m a g e d
• P u m p S u p p o rt Seal R ing #2, le a k a g e fro m
L u b e C irc u it in to FC C irc u it
3 Forward/Coasting Clutch Assembly Yes S e rvice as re q u ire d

• F rictio n p la te s s e v e re le y d a m a g e d
46U0K2-499
36 OTHER: SHIFT EFFORTS HIGH

© S h ift in te rlo c k
© In te rn a l o r e x te rn a l sh ift lin k a g e
© C o n tro l v a lv e b o d y
1 Shift Interlock Yes S e rvice as re q u ire d
— Is th e re a n y p ro b le m ?
c r page K 2-58

• D am aged
c r page K 2-58
3 Yes S e rvice as re q u ire d

• M a n u a l le v e r d a m a g e d
• P a rk m e c h a n is m d a m a g e d
• S h a ft b e n t
• D e te n t le v e r sh a ft b o re (in ca se ) d a m a g e d
• D e te n t s p rin g b e n t/d a m a g e d
• N u t lo o se

• B o lts a re n o t to rq u e d to sp e c ific a tio n
• M a n u a l v a lv e stu ck, d a m a g e d
46U0K2-527
K2—132
37 OTHER: EXTERNAL LEAKS
©ATF

1 ATF Yes S e rvice as re q u ire d
— Is A T F im p ro p e r level?
c r page K2-21 No T h e p ro b le m is fixe d
46U0K2-528
K 2-133
35 OTHER: NOISE/VIBRATION—FORWARD/REVERSE
© F o r N o is e s /V ib ra tio n s th a t C h a n g e w ith E n g in e S p e e d
@ F or N o is e s /V ib ra tio n s th a t C h e n g e w ith V e h ic le sp e e d
® O th e r N o is e s /V ib ra tio n s
1 For Noises/Vibrations that Change with En Yes S e rvice as re q u ire d
gine Speed
• T o rq u e c o n v e rte r
• A T F level (low ) p u m p c o u ita tio n
• O il p u m p
• E n g in e d riv e a c c e s s o rie s
• C o o le r lin e s g ro u n d in g o u t
• D riv e p la te
2 For Noises/Vibrations that Change with Ve Yes S e rvice as re q u ire d

hicle Speed
• E n g in e m o u n t
• T ire s
• D rive s h a ft o r jo in t shaft
• D iffe re n tia l (final d riv e /c h a in )
• S u sp e n s io n
• P la n e ta ry g e a r sets
• C h a in g ro u n d in g to c h a in p an
• F o rw a rd o n e -w a y c h u tc h
• T o rq u e c o n v e rte r
3 Other Noise/Vibrations Y es S e rvice as re q u ire d

• S hift c a b le v ib ra tio n g ro u n d in g
No T h e p ro b le m is fix e d
• C o o le r lin e s g ro u n d in g
46U0K2-529
ON-BOARD DIAGNOSIS SYSTEM K2
DESCRIPTION
When trouble codes occur in the main input or output devices, check for the cause by using the SST.
Failure of the input and output devices is indicated and retrieved from the powertrain control module (PCM)
as diagnostic trouble code numbers.
Refer to Section F3 for On-Board Diagnostic Test procedure.
46U0K2-500
PREPARATION
SST
4 9 U N 01 0 5 6 For 4 9 UN01 0 5 8 For

d ia g n o s is of in s p e c t P C M a n d
S u p e r ST A R n m a lfu n ctio n B re a k o u t b o x In p u t/O u tp u t
T este r d e vice s
46U0K2-5Q1
ON-BOARD DIAGNOSTIC TEST

Diagnostic Trouble Code (DTC) Number
No. Item Page
111 S ystem pass
112 A ir c h a rg e te m p (ACT) se n so r
In ta ke a ir te m p e ra tu re (IAT)
113
116 E n g in e c o o lin g te m p (ECT) se n so r

E n g in e c o o la n t te m p e ra tu re (ECT)
117
118
121 T h ro ttle p o sitio n s e n so r (TPS)
122
S e ctio n F3
123
157 M a ss a ir flo w (M A F ) se n so r
158
159
172 H e a te d o x y g e n s e n so r (H E G O )
173
179
181
K 2-135
K2 ON-BOARD DIAGNOSIS SYSTEM
No. Item Page
211 Ig n ito r syste m
212
213
214 C y lin d e r id e n tific a tio n d is p la y (C ID )
244
S e ctio n F3
327 EG R p o s itio n s e n so r (EGRP)
332
337
411 Id le a ir c o n tro l s o le n o id
412
452 V e h ic le s p e e d o m e te r s e n s o r (VSS) S e ctio n K1
511 E le c tro n ic c o n tro l a s s e m b ly (ECA)

P o w e rtra in c o n tro l m o d u le (P C M )
512
513 S e ctio n F3
519 P o w e r s te e rin g p re s s u re s e n so r (PSPS)
521
522 P a rk /N e u tra l sw itch (T ra n sm issio n ra n g e sensor) K 2 -1 4 7
536 S to p lig h t sw itch
538 D y n a m ic re s p o n s e test
539 A /C s e n s o r
554 P re ssu re re g u la to r so le n o id
559 A /C relay
S e ctio n F3
563 E le c tro n ic c o o la n t fa n re la y (H ig h /s p e e d )
564 E le c tro n ic c o o la n t fa n relay (L o w /s p e e d )
565 P u rg e s o le n o id va lve
571 EG R s o le n o id v a lve (Vent)
572 E G R s o le n o id v a lve (va cu u m )
621 S h ift s o le n o id No.1 K 2 -1 3 8
K 2-136
No. Item
622 S hift so le n o id N o .2
624 E le c tro n ic p re s s u re c o n tro l
625
628 T o rq u e c o n v e rte r c lu tc h s o le n o id
634 T ra n sm issio n ra n g e se n so r
636 T ra n s a x le flu id te m p e ra tu re se n so r
637
638
639 T u rb in e sh a ft s p e e d s e n so r
641 3 -2 tim in g /c o a s tin g c lu tc h s o le n o id
645 In c o rre c t g e a r ratio fo r 1st g e a r
646 In c o rre c t g e a r ratio fo r 2 n d g e a r
647 In c o rre c t g e a r ratio fo r th ird g e a r
648 In c o rre c t g e a r ratio fo r fo u rth g e a r
652 T o rq u e c o n v e rte r c lu tc h s o le n o id
657 T ra n s a x le flu id te m p e ra tu re se n so r
659 H ig h v e h ic le s p e e d in P A R K
667 T ra n sm issio n ra n g e
668
675
998 P o w e rtra in C o n tro l M o d u le (PC M )

Pinpoint Test
Pinpoint test A
DIAGNOSTIC TROUBLE CODE N0.621, 622, 645, 646, 647, 648

T h is P in p o in t T est is in te n d e d to d ia g n o s e th e fo llo w in g c o m p o n e n ts :
DESCRIP
• T ra n s m issio n W irin g H a rne ss, SS1, SS2, VPW R
TION
• P o w e rtra in C o n tro l M o d u le (PC M )
E n g in e : P e rfo rm a n c e , C o o lin g , B ra ke s
E le c tric a l: B a tte ry, In p u t S ensors, W irin g H a rn e sse s
T ra n s a x le : In te rn a l T ra n s a x le C o m p o rn e n ts , L in ka g e s, C o o lin g
A1 ELECTRONIC DIAGNOSTICS Yes R E M A IN in O u tp u t State.
• C h e c k th e s o le n o id b o d y c o n n e c to r is fu lly G o to A 2
s e a ted , te rm in a ls a re fu lly e n g a g e d in th e
No D e p re ss th o ttle a n d Release.
c o n n e c to r a n d in g o o d c o n d itio n b e fo re
If v e h ic le D ID N O T EN TER O u tp u t State.
p re c e e d in g .
Refer to S ection F3.
• E n te r O u tp u t S ta te D ia g n o s tic T est R efer to
sp e c ia l te s t m o d e s in se ctio n F3.
• C o n n e c t S u p e r S tar n tester.
• P e rfo rm K O E O TEST until C o n tin u o u s M e m o
ry D TC h a v e b e e n d is p la y e d .
• D e p re s s th ro ttle to W O T a n d Release.
• D o e s v e h ic le e n te r O u tp u t State?
A2 CHECK ELECTRICAL SIGNAL OPERATION Yes G o to A 5
Caution No G o to A3
• Removing the solenoid body connector
by prying with a screwdriver will dam
age the connector. Remove the solenoid
body connector by pushing on the wire
tag and pulling on the wiring harness.
• D is c o n n e c t s o le n o id b o d y c o n n e c to r.
• U s in g a m irro r, in s p e c t b o th e n d s o f th e c o n
n e c to r fo r d a m a g e d o r p u s h e d o u t pins, c o r
rosion , lo o s e w ire s, a n d m issin g o r d a m a g e d
se a ls
• R EFER T O S C H E M A T IC A N D T A B L E .
• C o n n e c t V O M /D V O M p o sitive te st le a d to
V P W R c irc u it a n d n e g a tiv e te st le a d to th e
s u s p e c t s o le n o id c irc u it o f th e tra n sm issio n
v e h ic le h a rn e ss c o n n e c to r.
• V O M /D V O M O N 20 V o lt scale.
• W h ile o b s e rv in g D V O M , d e p re s s a n d release
th ro ttle to c y c le so le n o id o u tp u t O N a n d OFF.
• D o e s th e s u s p e c te d so le n o id o u tp u t v o lta g e
c h a n g e at least 0 .5 volt?
A3 CHECK CONTINUITY OF SOLENOID SIGNAL Y es G o to A 4
AND VPWR HARNESS CIRCUITS
• T u rn ke y OFF.
No S e rvice o p e n circuit(s).
• S o le n o id b o d y c o n n e c to r d is c o n n e c te d .
R e m ove b re a k o u t box.
• D is c o n n e c t P o w e rtra in C o n tro l M o d u le (PCM ).
R e co n n e ct all co m p o n e n ts .
In s p e c t fo r d a m a g e d o r p u s h e d o u t pins, c o r
R E R U N O B D Tests.
rosion , lo o se w ire s, etc. S e rvice as R eqd.
• Install b re a k o u t b o x, le a ve P C M d isco n -
necteci
• M e a su re re sista n ce b e tw e e n PCM sig n a l test
p in (51 o r 52) at th e b re a k o u t b o x a n d signal
p in a t s o le n o id b o d y c o n n e c to r.
• M e a s u re re sista n ce b e tw e e n P C M T est Pin
(3 7 /5 7 ) a t th e b re a k o u t b o x a n d VPW R p in at
s o le n o id b o d y c o n n e c to r.
• M e a s u re re sista n ce b e tw e e n . T est p in 4 0 /6 0
a t th e b re a k o u t b o x a n d G N D .
• Is e a c h re sista n ce less th a n 5 .0 oh m s?
A4 CHECK SOLENOID HARNESS FOR SHORTS Y es G o to A 5

TO POWER AND GROUND
• B re a k o u t b o x in stalled, P C M d is c o n n e c te d .
No S e rvice s h o rt circu it.
• REFER T O S C H E M A T IC A N D T A B L E .
R E C O N N E C T all c o m p o n e n ts .
• M e a s u re re sista n ce b e tw e e n P C M sig n a l test
p in (51 o r 52) a n d T est Pin (37 /5 7 ) at th e
b re a k o u t box.
• M e a s u re re sista n ce b e tw e e n T est p in s (40/60)
a n d (46) a t b re a k o u t b o x a n d ch a ssis g ro u n d .
• M e a s u re re siste n ce b e tw e e n PCM sig n a l test
p in (51 o r 52) a n d te st p in 4 0 /6 0 .
• M e a s u re re sista n ce b e tw e e n P C M sig n a l test
p in 3 7 /5 7 a n d 4 0 /6 0 .
• Is e a c h re sista n ce g re a te r th a n 1 0 ,0 0 0 o h m s?
A5 SOLENOID FUNCTIONAL TEST Yes G o to A 6

• E n s u re th a t th e h a rn e ss is d is c o n n e c te d at
th e tra n sm issio n .
No G o to A 7
• Install te ste r (49 U N 01 0 9 1 ) a t th e s o le n o id
b o d y c o n n e c te r.
• U s in g tests o u tlin e d u n d e r T este r In stru ctio n s,
P e rfo rm th e S O L E N O ID V O L T A G E test.
Note
• L E D w ill tu rn " G R E E N " w h e n s o le n o id a c ti
v a te s a n d tu rn " O F F ” w h e n d e a c tiv a te d
L E D w ill tu rn " R E D " if a c tiv a te d so le n o id is
s h o rte d to B A T + .
L E D w ill re m a in " O F F ” if an a c tiv a te d s o le
n o id is s h o rte d to g ro u n d o r n o co n tin u ity.
• D o e s th e s o le n o id s a ctiva te ? (LE D G R E E N )

A6 TRANSMISSION DRIVE TEST Yes E rase all c o d e s a n d p e rfo rm th e D rive C ycle.
• P e rfo rm th e D rive test. (R efer to p a g e K 2 - )
(R efer to p a g e K 2 - ) R e run O B D Tests.
• D o e s th e v e h ic le u p s h ift w h e n c o m m a n d e d
No G o to A 7
b y th e tester?
A7 CHECK RESISTANCE OF SOLENOID Yes G o to A 8
Note No R e p la ce S o le n o id B o d y asse m b ly.

• R e fe r to th e T ra n sm issio n T este r fo r te rm in a l
R e co rd a n d e ra se c o d e s , R e run O B D Tests.
lo ca tio n .
• B e n c h /D riv e sw itch in B E N C H m o d e .
• R ota te g e a r se le c to r sw itch to O H M S p o sitio n .
• C o n n e c t o h m m e te r n e g a tiv e le a d to th e SS1
ja c k a n d th e p o sitive le a d to VPW R ja c k on
tester.
T h is is to te s t S S 1 .
• R e c o rd resistance.
• C o n n e c t o h m m e te r n e g a tiv e le a d to th e SS2
ja c k a n d th e p o sitive le a d to VPW R ja c k on
tester.
T h is is to te s t SS2.
• A re all th e sh ift so le n o id s rsista n ce b e tw e e n
12 a n d 2 2 o h m s?
A8 CHECK SOLENOID FOR SHORT TO GROUND Y es R e p la ce S o le n o id B o d y a sse m b ly.

• C h e c k fo r c o n tin u ity b e tw e e n BAT- (e n g in e R e co rd a n d e ra se c o d e s , R erun O B D Tests.
g ro u n d ) a n d a p p ro p ria te ja c k w ith an o h m
No R efer to S ym p to n T ru b le sh o o tin g .
m e te r o r o th e r lo w c u rre n t te ste r (less th a n
2 0 0 m illia m ps).
S o le n o id T e ste r J a c k
551 SS 1A/PW R
552 SS 2A/PW R
• C o n n e c tio n s h o u ld s h o w in fin ite re sista n ce (no

c o n tin u ity ).
• Is th e re c o n tin u ity ?
46U0K2-503
K2—140
Pinpoint test B
DIAGNOSTIC TROUBLE CODE N0.636, 637, 638, 657

DESCRIP
• T ra n sm issio n W irin g H a rne ss, TFT, S IG N A L R E TU R N
TION
E n g in e : C o o lin g
E le ctrica l: B a tte ry, W irin g H a rn e ss
T ra n s m is s io n : In te rn a l T ra n sm issio n C o m p o n e n ts , C o o lin g , F luid

B1 LA4A-EL ELECTRONIC DIAGNOSTICS Y es G o to B2
• C h e c k th e s o ln o id b o d y c o n n e c to r is fu lly
se a te d , te rm in a ls a re fu lly e n g a g e d in th e
No P e rfo rm ch e cks.
Erase c o d e s R erun O B D Tests.
p re c e e d in g .
• H a ve th e ite m s b e e n c h e c k e d ?
B2 CHECK ELECTRICAL SIGNAL OPERATION Yes G o to B3

• K e y off.
No Refer to S e ctio n F3.
Caution N O VR E F V oltage.
• D is c o n n e c t s o ln o id b o d y c o n n e c to r.
• U s in g a m irro r, in s p e c t b o th e n d s o f th e c o n
rosion , lo o se w ires, a n d m issin g o r d a m a g e d
seals
• C o n n e c t V O M /D V O M p o s itiv e te s t le a d to TFT
c irc u it a n d n e g a tiv e te st le a d to SIG RTN c ir
c u it o f th e so le n o id b o d y c o n n e c to r.
• V O M /D V O M O N 20 V o lt scale.
• T u rn K e y O N . (e n g in e off).
• Is th e v o lta g e b e tw e e n 4.75 a n d 5.25 volts?
B3 CHECK CONTINUITY OF TFT AND SIG RTN Y es G o to B4

CIRCUITS
• K e y O FF.
• S o le n o id c o n n e c to r d is c o n n e c te d .
• D is c o n n e c t P o w e rtra in C o n tro l M o d u le (PC M ).
R e co n n e ct all c o m p o n e n ts .
E rase co d e s.
rosion , lo o se w ire s, etc. S e rvice as R e q d .
R e run O B D Tests.
• Install b re a k o u t b o x, le a ve P C M d is c o n n e c te d
• M e a s u re re sista n ce b e tw e e n PC M sig n a l test
p in (49) a t th e b re a k o u t b o x a n d sig n a l p in at
s o le n o id b o d y c o n n e c to r.
• M e a su re resista n ce b e tw e e n PCM signal test pin
(46) a t th e b re a k o u t b o x a n d sig n a l p in a t s o le
n o id b o d y tra n s m is s io n h a rn e ss c o n n e c to r.
• A re b o th re sista n ce s less th a n 5 .0 o h m s?
K2-141

B4 CHECK TFT CIRCUIT FOR SHORT TO VPWR Yes G o to B5
AND GROUND
• K e y off.
No S e rvice sh o rt circu it.
R e m o ve b re a k o u t box.
• D is c o n n e c t P C M , In s p e c t fo r d a m a g e d or
p u s h e d o u t pins, c o rro s io n , lo o se w ire s, etc.
E rase c o d e s R erun O B D Tests.
• Install b re a k o u t b o x, le a ve PCM d is c o n - ^
n e c te d
• M e a s u re re sista n ce b e tw e e n T FT T est p in 49
a n d P ins 3 7 /5 7 at b re a k o u t box.
• M e a s u re re sista n ce b e tw e e n T FT T est Pin 49
a n d P ins 4 0 /6 0 a n d 4 6 at b re a k o u t b o x.
• Is e a c h re s ista n ce g re a te r th a n 1 0 ,0 0 0 o h m s?
B5 CHECK RESISTANCE OF TFT SENSOR/ Yes G o to B6

HARNESS
No R e p la ce s o le n o id asse m b ly.
Note R e co rd a n d erase DTC.
• R e fe r to th e T ra n sm issio n T este r fo r T e rm i
R e p e a t O B D Tests.
nal L o c a tio n s.
• E n s u re th a t th e e m issio n h a rn e ss is d is c o n
n e cte d .
• Install te s te r to so le n o id b o d y c o n n e c to r.
• S et B e n c h /D riv e sw itch to B E N C H m o d e .
• R ota te G e a r se le c to r sw itch to O H M S C h e c k
p o sitio n .
• C o n n e c t o h m m e te r n e g a tiv e le a d to - T F T
ja c k a n d p o s itiv e le a d to + T F T ja c k no tester.
• P e rfo rm T es ts 1 a n d 2.
Note
• W h ile p e rfo rm in g T ests 1 a n d 2 o b s e rv e
resista n ce s.
C o d e 5 6 /6 3 7 is se t if re sista n ce v a lu e e x
c e e d s 8 6 9 K o h m s (O P E N circuit).
C o d e 6 6 /6 3 8 is set if re sista n ce va lu e falls
b e lo w 5 9 7 o h m s (S h o rt circu it).
TEST 1
• R e c o rd resista n ce .
• R e sista n ce s h o u ld b e a p p ro x im a te ly in th e fo l
lo w in g ran g e s:
T ra n sm issio n F luid T e m p e ra tu re
c F R esistance
0—20 3 2 — 58 100K— 37K
2 1 — 40 5 9 -1 0 4 3 7 K — 16K
4 1 — 70 1 0 5 -1 5 8 1 6 K -5 K
7 1 — 90 1 5 9 -1 9 4 5 K -2 .7 K
9 1 -1 1 0 1 9 5 -2 3 0 2 .7 K -1 .5 K
11 1 — 130 2 3 1 -2 6 6 1 .5 K -0 .8 K
TEST 2
• C h e c k fo r in te rm itte n t s h o rt o r op e n.
• If resistance was between 0 .8 K and 1 0 0 K
o h m s, p e rfo rm th e fo llo w in g test. If tra n s m is
s io n is c o ld , run tra n sm issio n to w a rm it u p . If
tra n s m is s io n is w a rm , a llo w tra n sm issio n to
c o o l. C k e c k TFT s e n so r re sista n ce a g a in .
C o m p a rt re sista n ce w ith in te rn a l resistance.
R e sista n ce s h o u ld d e c re a s e if tra n sm issio n
w a s w a rm e d a n d s h o u ld in cre a se if tra n s m is
sio n w a s a llo w e d to co o l. If c rre c t c h a n g e in
re s ista n ce o c c u r, re p e a t O B D Tests.
• Is th e re sista n ce w ith in ra n g e ?
B6 CHECK TFT SENSOR FOR SHORT TO Yes R e p la ce so le n o id asse m b ly.
GROUND R e p e a t O B D Test.
• C h e c k fo r c o n tin u ity b e tw e e n - B A T (e n g in e
No R erun O B D Test.
g ro u n d a n d a p p ro p ria te ja c k (-T F T a n d
If DTC a re p re se n t a n d o v e rte m p c o n d itio n e xiste d d e
+ T F T ) a p p ro p ria te w ire w ith o h m m e te r or te rm in e .
o th e r lo w c u rre n t te ste r (less th a n 2 0 0 m il-
If flu id is b u rn t, te a rd o w n u n it a n d re p a ir as re q u ire d .
lia m p s). R e run O B D Test.
co n tin u ity).
• Is th e re co n tin u ity ?
Pinpoint test C
DIAGNOSTIC TROUBLE CODE N0.628, 652

riF<;rR iP- T h is P in p o in t T est is in te n d e d to d ia g n o s e th e fo llo w in g co m p o n e n ts :
T (0N " • T ra n s m issio n W irin g H a rne ss, T C C , VPW R
• P o w e rtra in C o n tro l M o d u le (P C M )
E n g in e : P e rfo rm a n c e , C o o lin g
E le c tric a l: B a tte ry, In p u t S ensors, W irin g H a rne sse s, B ra ke S w itch
T ra n s m is s io n : In te rn a l T ra n sm issio n C o m p o n e n ts , L in ka g e , C o o lin g

C1 ELECTRONIC DIAGNOSTICS Y es R E M A IN in O u tp u t S tate
• C h e c k th e s o le n o id b o d y c o n n e c to r is fu lly G o to C 2
se a te d , te rm in a ls a re fu lly e n g a g e d in th e
No D e p re ss th o ttle a n d Release.
p re c e e d in g .
DID
If v e h ic le N O T E N T E R O u tp u t S ta te (DTM).
R efer to S e ctio n F3.
• E n te r O u tp u t S tate D ia g n o s tic T est M o d e
(D TM ). R efer to S p e cia l T est M o d e s in se ctio n
F3.
• C o n n e c t S u p e r STAR H tester.
• P e rfo rm K O E O TEST until C o n tin u o u s M e m o
ry D TC h a v e b e e n d is p la y e d .
• D e p re s s th ro ttle to W O T a n d Release.
• D o e s v e h ic le e n te r O u tp u t State?
C2 CHECK ELECTRICAL SIGNAL OPERATION Yes G o to C 5
Caution No G o to C 3
• D is c o n n e c t so ln o id b o d y D T M c o n n e c to r.
• U s in g a m irro r, in s p e c t b o th e n d s of th e c o n
rosion , lo o s e w ire s, a n d m issin g o r d a m a g e d
s e a is
• C o n n e c t V O M /D V O M p o sitive te st le a d to
VP W R c irc u it a n d n e g a tiv e te st le a d to s o le
n o id c irc u it o f th e so le n o id b o d y c o n n e c to r.
• V O M /D V O M O N 2 0 V o lt scale.
• W h ile o b s e rv in g D V O M , d e p re s s a n d release
th ro ttle to c y c le so le n o id o u tp u t O N a n d OFF.
• D o e s th e s u s p e c te d so le n o id o u tp u t v o lta g e
c h a n g e a t le a st 0 .5 volt?
C3 CHECK CONTINUITY OF SOLENOID SIGNAL Yes G o to C4
AND VPWR HARNESS CIRCUITS
• K e y O FF .
R em ove b re a k o u t b o x.
R ER U N O B D Tests.
ro s io n , lo o s e w ire s, etc. S e rv ic e as R e q d .
• Install b re a k o u t b o x , le a v e P C M d is c o n -
n e c te d
• R E F E R T O S C H E M A T IC A N D T A B L E .
• M e a s u re re s is ta n c e b e tw e e n P C M sig n a l p in
(53 ) a t th e b re a k o u t b o x a n d s ig n a l te s t p in at
s o le n o id b o d y c o n n e c to r
• M e a s u re re s is ta n c e b e tw e e n P C M te s t pin
(3 7 /5 7 ) a t th e b re a k o u t b o x a n d VP W R p in at
tra n s m is s io n h a rn e s s c o n n e c to r
• Is e a c h re sista n ce le ss th a n 5 .0 o h m s?
C4 CHECK SOLENOID HARNESS FOR SHORTS Yes G o to C 5

TO POWER AND GROUND
• K e y O FF.
No S ervice sh o rt circu it.
• B re a k o u t b o x in sta lle d , P C M d is c o n n e c te d .
R e m ove b re a k o u t b o x.
• S o ln o id b o d y c o n n e c to r d is c o n n e c te d .
• R E F E R T O S C H E M A T IC A N D T A B L E
RER U N O B D Tests.
• M e a s u re re s is ta n c e b e tw e e n P C M s ig n a l test
p in (5 3 ) a n d T est Pin (3 7 /5 7 ) a t th e b re a k o u t
box.
• M e a s u re re sista n ce b e tw e e n P C M T est p in s
(4 0 /6 0 ) a n d 4 6 a t b re a k o u t b o x a n d ch a ssis
g ro u n d
C5 SOLENOID FUNCTIONAL TEST Yes G o to C6

• E m is s io n h a rn e ss d is c o n n e c te d a t tra n s
m issio n .
No G o to C7
• Install S u p e r ST A R I I te s te r a t th e s o le n o id
b o d y c o n n e c te r.
• U s in g te sts o u tlin e d u n d e r T e s te r In stru ctio n s
P e rfo rm th e S O L E N O ID V O L T A G E test.
Note
• L E D w ill tu rn “ G R E E N " w h e n s o le n o id a c ti
v a te s a n d tu rn “ O F F ” w h e n d e a c tiv a te d .
L E D w ill tu rn “ R E D ” if a c tiv a te d s o le n o id is
s h o rte d to B A T + .
• L E D w ill re m a in " O F F ” if a n a c tiv a te d so le

n o id is s h o rte d to g ro u n d o r n o c o n tin u ity .
• D o e s th e s o le n o id a c tiv a te ? (L E D G R E E N )
(1994 626/MX-6)
K 2-145

C6 TRANSMISSION DRIVE TEST Yes Erase all c o d e s a n d p e rfo rm th e D rive C y c le as o u tlin e d
• P e rfo rm th e D riv e te s t as o u tlin e d in T ra n s in th is m an u a l.
m is s io n T este r m a n u a l. R e run O B D Tests.
• D o e s th e T C C a c tiv e w h e n c o m m a n d e d b y
No G o to C 7
th e tester?
• D o e s th e e n g in e R P M d ro p ?
C7 CHECK RESISTANCE OF SOLENOID Yes G o to C 8
Note
No R e p la ce so le n o id b o d y a sse m b ly.
• R e fe r to th e T ra n s m is s io n T este r fo r te rm in a l
lo ca tio n .
• S et B e n c h /D riv e s w itc h to B e n ch m o d e .
• R o ta te g e a r s e le ct s w itc h to O h m s C h e c k p o
sitio n .
• Connect ohmmeter negative lead to TCC jack
a n d p o s itiv e le a d to V P W R ja c k o n tester.
• Is re s is ta n c e b e tw e e n 1 .0 — 2 .0 o h m s?
C8 CHECK SOLENOID FOR SHORT TO GROUND Yes R e p la ce s o le n o id b o d y a sse m b ly.

• C h e c k fo r c o n tin u ity b e tw e e n BAT- (e n g in e
g ro u n d ) a n d a p p ro p ria te ja c k w ith a n d o h m
No R e fe r S y m p to m T ro u b le s h o o tin g to d ia g n o s e to rq u e c o n
v e rte r c lu tc h d ia g n o sis.
S o le n o id T e s te r J a c k
TCC TCC
VP W R VP W R

c o n tin u ity ).
Revised 3/99
Pinpoint test D
DIAGNOSTIC TROUBLE CODE NO.522, 634, 659, 667, 668, 675

T h is P in p o in t T e st is in te n d e d to d ia g n o s e th e fo llo w in g c o m p o n e n ts :
DESCRIP • T ra n s m is s io n W irin g H a rn e ss, M L P , s ig n a l R eturn
TION • P o w e rtra in C o n tro l M o d u le (PC M )
• S ta rte r C ircu its, B a c k u p C ircu its
E n g in e : S tarter, S ta rte r R e la y
E le ctrica l: B attery, Ig n itio n S w itch , W irin g H a rne ss
T ra n s m is s io n : In te rn a l T ra n sm issio n C o m p o n e n ts , L in k a g e

D1 LA4A-EL ELECTRONIC DIAGNOSTICS Yes R e m o v e to o ls
G o to D2
Note No A d ju s t s e n s o r as o u tlin e d u n d e r T ra n sm issio n A ssy.
• C o d e 6 3 4 m a y a lso b e se t b y ru n n in g O n-
A fte r a d ju s tm e n ts p la c e se le c to r le ve r in P ran g e .
B o a rd D ia g n o s tic s w ith th e tra n s m is s io n N o t
C le a r D TC c o d e s a n d R e run O n -B o a rd D ia g n o s tic Tests.
in P a rk o r th e A .C . is O N . M a k e s u re O n-
B o a rd D ia g n o s tic is p e rfo rm e d p ro p e rly .
• C h e c k th e TR s e n s o r c o n n e c to r is fu lly se a t
e d , te rm in a ls a re fu lly e n g a g e d in th e c o n n e c
to r a n d in g o o d c o n d itio n b e fo re p re c e e d in g .
• V E R IFY S H IF T L IN K A G E A D J U S T M E N T in D
ra n g e .
• K e y off.
• A p p ly p a rk in g b ra ke .
• P la c e tra n s m is s io n in N range.
• V e rify th a t TR S e n s o r A lig n m e n t T oo l or
e q u iv a le n t fits in th e a p p ro p ria te slots.
• Is TR S e n so r p ro p e r a d ju ste d ?
D2 CHECK ELECTRICAL SIGNAL OPERATION Yes G o to D3

• T u rn ke y O FF .
• D is c o n n e c t s o le n o id b o d y c o n n e c to r. R e fe r to S e ctio n F3 fo r d ia g n o s is o f N o
No
R e fe re n c e vo la te g e .
Caution
• Do no pry on connector. Pull up on
solenoid body connector.
• U s in g a m irro r, in s p e c t both e n d o f th e c o n
n e c to r fo r d a m a g e d o r p u s h e d p u t p in s, c o r
rosion , lo o se w ire s a n d m issin g o r d a m a g e d
seals.
Note
• R e fe r to th e s c h e m a tic a n d ch a rt.
• C o n n e c t a V O M p o sitive test le a d to T F T c ir
c u it a n d n e g a tiv e te s t le a d to s ig n a l re tu rn
(SIG R TN ) c irc u it o f s o le n o id b o d y c o n n e c to r.
• P la c e V O M o n 2 0 v o lt scle.
• T u rn ke y O N , E n g in e OFF.
• IS v o lta g e b e tw e e n 4 .7 5 a n d 5 .2 5 vo lts?
(1994 626/MX-6 revised 3/99) K 2-147


D3 CHECK CONTINUITY OF TR SENSOR HAR Yes G o to D 4
NESS CIRCUITS
• K e y O FF.
No S e rv ic e o p e n c ir c u its ).
• D is c o n n e c t TR s e n s o r c o n n e c to r.
R e m o ve b re a k o u t b o x.
R e c o n n e c t all c o m p o n e n ts .
ro s io n , lo o s e w ire s , etc.
E ra se c o d e s.
ro s io n , lo o se w ire s, etc. S e rv ic e as R eqd.
• Install b re a k o u t b o x , le a ve P C M d isco n -
n e c te d
• R EFER T O S C H E M A T IC S A N D T A B L E .
• M e a s u re re s is ta n c e b e tw e e n P C M T est Pin
(46 ) a t th e b re a k o u t b o x a n d S IG RTN c irc u it
a t th e TR s e n s o r c o n n e c to r
(30 ) at th e b re a k o u t b o x a n d TR sig n a l c irc u it
a t th e TR s e n s o r c o n n e c to r
• Is e a c h re s is ta n c e less th a n 5 .0 o h m s?
D4 CHECK TR SENSOR CIRCUIT FOR SHORTS Y es G o to D5

TO POWER AND GROUND
• K e y O FF.
No S e rv ic e s h o rt circ u it.
R e m o ve b re a k o u t b o x.
• TR s e n o s r h a rn e s s c o n n e c to r d is c o n n e c te d .
R E C O N N E C T all co m p o n e n ts .
E ra se co d e s.
R E R U N O B D T ests.
(30 ) a n d P C M T e s t Pin (3 7 /5 7 ), (40 /6 0 ), a n d
(46) at th e b re a k o u t b o x
(30 ) a t th e b re a k o u t b o x a n d ch a s s is g ro u n d
• Is e a c h re s is ta n c e g re a te r th a n 1 0 ,0 0 0 o h m s?
D5 CHECK OPERATION OF TR SENSOR Y es R e p la c e PC M .

• E n s u re th a t th e TR s e n s o r c o n n e c to r is d is R e ru n O B D Tests.
c o n n e c te d a t tra n sm issio n .
No R e p la ce TR se n so r.
• Install TR o v e rla y o n th e tra n s m is s io n te ste r
R e a d ju st TR se n so r.
• C o n n e c t TR T e st H a rn e ss to TR S e n so r
R e c o rd a n d e ra s e c o d e s , reru n O B D Tests.
• U s in g p ro c e d u re s o n te ste r V e rify se n so r
fu n c tio n s in all p o sitio n s
— C h e c k c o n tin u ity a n d re s is ta n c e s in all p o
sitions. T h is in c lu d e s th e s ta rt c irc u its a n d
b a c k u p c irc u its
Note
• T h is s e n s o r a ls o c o n ta in s c o n ta c ts fo r g e a r
p o s itio n in d ic a tio n fo r th e in s tru m e n t pa n el
• Is th e TR s e n s o r O K ?
R e sista n ce
S e le c to r L e ve r (oh m s)
P osition
m in m ax
P 3770 4607
R 1304 1 593
N 660 807
D 361 442
2 190 232
1 78 95
46U0K2-506
K 2 -1 4 8
Pinpoint test E
DIAGNOSTIC TROUBLE CODE NO. 624, 625

T h is P in p o in t T est in te n d e d to d ia g n o s e th e fo llo w in g co m p o n e n ts :
DESCRIP
• T ra n sm issio n W irin g H a rne ss, EPC, EP C PW R
TION
E n g in e : P e rfo rm a n c e
E le ctrica l: B a tte ry, In p u t S ensors, W irin g H a rne ss
T ra n s m is s io n : In te rn a l T ra n sm issio n C o m p o rn e n ts , C o o lin g
E1 LA4A-EL ELECTRONIC DIAGNOSTICS Y es G o to E2
CHECK VPWR TO SOLENOID
• C h e c k th e tra n s m is s io n h a rn e ss c o n n e c to r is
No S e rvice o p e n in harness.
fu lly se a te d , te rm in a ls a re fu lly e n g a g e d in th e
ERASE C O D ES .
p re c e e d in g .
• K e y off.
• D is c o n n e c t s o le n o id b o d y c o n n e c to r.
• K e y o n , e n g in e off.
• M e a s u re th e v o lta g e b e tw e e n EPC PW R c ir
c u it a t s o le n o id b o d y c o n n e c to r a n d c h a s
s is /b a tte ry g ro u n d .
• Is v o lta g e g re a te r th a n 1 0 .5 volts?
E2 CHECK CONTINUITY OF SOLENOID SIGNAL

AND VPWR HARNESS CIRCUIT Y es G o to E3
• K e y off.
No S e rvice o p e n circu it.
ro sio n , lo o se w ire s, etc.
• Install b re a k o u t b o x, le a ve P C M d is c o n
ERASE C o d e s.
n e c te d .
(3 7 /5 7 ) at b re a k o u t b o x a n d EP C PW R c irc u it
a t th e so le n o id b o d y c o n n e c to r.
(38) a t th e b re a k o u t b o x a n d EPC s o le n o id
s ig n a l p in a t th e so le n o id b o d y c o n n e c to r.
• Is e a c h re sista n ce less th a n 5 .0 o h m s?
K2—149

E3 CHECK HARNESS FOR SHORT TO POWER Yes G o to E4
OR GROUND
• K e y off.
No S e rvice sh o rt circu it.
• B re a k o u t b o x insta lle d , P C M d is c o n n e c te d .
R E R U N O B D Tests
• M e a s u re re sista n ce b e tw e e n E P C s o le n o id
c irc u it te s t p in (38) a n d te st pin (3 7 /5 7 ) a t th e
b re a k o u t b o x.
• M e a s u re re sista n ce b e tw e e n E P C so le n o id
c irc u it te st p in (38) a n d te s t p in s (40 /6 0 ), (46)
a t th e b re a k o u t box.
• M e a s u re re sista n ce b e tw e e n T est p in (37/57)
a n d te s t p in s (40/60).
• Is e a c h re s ista n ce g ra te r th a n 1 0 ,0 0 0 o h m s?
E4 TRANSMISSION FUNCTIONAL TEST Yes R e p la ce PCM .

• S o le n o id b o d y c o n n e c to r d is c o n n e c te d . R E R U N O B D Tests.
• Install T ra n s m issio n T ester.
No G o to E5
• S et B e n c h /D riv e sw itch to D rive m o d e .
• R otate G e a r se le c to r sw itch to 1 st G e a r p o
sition.
• U s in g te s ts o u tlin e d in th e m a n u a l p e rfo rm
th e E P C fu n c tio n test.
• D o e s th e EPC (LE D G R E E N ) a c tiv e w h e n the
EPC s w itc h is d e p re s s e d ?
• O b s e rv e lin e p re s s u re on th e g a u g e w h ile
d e p re s s in g th e EP C sw itch .
(V E H IC L E M U S T BE R U N N IN G )
• D o e s th e line p re s s u re d ro p ?
E5 CHECK RESISTANCE OF SOLENOID Yes G o to E6
Note No R e p la ce s o le n o id b o d y asse m b ly.

• Be s u re th a t te ste r p o w e r is O F F o r d a m a g e
R e co rd a n d e ra se co d e s.
to o h m m e te r m a y result. R e run O B D tests.
• C o n n e c t o h m m e te r n e g a tiv e le a d to VPW R
ja c k a n d p o sitive le a d to EPC ja c k on tester.
T h is is to te st EPC so le n o id .
• Is th e re s is ta n ce b e tw e e n 3 .7 5 — 5 .9 2 o h m s?
E6 CHECK SOLENOID FOR SHORT TO GROUND Yes R e p la ce S o le n o id B o d y A sse m b ly.

• C h e c k fo r c o n tin u ity b e tw e e n BA T- (e n g in e R e co rd a n d e ra se c o d e s, re p e a t O B D Tests.
No R efer to Q U IC K D IA G N O S IS C H A R T to d ia g n o s e EPC
c o n c e rn s u n d e r E n g a g e m e n t a n d /o r Shift d ia g n o sis.
S o le n o id T e ste r ja c k
EP C EPC
VPW R
• C o n n e c tio n s h o u ld s h o w in finite re sista n ce (no

co n tin u ity ).
46U0K2-507
K 2-150
Pinpoint test F
DIAGNOSTIC TROUBLE CODE N0.639

T his P in p o in t T est is in te n d e d to d ia g n o s e th e fo llo w in g co m p o n e n ts :
DESCRIP
• T ra n sm issio n W irin g H a rne ss, TSS, S IG N A L R E TU R N
TION
E le ctrica l: B attery, In p u t S ensors, W irin g H a rne ss
T ra n s m is s io n : In te rn a l T ra n sm issio n C o m p o n e n ts
F1 ELECTRONIC DIAGNOSTICS Yes G o to F2
• C h e c k th e tu rb in e sh a ft s p e e d s e n so r c o n n e c
to r is fu lly se a te d , te rm in a l a re fu lly e n g a g e d
No P e rfo rm th e ch e cks.
in th e c o n n e c to r a n d in g o o d c o n d itio n b e fo re
E rase co d e s.
p ro c e e d in g .
R erun O B D Tests.
• H a v e th e ite m s a b o v e b e e n c h e c k e d ?
F2 CHECK CONTINUITY OF TSS HARNESS Yes G o to F3

CIRCUIT
• K e y O FF.
• D is c o n n e c t TSS.
Caution R e run O B D Tests.
• Do not Pry on Connector.
Pull up on Harness.

rosion , lo o se w ire s, etc.
• Install b re a k o u t b o x, le a ve P C M d is c o n
n e c te d .
• R EFER T O S C H E M A T IC S A N D TA B LE S .
• M e a su re re sista n ce b e tw e e n P C M T est p in (5)
a t th e b re a k o u t b o x a n d th e TSS ( + ) c irc u it
a t th e TSS c o n n e c to r.
• M e a su re re sista n ce b e tw e e n P C M T est pin
(46) at th e b re a k o u t b o x a n d th e TSS ( - ) c ir
c u it a t th e TSS c o n n e c to r.
• Is e a ch re sista n ce less th a n 5 .0 oh m s?
F3 CHECK TSS CIRCUIT FOR SHORT TO Y es G o to F4

POWER AND GROUND
• K e y off.
• TSS d is c o n n e c te d .
• M e a s u re re sista n ce b e tw e e n PC M T est p in s
(5), (46) a n d T e st p in s (3 7 /5 7 ) a t b re a k o u t
b o x.
• M e a s u re re sista n ce b e tw e e n P C M T est p in s
(5), (46), (3 7 /5 7 ) a n d T est p in s (40 /6 0 ) at
b re a k o u t b o x.
• M e a s u re re sista n ce b e tw e e n P C M T est pin s
(5), (4 0 /6 0 ) a n d T est p in (46) at b re a k o u t box.
K2-151

F4 TURBINE SHAFT SPEED SENSOR Yes R e p la ce PCM .
FUNCTIONAL TEST
• D is c o n n e c t v e h ic le h a rn e ss at TSS sensor.
No G o to F5
Caution
• Do not Attempt to PRY on Connector.
Pull on harness.
• Install tra n s m is s io n te ste r o n to TSS sensor.

• C o n n e c t v o ltm e te r p o sitive le a d to ( + ) TSS
a n d n e g a tiv e le a d to ( - ) TSS ja c k s S et vo lt
m e te r to 2 0 vo lts AC .
• P e rfo rm d riv e c y c le test. M o n ito r vo ltm e te r.
• D o e s th e v o lta g e in c re a s e w ith an in c re a s e in
v e h ic le s p e e d ?
F5 CHECK RESISTANCE OF TURBINE SHAFT Y es G o to F6

SPEED SENSOR
Note
No R e p la ceTSS sensor.
• R e fe r to th e L A 4 A -E L T ra n sm issio n T ester
R e run TSS fu n c tio n a l test.
fo r T e rm in a l L o c a tio n s
• C o n n e c t o h m m e te r n e g a tiv e le a d to + T S S
ja c k a n d p o s itiv e le a d to - T S S ja c k o n te ste r
T h is is to te s t TSS sensor.
• Is th e re s is ta n ce b e tw e e n 1 4 0 — 2 9 0 o h m s?
F6 CHECK SENSOR FOR SHORT TO GROUND Yes R e p la ce TSS sensor.

• C h e c k fo r c o n tin u ity b e tw e e n B A T - (e n g in e R e run fu n c tio n test.
No G o to F7
S o le n o id T e ste r ja c k
TSS +TSS
-T S S

c o n tin u ity ).
• Is th e r c o n tin u ity ?
F7 CHECK TSS MAGNETISM Yes G o to F8

• R e m o v e TSS fro m tra n sm issio n .
• P la c e TSS a g a in s t a m eta l su rfa c e to w h ic h a
No R e p la ce TSS sensor.
m a g n e t w o u ld stick. T h e TSS s h o u ld be
R e run fu n c tio n a l test.
m a g n e tiz e d a n d s tic k to th e m eta l su rfa ce .
• D o e s th e TSS stick?
K2—152
F8 CHECK EXCITER WHEEL Yes R e p la ce TSS sensor.
• Remove Turbine shaft Speed Sensor. R erun fu n c tio n a l test.
• With a remote starter, start and stop until a No S e rvice o r re p la ce as re q u ire d .
tooth of the exciter wheel is visible through T he n re ru n fu n c tio n test.
the TSS hole.
Continue until all 4 teeth have been visibly in
spected.
• Were all teeth Present?
46U0K2-508
Pinpoint test G

DESCRIP
• T ra n s m issio n W irin g H a rne ss, 3 -2T /C C S , VPW R
TION
• P o w e rtra in C o n tro l M o d u le (P C M )
E n g in e : P e rfo rm a n c e
E le c tric a l: B a tte ry, In p u t S ensors, W irin g H a rn e ss
T ra n s m is s io n : In te rn a l T ra n sm issio n C o m p o n e n ts
G1 ELECTRONIC DIAGNOSTICS CHECK VPWR Y es G o to G 2
TO SOLENOID
• C h e c k th e so le n o id b o d y c o n n e c to r is fu lly
No S e rvice o p e n in harness.
s e a te d , te rm in a ls a re fu lly e n g a g e d in th e
E R A C E C O D ES .
p re c e e d in g .
R E R U R N O B D Tests.
• K e y off.
• D is c o n n e c t so le n o id b o d y c o n n e c to r.
• K e y o n , e n g in e off.
• M e a s u re th e v o lta g e b e tw e e n S O L PW R c ir
c u it at s o le n o id b o d y c o n n e c to r a n d c h a s
s is /b a tte ry g ro u n d .
• Is v o lta g e g re a te r th a n 1 0 .5 volts?
G2 CHECK CONTINUITY OF SOLENOID SIGNAL Yes G o to G 3

AND VPWR HARNESS CIRCUIT
• K e y off.
In s p e c t fo r d a m a g e d o r p u s h e d o u t pins, c o r R E C O N N E C T all c o m p o n e n ts .
rosion , lo o se w ire s, etc. ER ASE co d e s.
• Install b re a k o u t b o x, le a ve P C M d isco n -
R erun O B D Tests.
n e c te d
(3 7 /5 7 ) at b re a k o u t b o x a n d S O L PW R c irc u it
a t th e s o le n o id b o d y c o n n e c to r.
(55) a t th e b re a k o u t b o x a n d 3 -2 T /C C S so le
n o id s ig n a l p in at th e s o le n o id b o d y c o n
n e cto r.
• Is e a c h re s ista n ce less th a n 5 .0 o h m s?
G3 CHECK HARNESS FOR SHORT TO POWER Yes G o to G 4
OR GROUND
• K e y off.
R e m ove b re a ko u t box.
R E C O N N E C T all co m p o n e ts .
Caution
• M e a s u re re sista n ce b e tw e e n 3 -2 T /C C S so le
n o id c irc u it te st p in (55) a n d te st p in (37 /5 7 )
a t th e b re a k o u t b o x.
• M e a s u re re sista n ce b e tw e e n 3 -2 T /C C S so le
n o id c irc u it te s t p in (55) a n d te s t p in s (40/60),
(46) at th e b re a k o u t box.
• M e a s u re re sista n ce b e tw e e n T est pin (3 7 /5 7 )
a n d (4 0 /6 0 ) a t th e b re a k o u t box.
• Is e a ch re sista n ce g re a te r th a n 1 0 ,0 0 0 o h m s?
G4 TRANSMISSION FUNCTIONAL TEST Yes R E P LA C E PC M .

• S o le n o id b o d y c o n n e c to r d is c o n n e c te d . R E R U N O B D Tests.
• Install T ra n sm issio n Tester.
No G o to G 5
• S et B e n c h /D riv e sw itch to D rive m o d e .
• R ota te G e a r se le c to r sw itch to 1 st G e a r p o
sition.
• D o e s th e 3 -2 T /C C S (LE D G R E E N ) d e a c tiv a te
w h e n th e 3 -2 T /C C S sw itch is d e p re s s e d ?
• W h e n th e 3 -2 T /C C S sw itch is re le a se d d o e s
e n g in e b ra k in g o c c u r a n d th e 3 -2 T /C C S e n
g a g e (LE D O FF)?
G5 CHECK RESISTANCE OF SOLENOID Yes G o to G 6
Note No R e p la ce S o le n o id B o d y A sse m b ly.

• Be s u re th a t te ste r p o w e r is O F F or d a m a g e
R e co rd a n d e ra se co d e s.
to o h m m e te r m a y result.
• C o n n e c t o h m m e te r n e g a tive le a d to VPW R
ja c k a n d p o s itiv e le a d to 3 -2 T /C C S ja c k on
tester.
T his is to te st 3 -2 T /C C S s o le n o id .
• Is th e re sista n ce b e tw e e n 3 .7 5 — 5 .9 2 o h m s?
K 2-155

G6 CHECK SOLENOID FOR SHORT TO GROUND Yes R e p la ce so le n o id B o d y A sse m b ly.
• C h e c k fo r c o n tin u ity b e tw e e n B A T - (e n g in e R e c o rd a n d e ra se c o d e s , re p e a t O B D Tests.
g ro u n d ) a n d a p p ro p ria te ja c k w ith a n d o h m
No R efer to Q U IC K D IA G N O S IS C H A R T to d ia g n o se .
3 -2 T /C C S c o n c e rn s u n d e r S H IF T d ia g n o s is
2 0 0 m illia m p s ).
S o le n o id T e s te r J a c k
3 -2 T /C C S 3 -2 T /C C S
VP W R

c o n tin u ity ).
46U0K2-509
K 2-156
Connector
Solenoid body connector
TR sensor connector
R RANGE SWITCH (BACKUP LIGHT) START CIRCUIT

SENSOR SIGNAL RETURN—PCM
D RANGE SWITCH TEST PIN 46
JOINT BOX
L /0 Y /B BR G 0 Y/G
\
/ -A - \ \
P RANGE SWITCH
L RANGE SWITCH
TR SENSOR SIGNAL—PCM TEST PIN 30
S RANGE SWITCH START CIRCUIT
N RANGE SWITCH
46U0K2-511
K 2-157
K2 SERVICE POINTS
SERVICE POINTS
OUTLINE
Transmission Range (TR) Sensor
• If a malfunction occurs in the wiring of the TR or TR sensor, the powertrain control module (PCME) cannot
determine the range position, and shifting may be abnormal in D, S, and L ranges. There may not be
a shift to fourth gear, and all shifts will be firm.
Transaxle Fluid Temperature (TFT) Sensor

• If a malfunction occurs in the TFT sensor, the problem will be the torque converter clutch operation and
EPC pressure control.
Stoplight Switch
• If the stoplight switch is always ON, the torque converter clutch will not engage at less the 1/3 throttle.
• If the stoplight switch is always OFF, the torque converter clutch will not disengage when brake is applied.
Turbine Shaft Speed Sensor (TSS)

• If a malfunction occurs in the TSS, the torque converter clutch will not engage, and shifting may be harsh.
There may not be a shift to fourth gear and engine braking operate in 2nd and third gear.
Vehicle Speedometer Sensor (VSS)

• If a malfunction occurs in the VSS, shifting may be abnormal, the torque converter will not engage.
There may not be all shift to fourth gear.
Electronic Pressure Control (EPC) Solenoid

• If the EPC is always ON, the line pressure will be high but not maximum.
• If the EPC is always OFF, the line pressure will be maximum and harsh engagements or harsh shift.
Shift Solenoid No.1 and No.2 (SS1, SS2)

• If a malfunction occurs in the SS1 or SS2, shifting may be abnormal.
3-2 Timing/Coasting Clutch Solenoid (3-2T/CCS)

• If the 3-2T/CCS is always ON, the engine braking will not operate (except in fourth gear) and will delay
3-2, 4-2 downshifts.
• If the 3-2T/CCS is always OFF, the engine braking will operate in 2nd/third gear (D range) and firm or
flaire 3-2 downshifts.
Torque Converter Clutch (TCC) Solenoid

• If the TCC is always ON, the torque converter clutch will not disengage.
• If the TCC is always OFF, the torque converter clutch will not engage.
Engine Coolant Temperature (ECT) Sensor

• If a malfunction occurs in the ECT, the TCC will always be OFF.
Distributor Ignition (Dl) System

• If a malfunction occurs in the El, the torque converter clutch will not engage, and shifting may be abnormal.
Magnetic Clutch
• If the magnetic clutch is always ON, line pressure slightly low with A/C OFF.
• If the magnetic clutch is always OFF, line pressure slightly high with A/C ON.
Mass Air Flow Sensor (MAF)

• If a malfunction occurs in the MAF, shifting and torque converter clutch operation will be abnormal.
Throttle Position Sensor (TP)

• If a malfunction occurs in the TP, shifting and torque converter clutch operation will be abnormal.
46U0K2-255
K 2-158
wirsmq
B - lb FS ATX ■EC-AT CONTROL SYSTEM ■ENGINE CONTROL SYSTEM
MAIN FUSE BLOCK
MAIN IG KEY
IDLE AIR
diagram
CONTROL FRO EGR
SOLENOID SOLENOID SOLENOID
VALVE VALVE VALVE
R/B L/W R/B GY/R

ESL,
R/B W/L
BjL.
R/B V/R
(E) (E) (0 (?) E ) (E) (E) (E)
j ’
rxMoi |X-09i
LG/R GY/R W/L
fcBl-Ol

(7)
?B1-01
?
SOLENOID
B l-2 1 BODY
INTAKE AIR (SECTION B -lc )
[TEMPERATURE > COOLANT
[s ensor X\TEMPERATURE
B l-2 1 -31-22
2C 1A TRANSMISSION
-B/P (EM) — ^ 1 3 ) RANGE SENSOR
IX-221 * (SECTION B -lc )
DATA LINK
'14) CONNECTOR
(SECTION B -ld )
^<8>
B l-O l POWERTRAIN CONTROL MODULE(EM) B l-1 3 PURGE SOLENOID B l-1 4 PRC SOLENOID B l-1 5 IDLE AIR CONTROL
VALVE (E) VALVE (E) SOLENOID VALVE (E)
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 W/B R/B L/W R/B ( GY/r | R/B )

* * * L B * Y/B L /0 V/R W/B G/0 B/L GY/R 0/G R/B W Y/R GY/L W/G L/R
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
B/G L GY R/B G R/Y BR/Y W/L LG/R L/G O 0 L/B L/Y R/G G/L Y/G R V LG GY/R B l-1 6 EGR SOLENOID B l-1 7 EGR SOLENOID B l-1 8 HEATED OXYGEN
60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 VALVE (E) VALVE (E) SENSOR (EM)
B/Y L/W R/W R/B W Bfl/W G/W GY/B G/R P P/B BR/L LG/W P/L B/P * Y LG/B GY/G BR/B
/V---- ----
L Y
( V/R R/B ) W/L R/B
B/G LG/B
K 2 -1 5 9
B l-1 9 THROTTLE POSITION SENSOR (EM) B l-2 0 EGR FUNCTION SENSOR (EM) B l-2 1 INTAKE AIR TEMPERATURE SENSOR(EM) B l-2 2 ENGINE COOLANT TEMPERATURE SENSOR(EM)
46U0K2-513
ES i
B/P P/L G/L R/G G/L B/P
V B/P I)
* B - lc FS ATX .-EC-AT CONTROL SYSTEM ■ENGINE CONTROL SYSTEM
ro
BATTER MAIN FUSE BLOCK w ^ POWERTRAIN
MAIN IG KEY I----- B/P (EM) ------ » ( 1 3 ) CONTROL MODULE
o> TRANSMISSION RANGE SENSOR
(SECTION B -lb)
o 100A
F04l B l-2 5 BACK-UP LIGHTS
(SECTION F-2)
B l-2 5 :
LY/G (EM) - -Y /G (I)
INSTRUMENT
CLUSTER -R /Y (EM) - -R /Y (I)
(SECTION C-a) B/Y L/O Y/B R/L
(EM) (EM) (EM) (EM) (EM) -B R (EM) - -B R (I)
INSTRUMENT
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(SECTION C-b)
B/Y (I) - -Y /B (I) ------- ►<§>
HESS -L /O (I)
-BR/Y (I)
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-R /B (EM) - -R /B (EM)
TURBINE SHAFT
SPEED SENSOR POWERTRAIN PCM
CONTROL MODULE POWER RELAY (l f f c -
(SECTION B -lb ) (SECTION B -la )
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B l-0 1 POWERTRAIN CONTROL MODULE(EM) B l-2 3 TURBINE SHAFT B l-2 4 SOLENOID BODY(EM)
SPEED SENSOR(E)
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
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B/G
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R/Y BR/Y W/L LG/R
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B/Y
59
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R/B W
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BR/W G/W GY/B G/R
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P/B
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BR/L LG/W P/L
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B/P
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LG/B GY/G BR/B e
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B l-2 5 TRANSMISSION RANGE SENSOR (EM) B1-2B MASS AIR FLOW SENSOR(EM) 1-04 HOLD SWITCH(I)
B/Y R/L R/Y B/L B/P BR/B 0

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HYDRAULIC
7s
ro VARIABLE VARIABLE
FORCE
SIGNAL
FORCE
SIGNAL
LOW/REVERSE
ACCUMULATOR
2/4 ACCUMULATOR
3-2 TIMING/COASTING ELECTRONIC PRESSURE
O) CLUTCH SOLENOID CONTROL (EPC)
IO -J rA TFT L a
CIRCUIT
DIRECT CLUTCH
COASTING CLUTCH
SHIFT SOLENOID FORWARD CLUTCH

1 (SS1)
PULSEWIDTH
MODULATED X
LOW/REVERSE o
CLUTCH
3J
>
DIFFERNTIAL LUBE = C
r;
FRONT LUBE =
O
TCC RELEASED
O
J3
O
c
H
FINAL DRIVE -
GEAR LUBE
COASTING CLUTCH VALVE

HYDRAULIC CIRCUIT K2
K2 TRANSAXLE OVERHAUL
TRANSAXLE OVERHAUL
TRANSAXLE UNIT (DISASSEMBLY)
Preparation
SST
K2-164
TRANSAXLE OVERHAUL K2
Precaution
General notes:
1. Disassemble the transaxle in a clean area (dust proof work space) to prevent entry of dust into the mech
anisms.
2. Inspect the individual transaxle components in accordance with the QUICK DIAGNOSIS CHART during
disassembly. (Refer to page K2-62.)
3. Use only plastic hammers when applying force to separate the light alloy case joints.
4. Never use rags during disassembly; they may leave particles that can clog fluid passages.
5. Several parts look alike; organize them so they do not get mixed up.
6. Disassemble the control valve assembly and thoroughly clean it when a clutch or brake band is burnt
or when the ATF has degenerated.
Cleaning notes:
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before disassembly.
2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and
passages with compressed air, and verify that there are no obstructions.
3. Wear eye protection when using compressed air to clean components.
K2-165
K2__ TRANSAXLE OVERHAUL
C om ponents
GASKET, R EPLAC E
1. Torque converter 5. Control valve body

Inspection........................ page K2-189 Disassembly / Inspection .. page K2-215
2. ATF dipstick and oil filler Assembly ...................... .. page K2-222
3. Vehicle speedometer sensor On-vehicle
Inspection........................ section K1 removal / installation .. page K2- 44
4. Control valve body cover
K2-166
C om ponents
1. Converter housing 5. #13 driven sprocket thrust bearing

2. Final drive and differential 6. Driven sprocket
Disassembly / Inspection / 7. #12 driven sprocket bearing
Assembly...................... page K2-225 8. #11 driven sprocket shim
3. Chain cover pan 9. #18 driven sprocket bearing
4. Chain drive
K2-167
C om ponents
1. Reverse/fourth gear ring gear 6. Forward/coasting/direct clutch cylinder

Disassembly / Inspection / Disassembly / Inspection /
Assem bly............................page K2-213 Assembly............................page K2-198
2. Reverse/fourth gear carrier assembly 7. Direct clutch shell assembly
Disassembly / Inspection / 8. Reverse clutch drum
Assembly............................page K2-213 Disassembly / Inspection /
3. Reverse/fourth gear sun gear Assembly............................page K2-198
and low-intermediate carrier assembly 9. Retaining ring
Disassembly / Inspection / 10. Low one way clutch plate
Assembly............................page K2-194 11. Low one way clutch
4. Forward one way clutch and low-intermediate 12. Wave spring
sun gear 13. Low/reverse clutch
Disassembly / Inspection / 14. Low/reverse clutch piston assembly
Assembly............................page K2-194 15. Low/reverse clutch seal
5. Turbine shaft
K2-168
Components
1. Transaxle case 8. Thermal valve bracket

2. 2/4 band servo piston and rod 9. Manual control lever and shaft
3. Oil pump 10. Differential seal
Disassembly / Inspection / 11. Parking pawl acturing cam
Assem bly............................page K2-190 12. Parking cam actuator lever
4. 2/4 band 13. Parking pawl and shaft
5. Transmission range sensor 14. Manual valve detent lever actuating rod
Inspection..............................page K2- 23 15. Oil filter and seal
6. Manual valve detent lever assembly 16. Recirculating regulator exhaust seal
7. Thermostatic oil level valve
K2-169
1. Install SST or equivalents on the transaxle case. Posi
tion a drain pan under the transaxle.
2. Remove the drain plug from the transaxle case. Allow

the transaxle to drain completely.
3. Remove the torque converter from the transaxle. Drain

the fluid from converter.
4. Remove the oil pump shaft by pulling it from the end of

the turbine shaft.
5. Remove the turbine shaft speed sensor mounting bolt.
K2-170
6. Pull the sensor from the bore.
7. Remove the O-ring seal. Discard the O-ring seal.
8. Remove the two transmission range sensor mounting

bolts.
9. Pull the transmission range sensor from the shaft.
10. Use SSTs or equivalent to remove the RH and LH differ

ential seals. Check the seal contact surfaces on the LH
joint shaft and the RH drive shaft for excessive wear.
K2-171
Note
• Do not remove the stator support bolts behind the im
peller hub seal.
11. Use SSTs or equivalent to remove the torque converter

impeller hub seal. Check the seal contact surface on the
torque converter impeller hub for excessive wear.
12. Remove the oil filler tube mounting bolt.
13. Pull the tube from the bore.
14. Remove the tube seal grommet.
15. Remove the vehicle speedometer sensor bolt.
K2-172
16. Remove the sensor from the bore.
-p-frCr*
17. Remove the O-ring seal from the sensor. Discard the O-
ring seal.
18. Remove the fourteen control valve body cover-to-trans-

axle case bolts.
19. Pull the cover from the transaxle case.

20. Separate the cover from the gasket. Discard the gasket.
21. Inspect the vent and grommet.
22. Remove wire harness clip from valve body.
23. Remove the twelve control valve body assem bly mount
ing bolts.
K2-173
Caution
• Do not allow loose manual valve to become dam
aged.
24. Pull the control valve body slightly away from the trans
axle case. Disconnect the Z-link from the manual valve.
M A N U A L VALVE
Z-LIN G
Caution
• Do not pull on the connector wires or use a ham
mer on the connector.
25. Squeeze the retainer tabs of the solenoid body connec

tor and remove the connector from the bore in the case.
26. If seapage found around solenoid body connector area,
inspect O-ring for damaged and discard it.
E LE C T R IC A L
CONNECTOR
27. Remove the control valve body from the transaxle and
store in a clean location.
28. Remove the thermostatic oil level valve bracket bolt. Re
move the bracket.
29. Pull the thermostatic oil level valve from the transaxle
case.
T H E R M O S TA T IC
O IL LE V E L
VALVE
BRACKET
BO LT
30. Remove a cap from 2/4 servo assembly by using SST.

Discard the cap.
Warning
• The servo cover is under pressure.
31. Attach the SST or equivalent to the pump.
K2-174
32. Screw in the bolt to compress the servo cover and re
move the retaining ring.
33. Remove the SST.
34. Remove the servo cover from the bore.
COVER
35. Remove the 2/4 servo assembly.
2/4 S E R V O A S S E M B LY
36. Position the transaxle so the converter housing faces

up.
37. Remove the twenty converter housing-to-transaxle case
bolts.
CONVERTER 38. Separate the converter housing from the transaxle case.
H O U S IN G 39. Remove the split flange gasket from the converter hous
ing. Discard the split flange gasket.
S P L IT
FLA N G E
GASKET
T R A N S A X LE
CASE
K2-175
40. Remove the #15 differential bearing.

41. Remove the #14 differential bearing shim (selective fit)
from the differential case.
42. Remove the speedometer drive gear from the differen
tial case.
43. Remove the final drive carrier/differential case.
44. Remove the front part of the chain cover by unsnapping

it from the rear part.
# 1 3 D R IV E N S P R O C K E T T H R U S T B EA R IN G 45. Remove the #13 driven sprocket thrust bearing.
Note
• The thrust washer may be attached to the converter
housing.
46. Remove the #10 drive sprocket thrust washer (selective

fit) from the drive sprocket.
K2-176
Warning
• Wear gloves as personal protection from sharp
chain and sprocket teeth.
47. Lift the drive chain and both sprockets together from the
transaxle case.
48. Separate the chain drive from the sprockets.
49. Remove the rear part of the chain cover (with the magnet
attached) from the transaxle case.
Check magnet for excessive metal particles.
50. Remove the #12 driven sprocket bearing and the #11
driven sprocket shim (selective fit) from the transaxle
case.
51. Unsnap the socket end of the manual detent lever actu
ating rod from the parking cam actuator.
K2-177
52. Unsnap the socket end of the manual detent lever actu
ating rod from the manual detent lever.
#9 R E V /4G R Note
R IN G G E A R • Thrust bearing may be attached to drive sprocket.
THRUST
B E A R IN G
53. Remove the #9 reverse/fourth gear ring gear thrust bear
ing.
54. Remove the reverse/fourth gear carrier (with captured

#8 reverse/fourth gear carrier thrust bearing).
55. Remove the reverse/fourth gear sun gear and shell as
sembly.
56. Remove the #7 reverse/fourth gear sun gear thrust bear

ing.
K2-178
57. Remove the low-intermediate ring gear.
58. Remove the #6 low-intermediate carrier thrust bearing.

& —
#6 L O W -IN T
C A R R IE R
.
THRUST
B E A R IN G
59. Remove the low-intermediate carrier.
60. Remove the #5 low-intermediate sun gear thrust bearing

#5 L O W -IN T S U N G E A R
T H R U S T B E A R IN G and the forward one-way clutch and low-intermediate
sun gear assembly.
F O R W A R D O N E -W A Y
C L U T C H A N D LO W -IN T
S U N G E A R A S S E M B LY
#4 T U R B IN E 61. Remove the #4 turbine shaft thrust bearing.

SHAFT THRUST
K2-179
62, Remove the turbine shaft.
63. Remove the assembly of the forward/coasting/direct cyl

inder and reverse clutch drum.
F O R W A R D /C O A S T IN G /D IR E C T
C Y LIN D E R A N D R E V E R S E
C LU TC H D R U M
#1 P U M P S U P P O R T 64. Remove the #1 pump support thrust bearing.

T H R U S T B E A R IN G
65. Use SST or equivalent to remove the oil filter recircula

tion seal. Discard the recirculation seal.
66. Remove the oil filter and seal assembly and discard.
K2-180
67. Remove the low one-way clutch retaining ring.
68. Remove the low one-way clutch thrust plate.
69. Remove the low one-way clutch assembly.
70. Remove the low/reverse wave spring.
71. Remove the low/reverse clutch plates.
K2-181
72. Use a screwdriver to remove the return spring retaining

ring.
73. Remove the return spring.
74. Pull the piston from the bore.
75. Remove the outer seal from the piston. Discard the outer
seal.
76. Remove the inner seal from the piston. Discard the inner
seal.
K2-182
O IL P U M P A S S E M B LY
77. Position transaxle with oil pump facing up. Remove the
M O U N T IN G BO LTS (9) nine oil pump assembly mounting bolts.
78. Install SST or equivalents and remove the oil pump as
sembly from the transaxle case.
Note
• Use a piece of wire to secure the 2/4 band so that it
is not damaged by being stretched.
2 /4 BAN D
79. Slide the 2/4 band from the case.
80. Remove the fluid cooler line fitting. Inspect the fluid cool
er line fitting seal.
81. Remove the final drive ring gear retaining ring.
K2-183
82. Lift the final drive ring gear from the housing. Inspect
RING GEAR gear and housing lug teeth.
83. Remove the drive chain/differential lube tube mounting

DIFFERENTIAL LUBE TUBE bolt.
DRIVE CHAIN 84. Wiggle and pull the drive chain/differential lube tube
DIFFERENTIAL from the housing.
LUBE
85. Use a screwdriver to remove the final drive lube tube

from the case.
86. Use SST or equivalent to remove the final drive lube tube
seal from the case.
K2-184
87. Remove the parking pawl spring.
88. Remove the manual control outer lever bolt.

89. Remove the manual control outer lever.
90. Remove the manual control shaft nut.
91. Remove the parking lock cam, cam actuator, spacer, and
manual lever control shaft.
92. Remove the parking pawl shaft retainer and bolt.
K2-185
93. Use O-ring pick or magnet to remove the parking pawl

shaft.
94. Remove the parking pawl and return spring.
Caution
• Do not damage the case bore during seal remov
al.
95. Use a screwdriver to remove the manual control shaft

seal.
96. Remove the manual valve actuator rod (Z-link).
Caution
• Do not damage the transaxle case sealing sur
face.
97. Protect the case and use a pair of side cutters to remove
the manual valve detent lever roll pin. Discard the roll pin.
K2-186
Caution
• Do not damage the transaxle case sealing sur
face.
98. Protect the case and use a pair of side cutters to remove
the manual valve detent lever shaft roll pin. Discard the
roll pin.
99. Remove the manual valve detent lever and shaft from
the case.
Caution
• Do not damage the transaxle case during seal re
moval.
100. Use a screwdriver to remove the manual valve detent le

ver shaft seal from the case. Discard the seal.
101. Remove the line pressure port plug from the transaxle
case.
102. Remove the fluid cooler line fitting. Inspect the fluid cool
er line fitting seal.
103. If necessary, to replace #18 driven sprocket bearing

from the transaxle case, install SSTs.
K2-187
104. Remove the bearing using SSTs.
K2-188
TORQUE CONVERTER
Preparation
SST
49 UN01 123 For 49 UN01 120 For

End play torque converter End play torque converter
checking tool checking tool
sleeve
The torque converter is welded together and cannot be disassembled.

Inspection
Torque converter one-way clutch check
1. Place the torque converter on a workbench with the im
peller hub facing up.
2. Place a pick in a slot on the bottom of the stator.
3. While holding the bottom of the stator, rotate the inner
race of the one-way clutch.
4. If the inner race rotates in both directions during this
check, the stator one-way clutch is slipping.
Torque converter pump insert check

1. Install the oil pump shaft into the torque converter.
2. Verify that the insert can hold 14 N-m {1.5 kgf-m, 10 ft lbf}
of torque.
3. If the insert cannot hold the specified torque, replace the
torque converter.
4. Remove the oil pump shaft.
Turbine torque check

1. Install SSTs into the turbine splines in the torque convert
er.
2. Attach a torque wrench and determine the torque re
quired to turn the turbine.
3. If the torque exceeds 5.8 N-m {60 kgf-cm, 52 in-lbf}, re
place the torque converter.
Torque converter end play check

1. Install S S T s into th e tu rbin e s p lin e s in th e to rq u e c o n v e r t
er.
2. Attach dial indicator to the SSTs.
3. Zero the needle of the dial indicator.
4. Pull up on the SSTs and observe the dial indicator read
ing.
5. If end play exceeds 1.27 mm {0.05 in}, replace the torque
converter.
K2-189
OIL PUMP
Preparation
SST
49 UN01 108 ^ For 49 UN01 107 For

inspection of oil £ M O Assemble of oil
Gauge bar pump Pump pump
all9nmen,pln5 f ---------------« D

1. Disassembly in the order shown in the figure.
3. Assembly in the reverse order of disassembly, referring to Assembly Procedure.
1. Seal ring 6. Drive gear

2. Pump support Inspection.................. ...........page K2-191
3. Gasket 7. Driven gear
4. Separator plate Inspection.................. ...........page K2-191
5. Drive gear insert 8. Oil pump seal ring
9. Oil pump body
K2-190
Inspection
1. Use SST and a depth micrometer to measure the clear
ance between each gear and the pump body face.
2. The allowable clearance for each gear is 0.27—0.60
mm {0.001— 0.002 in}. If the clearance exceeds the
specification, replace the oil pump assembly.
3. Check for oil blockage. (Refer to page K2-9.)
Assembly Procedure
1. Install the driven gear in the oil pump body with the iden
tification dot facing down.
DRIVE GEAR
2. Install the drive gear and insert in the oil pump body.
3. Install the SST or equivalent in the oil pump body, with

the alignment pins in the holes as shown.
4. Install the separator plate and gasket on the oil pump

GASKET
body.
SEPARATOR
49 UN01 107 PLATE
OIL PUMP
K2-191
5. Install the pump support on the oil pump body.

PUMP SUPPORT
49 UN01 107
6. Install and tighten four pump support-to-oil pump body

bolts to 13 N m {1.3 kgf m, 10 ft lbf } and remove the
SST (alignment pins). Install and tighten the two remain
ing mounting bolts to 13 N-m {1.3 kgf m, 10 ft lbf}.
7. Install a new seal ring on the oil pump body.
OIL PUMP BODY

SEAL RING
Note
• Ensure that the scarf cut seals are overlapped cor
rectly.
8. Install seven new seal rings on the pump support.
K2-192
9. Install the oil pump drive shaft.
10. Use a torque wrench to rotate the oil pump. The maxi
mum rotating torque is 0.3 N m {3.1 kgf-m, 2 in-lbf}.
11. Remove the torque wrench and oil pump drive shaft.
12. If the rotating torque exceeds the specification, disas
semble and inspect the oil pump for contamination or im
proper end clearance.
K2-193
FORWARD ONE-WAY CLUTCH, LOW-INTERMEDIATE SUN GEAR ASSEMBLY, AND

LOW-INTERMEDIATE CARRIER ASSEMBLY
Preparation
SST

2. Inspect all parts, and repair or replace as necessary.
3. Assembly in the reverse order of disassembly, referring to Assembly Procedure.
1. Retaining ring 6. Retaining washer

2. Coasting clutch hub 7. Retaining ring
3. One-way clutch outer race 8. Low-intermediate sun gear
4. Sprag assembly 9. Low-intermediate carrier
5. End cap Inspection..............................page K2-195
Disassembly n o te .................page K2-195
K2-194
Disassembly note
End cap
Note
• Note the position of the end caps.
They are of different thickness and are not inter
changeable.
Separate the sprag assembly and end caps from the out
er race.
Inspection
Low-intermediate carrier assembly
Inspect the low-intermediate carrier assembly pinion
gear end play. End play should be between 0.15— 0.72
mm {0.005— 0.039 in}.
Assembly procedure
1. Install the retaining ring.
Note
• The tabs on the retaining washer should be facing
down.
2. Install the retaining washer.

RETAINING WASHER
3. Identify the thick and thin end caps.
K 2-195
4. Assemble the one-way clutch, sprag assembly and end

caps.
THIN END CAP

SPRAG ASSEMBLY 5. Use the SST or equivalent to install the sprag assembly
and end caps in the outer race.
OUTER
RACE
(LUBE
GROOVES
DOWN)
THICK END CAP
Caution
• Lube grooves face up (away from sun gear).
6. Flip the outer race and sprag assembly over and install
on the sun gear.
7. Install the coasting clutch hub.
COASTING
CLUTCH HUB
Note
• The end of the retaining ring should point towards the
coasting clutch hub.
8. Install the coasting clutch hub retaining ring.
K2-196
9. Check the operation of the forward one-way clutch with
the sun gear facing up. It should work as follows:
• When the sun gear is rotated in a clockwise direction,
it should not rotate the outer race.
• When the sun gear is rotated in a counterclockwise
direction, it should rotate the outer race.
K2-197
F O R W A R D /C O A S T IN G /D IR E C T C L U T C H C Y LIN D E R AN D R E V E R S E C LU TC H D R U M
P rep aratio n
SST
49 G019 0A7A For 49 G019 025 For

Compressor assembly of Body B assembly of
set, return coasting clutch (Part of coasting clutch
spring and reverse 49 G019 0A7A)
clutch
49 G019 026 For 49 G019 027 For

Plate assembly of Attachment A assembly of
(Part of coasting clutch (Part of coasting clutch
49 G019 0A7A) and reverse 49 G019 0A7A) and reverse
clutch clutch
49 G019 029 For 49 UN01 095 For

disassembly / installation of
Nut assembly of Coasting clutch forward clutch
(Part of coasting clutch piston seal piston
49 G019 0A7A) and reverse protector
clutch
49 UN01 096 For 49 UN01 094 For

Seal sizer F/C/D clutch Reverse clutch reverse clutch
cylinder hub seal piston seal piston
protector
49 L019 001 For

removal /
Bolt installation of
snap ring
K2-198
D is as se m b ly / In sp ectio n / A ss em b ly
1 . Disassemble as shown in the figure, referring to D isassem bly Note.
3. Assemble in the reverse order of disassembly, referring to A ssem b ly P rocedure.
1. Retaining ring 20. Retaining ring

Disassembly note ................ . page K2-200 Disassembly note ...............
2. Reverse clutch hub 21. Return spring assembly
3. Reverse clutch drum Inspection............................
4. Direct clutch hub/shell 22. Direct clutch piston
5. Forward/coasting/direct clutch cylinder Disassembly note ...............
6. Reverse clutch seal rings 23. Direct clutch piston inner seal
7. Direct clutch thrust washer 24. Direct clutch piston outer seal
8. F/C/D clutch cylinder hub seal 25. Retaining ring
9. Retaining ring 26. Pressure plate
10. Pressure plate 27. Friction plates
11. Friction plates Inspect for wear and burning
Inspect for wear and burning 28. Steel plates
12. Steel plates 29. Pressure plate
13. Retaining ring 30. Friction plates
Disassembly note .................. page K2-200 Inspect for wear and burning
14. Return spring assembly 31. Steel plates
Inspection............................. page K2-201 32. Retaining ring
15. Reverse clutch piston Disassembly n o te ...............
16. Retaining ring 33. Return spring assembly
17. Pressure plate Inspection............................
18. Friction plates 34. Forward clutch piston
Inspect for wear and burning 35. Forward clutch piston outer seal
19. Steel plates 36. Forward clutch piston inner seal
37. Coasting clutch piston
K2-199
D isassem b ly note
R etaining ring (R everse clutch hub)
1. Reverse clutch hub facing up.
2. Forward/Coasting/direct clutch cylinder supported on
block.
3. Direct clutch hub/shell not touching workbentch.
49 G019 026
R etaining ring (R everse clutch)
1. Use the SST or equivalent to compress the return spring
assembly.
49 G019 025
49 G019 027
2. Remove the retaining ring.
R etaining ring (D irect clutch)

assembly.
K2-200
Direct clutch piston
Remove the direct clutch piston by using external snap-
ring pliers as shown, in figure.
49 G019 026 R etaining ring (Forw ard and co astin g clu tch )
1 . Use the S S T or equivalent to compress the return spring
assembly.
49 G019 027
Inspection
Springs
• Springs must be the same length.
• Springs must not be twisted.
• Springs must not be damaged.
A ssem b ly procedu re
1. Install the inner forward clutch piston seal in the forward/
coasting/direct clutch cylinder.
K2-201
2. Install a new outer seal on the forward clutch piston.
3. Install the forward clutch piston in the forward/coasting/

direct clutch cylinder.
4. Install coasting clutch piston in the SST.
5. Use the SST or equivalent to install the coasting clutch

piston into the forward clutch piston.
6. Install the return spring assembly.

RETURN SPRING
K2-202
49 G019 026 7. Use the SST or equivalent to compress the return spring
assembly.
49 G019 027
8. Install the retaining ring.

9. Remove the SST.
FORWARD CLUTCH 10. Install the forward and coasting clutch plates.
PRESSURE PLATE
FORWARD
PLATES
COASTING
CLUTCH
COASTING PLATES
CLUTCH
PRESSURE
PLATE
11. Install the forward clutch plate retaining ring (selective

fit).
K2-203
12. Use a feeler gauge to measure the clearance between

the clutch plates and the forward clutch plate retaining
ring. Make a second measurement on the opposite side.
Average the two measurements to get the clearance.
13. The standard clearance is 0.50— 1.09 m m {0.02— 0.04
in}. If the clearance is not within the specification, select
and install the proper thickness retaining plate to obtain
the standard clearance.
R etaining ring sizes are as fo llo w s:
Thickness mm {in}
1.28— 1.38 {0.050— 0.054}
1.39— 1.49 {0.055— 0.059}
1.52— 1.62 {0.060— 0.064}
1.65— 1.75 {0.065—0.069}
14. Install the forward/coasting/direct clutch cylinder hub

seal ring on the forward/coasting/direct clutch cylinder.
15. Install a new outer seal on the direct clutch piston.
16. Install a new inner piston seal in the forward/coasting/di

rect clutch cylinder.
K2-204
17. Install the direct piston in the forward/coasting/direct
clutch cylinder.
RETURN SPRING
49 G019 029 19. Use the SST or equivalent to compress the return spring
assembly.
49 G019 025
49 G019 027
20. Use a pair of snap ring pliers to install the retaining ring.
21. Remove the SST.
K2-205
22. Install the direct clutch plates.

PRESSURE PLATE
STEEL
PLATES
FRICTION
PLATES
23. Install the direct clutch plate retaining ring (selective fit)
24. Measure the direct clutch clearance as follows:

• Install a dial indicator on the side of the forward/coasting/
direct clutch cylinder and zero the needle on the pres
sure plate.
• Use two picks to pull the pressure plate upward. Observe
the dial indicator reading.
• Make a second measurement on the opposite side. Av
erage the two measurements to get the clearance.
25. The standard clearance is 0.52— 1.12 mm {0.02—0.04
and install the proper thickness retaining ring to obtain
R etaining ring sizes are as fo llo w s:
Thickness mm {in}
1.28— 1.38 {0.050— 0.054}
1.39— 1.49 {0.054— 0.06}
1.52— 1.62 {0.060— 0.063}
1.65— 1.75 {0.064— 0.068}
K2-206
26. Install the reverse clutch piston in the SST or equivalent.
27. Use the SST or equivalent to install the reverse clutch

piston with integral seals.

assembly.
30. Use a pair of snap ring pliers to install the retaining ring.
31. Remove the SST.
K2-207
32. Install the reverse clutch plates.

PRESSURE PLATE
FRICTION
STEEL
PLATES
33. Install the reverse clutch plate retaining ring (selective

fit).

the clutch plates and the reverse clutch plate retaining
ring. Make a second measurement on the opposite side.
Average the two measurements to get the clearance.
and install the proper thickness retaining ring to obtain
R etaining ring sizes are as fo llo w s :
Thickness mm {in}
1.39— 1.49 {0.055—0.059}
1.53— 1.63 {0.060— 0.064}
1.68— 1.78 {0.066— 0.070}
K2-208
C aution
F/C/D CLUTCH • Tabs on direct clutch th ru st w a s h e rs m u st be
CYLINDER
sealed in return spring assem bly.
DIRECT CLUTCH
THRUST 36. Install the direct clutch thrust washer on the forward/
WASHER coasting/direct clutch cylinder with the tabs facing down.
Note
• Ensure that the scarf cut seals are overlapped cor
rectly.
37. Install the two reverse clutch seal rings.

REVERSE
CLUTCH SEAL
RINGS
38. Support the forward/coasting/direct clutch cylinder on a

block of wood so that the direct clutch faces upward.
K2-209
39. Install the direct clutch hub/shell on the forward/coast

ing/direct clutch cylinder.
40. Install the reverse clutch drum.
41. Install the reverse clutch hub.
42. Install the reverse clutch hub retaining ring.
43. Flip assembly over. Use the SST to size the forward/
coasting/direct clutch cylinder hub seal. Leave the seal
sizer on until the assembly is installed in the case.
K2-210
44. Lower forward/coasting/direct clutch cylinder and re
REVERSE CLUTCH verse clutch drum assembly on oil pump as shown, in fig
FORWARD
ure.
CLUTCH
W arning
DIRECT • W ear eye p ro tection w h en using c o m p re s s e d air.
CLUTCH
45. Apply compressed air 275 kPa {2.8 kgf/cm2, 40 psi} to
each clutch passage and listen for dull thud sound when
COASTING
CLUTCH
clutch applies.
46. If hissing sound occurs during check, disassemble and
locate source of leakage.
47. Lift cylinder and drum assembly from oil pump.
K2-211
LO W O N E-W A Y C L U T C H
D isa s se m b ly / In sp e ctio n / A ssem b ly
1. Disassemble as shown in the figure.
3. Assemble in the reverse order of disassembly, referring to A ssem b ly P rocedure.
1. Low one-way clutch inner race 3. Low one-way clutch outer race
2. Roller assembly
A ssem b ly procedure
Note
• The outer tabs of the roller assembly must be facing
up.
1. Install the roller assembly into the outer race.
Caution
• Inner race g ro o ve m ust be fa c e up.
2. Install the inner race with the grooves facing up.
3. Check the operation of the low one-way clutch as fol

lows:
• When the inner race is rotated in a clockwise direc
tion, it should move freely.
• When the inner race is rotated in a counterclockwise
direction, it should lock to the outer race.
K2-212
REVERSE/FOURTH GEAR RING GEAR, REVERSE/FOURTH GEAR CARRIER ASSEMBLY, AND
CHAIN DRIVE
Preparation
SST
49 0223 630B For 49 UN01 124 For

removal of drive removal of drive
Puller, axle ^------q,-----^ sprocket Shaft bearing sprocket bearing
shaft " ----- V-----III------- bearing/stator remover —
support bearing
49 S231 660 For 49 F027 003 For

removal of stator installation of
Puller, needle support bearing Handle drive sprocket
bearing (Part of bearing
49 F028 2A0)

1. Reverse/fourth gear carrier assembly 3. Reverse/fourth gear ring gear

Inspection..............................page K2-214 Inspect for wear
2. Bearing 4. Chain drive
Disassembly N o te .................page K2-214 Inspect for excessive stretching, wear, or
tight link(s)
K2-213
Disassembly note
Bearing
1. If necessary, use the SSTs or equivalents to remove the
drive sprocket bearing.
2. If necessary, use the SSTs or equivalents to remove the

stator support bearing.
Inspection
Reverse/fourth gear carrier assembly
Inspect the Reverse/fourth gear carrier assembly pinion
gear end play. End play should be between 0.15— 0.72
mm {0.006— 0.028 in}.
Assembly procedure
1. If removed, install the drive sprocket bearing on the SST
2. If removed, use the SSTs or equivalents to install the

drive sprocket bearing.
K2-214
3. If removed, install the stator support bearing on the SST
4. If removed, use the SSTs or equivalents to install the sta

tor support bearing.
5. Assemble the chain on both the sprockets.
CONTROL VALVE BODY (DISASSEMBLY / INSPECTION)

Caution
• Be especially careful when handling the control valve because it consists of the most precise
and delicate parts of the transaxle.
• Neatly arrange the removed parts to avoid confusing the similar parts.
• Clean the removed parts with cleaning solvent, and dry them with compressed air. Clean out
all holes and passages with compressed air.
• Wear eye protection when using compressed air to clean components.
1. Disassemble in the order shown in the figure, referring to Disassembly Procedure.

1. Bolt 9. Bolt
2. Solenoid body assembly 10. Accumulator body assembly
3. Solenoid gasket 11. Gaskets
4. Bolt 12. Separator plate
5. Pressure tap plate 13. Valve body assembly
6. Pressure tap gasket 14. Gaskets
7. Bolt 15. Separator plate
8. Detent lever 16. Transfer plate
K2-216
Disassembly procedure
1. Remove manual control valve from valve body.
Remove the two solenoid body assembly bolts. Remove
the solenoid body assembly.
S O LE N O ID 2. Remove the solenoid gasket from the accumulator body.

Discard the solenoid gasket.
3. Remove the three pressure tap plate bolts. Remove the

pressure tap plate.
4. Remove the gasket from the accumulator body assem

bly. Discard the gasket.
GASKET
5. Remove the three valve body-to-transfer plate bolts. Re

move the detent lever.
K2-217
A C C U M U LA T O R B O D Y 6. Remove the three accumulator body assembly bolts.

A S S E M B L Y BO LTS
A C C U M U LA T O R B O D Y 7. Remove the accumulator body, separator plate and gas

kets from the valve body assembly. Discard the gaskets.
S EP A R ATO R
PLATE
VALVE
BODY
A S S E M B LY
GASKETS
8. Remove the valve body, separator plate and gaskets

from the transfer plate. Discard the gaskets.
K2-218
ACCUMULATOR BODY
Caution
• Each valve should slide out/in under its own weight.
• When a valve will not slide out under its own weight, depending on the valve, push it out with
a wire or place the valve body open-side down and lightly tap it with a plastic hammer. Never
scratch or other wise damage a valve surface or bore.
• Do not drop or lose the valves or internal parts.
• Before assembly, make sure all parts are thoroughly clean.
• Apply ATF to all parts and bores.
• Note the proper direction of the valve and internal parts.
• Do not reuse any part that has been dropped.
• Wrap a screwdriver or rod with tape before using it to insert a valve.

1. Retaining plate 10. Forward accumulator spring

2. Low/reverse accumulator spring Inspection.......................... page K2-220
Inspection............................. page K2-220 11. Forward accumulator piston
3. Low/reverse accumulator piston 12. Spring retaining plate
4. Retaining plate 13. Pull-in control valve spring
5. 2/4 accumulator plug Inspection.......................... page K2-220
Disassembly note ................. page K2-220 14. Pull-in control valve
6. 2/4 accumulator piston 15. Valve plug retainer
7. 2/4 accumulator spring 16. Valve retainer plug
Inspection............................. page K2-220 17. 3-2 timing valve spring
8. 2/4 accumulator plug seal Inspection.......................... page K2-220
9. Retaining plate 18. 3-2 timing valve
19. Accumulator body assembly
K2-219
Disassembly note
2/4 accumulator plug
1. Remove the 2/4 accumulator plug, using bolt.
2. Remove the 2/4 accumulator plug seal. Discard the seal.
Inspection
Springs
VALVE BODY ASSEMBLY

Caution
• Each valve should slide out/in under its own weight.
• When a valve will not slide out under its own weight, depending on the valve, push it out with
a wire or place the valve body open-side down and lightly tap it with a plastic hammer. Never
scratch or otherwise damage a valve or bore.
• Do not drop or lose the valves or internal parts.
• Before assembly, make sure all parts are thoroughly clean.
• Apply ATF to all parts and bores.
• Note the proper direction of the valve and internal parts.
• Do not reuse any part that has been dropped.
• Wrap a screwdriver or rod with tape before using it to insert a valve.

K2-220
1. Manual control valve 25. Spring retaining plate

2. Spring retaining plate 26. Coasting clutch shift valve spring
3. Solenoid regulator valve spring Inspection..............................page K2-222
Inspection..............................page K2-222 27. Coasting clutch shift valve
4. Solenoid regulator valve 28. Valve plug retainer
5. Valve plug retainer 29. Valve retainer plug
6. Valve retainer plug 30. Low/reverse modulator spring
7. Bypass clutch control valve spring Inspection..............................page K2-222
Inspection..............................page K2-222 31. Low/reverse modulator valve
8. Bypass clutch control sleeve 32. Valve plug retainer
9. Clutch control valve plunger 33. Valve retainer plug
10. Bypass clutch control valve 34. 1-2 shift valve spring
11. Spring retaining plate Inspection..............................page K2-222
12. Converter regulator valve spring 35. 1-2 shift valve
Inspection..............................page K2-222 36. Valve plug retainer
13. Converter regulator valve 37. Valve retainer plug
14. Valve plug retainer 38. 3-2 control valve spring
15. Valve retainer plug Inspection..............................page K2-222
16. Line modulator spring 39. 3-2 control valve
17. Line modulator valve 41. Valve retainer plug
18. Valve plug retainer 42. 2-3 shift valve spring
19. Valve retainer plug Inspection..............................page K2-222
20. Main regulator valve spring 43. 2-3 shift valve
21. Main regulator valve 45. Valve retainer plug
22. Spring retaining plate 46. 3-4 shift valve spring
23. Servo release shuttle valve spring Inspection..............................page K2-222
Inspection..............................page K2-222 47. 3-4 shift valve
24. Servo release shuttle valve
K2-221
Inspection
Springs
CONTROL VALVE BODY (ASSEMBLY)

Preparation
SST
49 UN01 106 For

(SST7 ~® assemble of
Valve body control valve
guide pin body
< U ___
Caution
• Before assembly, make sure all parts are perfectly clean.
• Apply ATF to all parts.
• Do not reuse the gaskets or O-rings.
Assemble as shown in the figure, referring to Assembly Procedure.
m i.i,
N m {kgf m, ft lbf)
1. Transfer plate 9. Detent lever

2. Separator plate 10. Bolt
3. Gaskets 11. Pressure tap gasket
4. Valve body assembly 12. Pressure tap plate
5. Separator plate 13. Bolt
6. Gaskets 14. Solenoid gasket
7. Accumulator body assembly 15. Solenoid body assembly
8. Bolt 16. Bolt
K2-222
1. Install the SST or equivalent in the valve body transfer
plate.
2. Install the valve body separator plate and a new gaskets

on the transfer plate.
3. Install the valve body assembly on the transfer plate.
4. Install the accumulator body separator plate and a new

gaskets on the valve body assembly.
5. Install the accumulator body assembly on the valve body

assembly.
K2-223
ACCUMULATOR BODY 6. Install and tighten the three accumulator body assem-
BOLTS bly-to-transfer plate bolts.
Tightening torque: 11 N m {1.1 kgf m, 8 ft lbf}
7. Install the three valve body-to-transfer plate bolts and

detent lever.
Tightening torque: 11 N-m {1.1 kgf-m, 8 ft-lbf}
8. Install the pressure tap plate, gasket and three bolts on

the accumulator body assembly.
Tightening torque: 8 N-m {0.8 kgf-m, 6 ft lbf}
Note
• Match solenoid body gasket to passages.
9. Install the solenoid body and a new gasket on the accu

mulator body.
SOLENOID BODY-TO-ACCUMULATOR BODY

10. Install the two solenoid body-to-accumulator body bolts.
BOLTS (2) \
Tightening torque: 11 N m {1.1 kgf m, 8 ft-lbf}
11. Remove the valve body alignment pins.
K2-224
DIFFERENTIAL
1. Roll pin 4. Thrust washer

Disassembly Note below 5. Side gears
2. Pinion shaft 6. Thrust washer
3. Pinion gears 7. Differential case
Disassembly note
Roll pin
Use a punch to remove the pinion shaft roll pin.
K2-225
THRUST Assembly procedure

1. Install the side gears and thrust washers.
THRUST
WASHER
2. Install the pinion gears and thrust washers.
3. Install the pinion shaft.
4. Install the pinion shaft roll pin.
K2-226
TRANSAXLE UNIT (ASSEMBLY)
Preparation
SST
K2-227
49 UN01 104 For 49 UN01 105 For

installation of 2/4 installation of 2/4
Servo cover servo piston Servo piston servo piston
remover/ rod selector
replacer
49 UN01 113 For 49 UN01 085 For

checking clutch adjustment of
Transmission hydraulic circuit Shifter shaft shifter shaft
test plate with alignment tool
valve body
49 UN01 086 For 49 UN01 129 For

adjustment of TR installation of
MLPS sensor Seal replacer differential seal
alignment tool
49 UN01 088 For 49 G019 038 For

installation of assembly of
Converter seal torque converter Transaxle transaxle
replacer impeller hub seal hanger
49 0107 680A For

assembly of
Engine stand transaxle
Precaution
1. If the drive plates or 2/4 band are replaced with new ones, soak the new part in ATF for at least 15 minutes
before installation.
2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
3. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
4. Use petroleum jelly, not grease, during reassembly.
5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
Bearing assembly location

Outer diameter of bearing assembly
No. Name Outer diameter mm {in}

#1 Pump support thrust bearing 75.09 {2.956}
#4 Turbine shaft thrust bearing 44.25 {1.742}
#5 Low-int sun gear thrust bearing 49.90(1.965}
#6 Low-int carrier thrust bearing 66.41 {2.615}
#7 Rev/4gr sun gear thrust bearing 76.75 {3.022}
#8 Rev/4gr carrier thrust bearing 72.87 {2.869}
#9 Rev/4gr ring gear thrust bearing 99.70 {3.925}
#12 Driven sprocket thrust bearing 79.26 {3.120}
#13 Driven sprocket thrust bearing 79.95 {3.148}
#15 Differential bearing 58.44 {2.301}
K2-228
Bearing and race locations
#9 REV/4GR RING GEAR

THRUST BEARING
99.7 mm
#7 REV/4GR SUN GEAR

THRUST BEARING
76.25 mm
#6 LOW-INT CARRIER
THRUST BEARING
#10 DRIVE SPROCKET
ASSEMBLY THRUST WASHER
66.41 mm 89.0 mm
#5 LOW-INT SUN
GEAR THRUST
^ f t
BEARING
49.9 mm
#4 TURBINE SHAFT
THRUST BEARING
ASSEMBLY #17 STATOR SUPPORT
44.25 mm BEARING ASSEMBLY
DIFFERENTIAL
#1 PUMP SUPPORT THRUST
SIDE GEAR
BEARING ASSEMBLY THRUST WASHER
75.69 mm
#15
as—ss) 1 DIFFERENTIAL
#16 REV/4GR RING BEARING
GEAR B E A R I N G / 58.44 mm
ASSEMBLY
#2 DIRECT CLUTCH
THRUST WASHER
#14 DIFFERENTIAL
BEARING SHIM
#11 DRIVEN 69.5 mm
SPROCKET SHIM
#13 DRIVEN SPROCKET

#18 DRIVEN SPROCKET THRUST BEARING
BEARING ASSEMBLY 79.95 mm DIFFERENTIAL
#12 DRIVEN
PINION THRUST
SPROCKET
WASHER
BEARING
79.26 mm
K2-229
1. Recirculating regulator exhaust seal 9. Thermal valve bracket

2. Oil filter and seal 10. Thermostatic oil level valve
3. Manual valve detent lever actuating rod 11. Manual valve detent lever assembly
4. Parking pawl and shaft 12. Transmission range sensor
5. Parking cam actuator lever 13. 2/4 band
6. Parking pawl actuating cam 14. Oil pump
7. Differential seal 15. 2/4 band servo piston and rod
8. Manual control lever and shaft 16. Transaxle case
K2-230
1. Low/reverse clutch seal 10. Forward/coasting/direct clutch cylinder

2. Low/reverse clutch piston assembly 11. Turbine shaft
3. Low/reverse clutch 12. Forward one-way clutch and low-intermediate
4. Wave spring sun gear
5. Low one-way clutch 13. Reverse/fourth gear sun gear and low-inter-
6. Low one-way clutch plate mediate carrier assembly
7. Retaining ring 14. Reverse/fourth gear carrier assembly
8. Reverse clutch drum 15. Reverse/fourth gear sun gear
9. Direct clutch shell assembly
K2-231
1. #18 driven sprocket bearing 6. Chain drive

2. #11 driven sprocket shim 7. Chain cover pen
3. #12 driven sprocket bearing 8. Final drive and differential
4. Driven sprocket 9. Converter housing
5. #13 driven sprocket thrust bearing
K2-232
GASKET, NEW
1. Control valve body 4. ATF dipstick and oil filter

2. Control valve body cover 5. Torque converter
3. Vehicle speedometer sensor
K2-233
Assembly Procedure
1. If necessary, use the SSTs or equivalents to install the
#18 driven sprocket bearing in the transaxle case.
2. Apply thread sealant to fitting. Install the fluid cooler line

fitting on the transaxle case.
Tightening torque: 40 N m {4.1 kgf m, 30 ft Ibf}
3. Apply thread sealant to port plug. Install the line pressure

port plug on the transaxle case.

FLUID COOLER
LINE FITTING
4. Use a small rubber mallet to install the manual valve det

ent lever shaft seal in the case.
5. Install the manual valve detent lever and shaft into the
case.
6. Use a hammer and a punch to install the manual valve

detent lever shaft roll pin.
K2-234
Caution
• Do not allow the manual valve detent lever roll pin
to make contact with the case.
7. Use a hammer and a punch to install the manual valve

detent lever roll pin.
8. Verify that the manual valve detent lever rotates freely.

Install the manual valve actuator rod (Z-link).
9. Use the SST or equivalent to install the manual control

shaft seal.
10. Install the parking pawl and return spring.
11. Install the parking pawl shaft.
K2-235
12. Install the parking pawl shaft retainer and bolt.
13. Assemble the parking lock cam, cam actuator, spring,

spacer on the manual lever control shaft.
Note
CAM ACTUATOR • Verify that the manual lever control shaft assembly
can move freely.
14. Install the manual lever control shaft assembly into the
case.
15. Install the manual control shaft nut.
16. Install the parking pawl spring.
K2-236
Note
• Bolt will be torque after linkage adjustment.
17. Install the manual control outer lever and bolt by finger.
18. Use the SST or equivalent to install the final drive lube
tube seal into the case.
FINAL DRIVE LUBE TUBE 19. Push the final drive lube tube into its seal.
20. Push the final drive lube tube into the bearing of the case
and seat with SST
DRIVE CHAIN 21. Push the drive chain/differential lube tube into the hous
DIFFERENTIAL ing.
LUBE
K 2-237
22. Seat the end of the drive chain/differential lube tube with
SST.
23. Install the mounting bolt.

DIFFERENTIAL LUBE TUBE
Note
RING GEAR • Gear is installed with lug end up away from housing.
24. Lower the final drive ring gear into the housing.
25. Install the final drive gear retaining ring.
26. Install the fitting to the converter housing.
K2-238
27. Slide the 2/4 band into the case.
2/4 BAND
28. Lower the pump into the transaxle case.
29. Install the nine oil pump assembly-to-transaxle case

bolts.
PISTON
30. Install the outer seal on the piston.
OUTER SEAL
31. Install the inner seal on the piston.
K2-239
32. Install the low/reverse clutch piston into SST (49 UN01
093) and SST (49 UN01 097).
Install the low/reverse clutch piston into case. Remove
the SSTs.
RETURN SPRING 33. Install the return spring assembly.
34. Use a screwdriver to install the retaining ring.
Caution
• The wave spring is installed in this position for
measurement purposes only.
35. Install the low/reverse wave spring.
36. Install the low/reverse steel and friction plates, and the
pressure plate.
K 2-240
Note
• The thrust plate is installed in this position for mea
surement purposes only.
37. Install the low one-way clutch thrust plate.

the pressure plate and the thrust plate. Make a second
measurement on the opposite side. Average the two
measurements to obtain the clearance.
in}. If the clearance is not within specification, select the
proper thickness pressure plate to obtain the standard
THRUST PLATE clearance.
PRESSURE /
PLATE
Pressure plate sizes are as follows:
FRICTION
STEEL
PLATES
PLATES Thickness mm{in} Number of notches
2 .5 7 — 2 .4 7 {0 .1 — 0 .0 9 7 } 1
2 .3 6 — 2 .2 6 {0 .0 9 2 — 0 .0 8 8 } 2
2 .1 6 — 2 .0 6 {0 .0 8 5 — 0 .0 8 1 } 3
WAVE SPRING
40. Remove the thrust plate, pressure plate, steel and fric
W i tion plates, and the wave spring.
41. Install the #1 pump support thrust bearing.
FORWARD/COASTING/ 42. Remove the SS T (seal sizer) from the forward/coasting/

DIRECT CLUTCH direct clutch cylinder.
CYLINDER AND REVERSE
ASSEMBLY 43. Install the assembly of the forward/coasting/direct clutch
cylinder and reverse drum assembly.
TURBINE SHAFT 44. Install the turbine shaft.
K2-241
45. Install the #4 turbine shaft thrust bearing.

g D__ _____tasi
#4 TURBINE SHAFT
THRUST BEARING
FORWARD ONE-WAY 46. Install the forward one-way clutch/low-intermediate sun

CLUTCH/LOW-INT gear.
GEAR
47. Install the #5 low-intermediate sun gear thrust bearing.
LOW-INT CARRIER 48. Install the low-intermediate carrier.
49. Install the #6 low-intermediate carrier thrust bearing.
K2-242
50. Install the low-intermediate ring gear.
51. Install the #7 reverse/fourth gear sun gear thrust bear

ing.
52. Install the reverse/fourth gear sun gear/shell.
53. Install the reverse/fourth gear carrier with the captured

#8 reverse/fourth gear carrier thrust bearing.
54. Install the lo w /re ve rse clu tch p la te s.
K2-243
55. Install the low/reverse pressure plate previously se

lected.
LOW/REVERSE 56. Install the low/reverse wave spring.

WAVE SPRING
LOW ONE-WAY Note

CLUTCH ASSEMBLY • Be sure grooves in inner and outer races face up.
57. Install the low one-way clutch assembly with the I.D.
groove on the inner ring facing up.
LOW ONE-WAY 58. Install the low one-way clutch thrust plate.
CLUTCH 59. Install the low one-way clutch retaining ring.
RETAINING RING
LOW ONE-WAY
CLUTCH
THRUST PLATE
M A N U A L VALVE 60. S n a p the s o c k e t e n d of the m a n u a l v a lv e d e te n t le v er a c

DETENT LEVER tu atin g rod on th e p a rk in g c a m actuator.
ACTUATING ROD
SOCKET END
PARKING CAM
ACTUATOR
K2-244
MANUAL
61. Snap the opposite socket end of the manual valve detent
VALVE lever actuating rod on the manual valve detent lever.
DETENT
LEVER
MANUAL VALVE
DETENT LEVER
ACTUATING ROD
SOCKET END
62. Install the SSTs on the reverse/fourth gear carrier.
Tightening torque: 13.5 N m {1.4 kgf m, 10 ft Ibf}
63. Install the SST across the case.
64. Use a depth micrometer to measure the distance from

the top of the gauge bar to the bearing surface on the re
verse/fourth gear carrier. This is dimension A.
65. Measure the distance from the top of the SST to the #12
driven sprocket bearing surface area of the case. This is
dimension B.
66. Subtract dimension A from dimension B to get dimen
sion C.
67. Use dimension C to select the proper #11 driven sprock
et shim from the following chart.
D im e n s io n C m m { in } S h im T h ic k n e s s m m { in }
14.34— 1 4 .1 7 {0 .5 6 5 — 0 .5 5 8 } 2 .2 0 — 2 .1 0 {0 .0 8 7 — 0 .0 8 3 }
14.16— 1 4 .0 0 {0 .5 5 7 — 0 .5 5 1 } 2 .0 2 — 1 .9 2 {0 .0 8 0 — 0 .0 7 6 }
13.99— 1 3 .83 {0 .5 5 0 — 0 .5 4 4 } 1 .8 5 — 1 .7 5 {0 .0 7 3 — 0 .0 6 9 }
13.82— 1 3 .66 {0 .5 4 3 — 0 .5 3 8 } 1 .6 7 — 1 .5 7 { 0 .0 6 6 — 0 .0 6 2 }
1 3 .65 — 1 3 .49 {0 .5 3 7 — 0 .5 3 1 } 1 .5 0 — 1 .4 0 {0 .0 5 9 — 0 .0 5 5 }
1 3 .48 — 1 3 .32 {0 .5 3 0 — 0 .5 2 4 } 1 .3 2 — 1 .2 2 {0 .0 5 2 — 0 .0 4 8 }
68. Remove SSTs.
69. Lubricate needles and seals of bearing.

70. Install the selected #11 driven sprocket shim on the
case.
71. Install the #12 driven sprocket thrust bearing.
72. Install the #9 reverse/fourth gear thrust bearing.
#9 REV/4GR RING
GEAR THRUST
BEARING
73. Install th e d rive sp ro c k e t, for g a u g i n g only.

DRIVE SPROCKET
K 2-246
74. Install the SSTs on the drive sprocket.
Tightening torque: 13.5 N m {1.4 kgf m, 10 ft lbf}
75. Install the SST on the case.

the top of the gauge bar to the face of the drive sprocket.
This is dimension A.
77. Use combined thickness 25.4 mm {1.00 in} of gauge bar

and short spacers as distance B.
sion C.
79. Use dimension C to select the proper #10 drive sprocket
thrust washer from the following chart.
D im e n s io n C m m { in } # 1 0 W a s h e r T h ic k n e s s m m { in }
1.12— 0 .8 6 {0 .0 4 4 — 0 .0 3 4 } 1.5 1 — 1.41 {0 .0 5 9 — 0 .0 5 6 }
0 .8 5 — 0 .6 0 {0 .0 3 3 — 0 .0 2 4 } 1.7 7 — 1 .6 7 {0 .0 7 0 — 0 .0 6 6 }
0 .5 9 — 0 .3 4 {0 .0 2 3 — 0 .0 1 3 } 2 .0 3 — 1 .9 3 {0 .0 8 0 — 0 .0 7 6 }
0 .3 3 — 0 .0 8 {0 .0 1 3 — 0 .0 0 3 } 2 .2 9 — 2 .1 9 {0 .0 9 0 — 0 .0 8 6 }
80. Remove the drive sprocket.
K2-247
81. Remove the gauge bar and preload tool.

Apply petroleum jelly to the selected #10 drive sprocket
thrust washer and install on the converter housing.
Remove the drive sprocket.
82. Install the oil filter and seal assembly.
83. Temporarily install the SST or equivalent.
84. Use the SST to install the oil filter recirculation seal.
85. Install the rear part of the chain cover in the transaxle
case.
K2-248
Warning
• Wear gloves as personal protection from sharp
chain and sprocket teeth.
86. Lower the chain drive and its sprockets together in the
transaxle case. Verify that both sprockets are seated.
87. Install the front part of the chain cover by snapping it into
place.
88. Install the #13 driven sprocket thrust bearing.
FINAL DRIVE 89. Install the final drive carrier/differential case.

CARRIER/DIFFERENTIAL
CASE
TRANSAXLE
4 9 U N 0 1 108 90. Install the SSTs on the case. Secure with the two bolts.
K 2-249

the top of the gauge bar to the shim surface area of the
final drive carrier and differential assembly. Make two
measurements and average. This is dimension A.
92. Use combined thickness of gauge bar with long spacers
177.8 mm {7.00 in} as distance B.
sion C.
94. Use dimension C to select the proper #14 differential
bearing shim from the following chart.
Dimension C mm{in} #14 Shim Thickness mm{in}
13 0 .7 6 — 1 3 0 .4 6 {5 .1 4 8 — 5 .1 3 6 } 1 .0 8 — 0 .9 8 {0 .0 4 3 — 0 .0 3 9 }
13 0 .4 5 — 1 3 0 .1 6 {5 .1 3 6 — 5 .1 2 4 } 1 .3 8 — 1 .2 8 {0 .0 5 4 — 0 .0 5 0 }
13 0 .1 5 — 1 2 9 .8 7 {5 .1 2 3 — 5.1 13 } 1 .6 7 — 1 .5 7 {0 .0 6 6 — 0 .0 6 2 }
12 9 .8 6 — 1 2 9 .5 7 {5 .11 3 — 5 .1 0 1 } 1 .9 7 — 1 .8 7 {0 .0 7 8 — 0 .0 7 4 }
1 2 9 .5 6 - 1 2 9 .2 7 {5 .1 0 0 — 5 .0 8 9 } 2 .2 7 — 2 .1 7 {0 .0 8 9 — 0 .0 8 5 }
95. Remove the gauge bar and long spacers.
96. Install the speedometer drive gear.

97. Install the selected #14 differential bearing shim.
98. Install the #15 differential bearing.
#15 DIFFERENTIAL BEARING
#14 DIFFERENTIAL
BEARING SHIM
SPEEDOMETER
DRIVE GEAR
99. Attach the gasket to the transaxle case split flange.
100. Lower the converter housing onto the transaxle case.
K2-250
101. Install the twenty converter housing-to-transaxle case
bolts or replace bolts. Tighten the bolts in sequence
shown.
Tightening torque: 22.5 N m {2.3 kgf m, 19 ft Ibf}
Note
• Note the number of grooves on the piston rod.
102. Install the 2/4 servo piston and return spring assembly.
103. Install the SST on piston.
Note
• Legs of the SST fit into servo piston cover retaining
ring groove.
104. Install the SST in case bore. SST bolts should be loosely
assembled for easy installation.
105. Tighten SST using bolts as shown.

106. Tighten the screw.
Tightening torque: 4 N m {40 kgf m, 36 ft Ibf}
SCREW
K2-251
107. Install depth micrometer on head of the SST. Measure

and recard distance to bar of the SST. (distance A).
108. Back off screw until servo piston movement stops. Mea
sure and recard distance to bar of the SST. (distance B).
109. Subtract A from B to obtain travel C.
T ra v e l S p e c if ic a tio n R o d L e n g th
N u m b e r o f G ro o v e s
m m { in } m m { in }
0 108.1 {4.26}
1 2.43—4.82
107.1 {4.22}
{0.096—0.190}
2 105.7 {4.16}
110. If the depth micrometer reading is not within the travel

specification, replace the 2/4 servo piston and recheck.
111. Remove the SST.
112. Install the servo cover in the case.

113. Install the SST.
114. Compress the servo cover and install the retaining ring.
115. Remove the SST.
116. Install the servo cover cap using SST.
Warning
• Use safety glasses when using compressed air.
Caution
49 U N 0 1 113
• The coasting clutch circuit should not be applied.
Failure to do so may result in the coasting clutch
piston coming out of the forward clutch piston.
K2-252
117. Install the SST using six mounting bolts.
Use a rubber tipped blow gun and compressed air to
check the following clutch hydraulic circuits for function
and leakage.
• REVERSE CLUTCH
• FORWARD CLUTCH
• DIRECT CLUTCH
• LOW/REVERSE CLUTCH
• SERVO RELEASE
• SERVO APPLY
Warning
• Wear eye protection when using compressed air.
118. If leakage is heard in any circuit the transaxle must be

disassembled and the source of leakage corrected.
Remove the SST.
119. Place the thermostatic oil level control valve in the trans
axle case.
120. Install the bracket and the bolt.
Tightening torque: 13 N m {1.3 kgf-m, 10 ft Ibf}
121. Install O-ring on the solenoid body connector.
Caution
THERMOSTATIC C BRACKET • Do not pull wires or damage connector body.
OIL LEVEL VALVE
122. Place the control valve body slightly away from the trans
axle case and push the solenoid body connector into its
bore.
123. Align the Z-link in the manual valve. Install the wiring har
ness clip.
124. Install the 12 mounting bolts. Tighten the mounting bolts

in the sequence shown.
Tightening torque: 10 N m {1.0 kgf-m, 7 ft lbf}
K2-253
125. Loosen the nut on the ball stud for the manual valve det
ent actuating rod.
126. Remove the manual lever control shaft outer lever.
127. Use the SST to move the shaft to the D range position
and install the pin to hold the tool in position.
MANUAL VALVE 128. Move the manual valve detent lever to the D range posi
LEVER tion.
129. Initially tighten the nut on the ball stud.
130. Remove the manual control outer lever pin and the SST.
131. Install the manual lever control shaft outer lever and bolt.
K2-254
132. Rotate the manual detent cover and tighten the ball stud
nut.
Tightening torque: 12 N m {122 kgf-cm, 106 in-lbf}
133. Install the transmission range sensor on the manual le

ver shaft. Finger tighten the two mounting bolts.
Note
• Outer lever must be in N range position.
134. Use the SST to align the sensor on the shaft and case.
TRANSMISSION RANGE (TR) SENSOR
135. Tighten the transmission range sensor bolts.

Remove the SST.
136. Install the control valve body cover gasket on the case.
Attach the cover to the case.
137. Install the fourteen mounting bolts in the sequence
shown.
K2-255
138. Install and tighten the control valve body cover-to-trans-

axle case bolts.
VEHICLE SPEEDOMETER SENSOR 139. Install the O-ring seal on the vehicle speedometer sen
sor.
140. Push the vehicle speedometer sensor into the bore.
141. Install the bolt.
142. Tighten the bolt.
143. Install the oil filler tube seal grommet into the case.
144. Install the oil filler tube.

145. Install the mounting bolt. Tighten the mounting bolt.
Tightening torque: 14 N m {1.4 kgf-m, 10 ft lbf}
146. Install the oil level indicator in the tube.
147. Install the turbine shaft speed sensor O-ring seal.

148. Push the turbine shaft speed sensor into the bore.
149. Install the mounting bolt.
150. Tighten the bolt.
K2-256
151. Use the SST or equivalent and a hammer to install the
RH and LH differential seals.
152. Use the SST or equivalent and a hammer to install the

torque converter impeller hub seal.
153. Apply sealant to drain plug. Install the drain plug. Tighten
the drain plug.
154. Install the oil pump drive shaft into the end of the turbine
shaft.
155. Install the torque converter in the transaxle.
K2-257
156. Remove the transaxle from the SST.

157. Dry the transaxle exterior and prepare it for installation.
K 2-258
Before beginning any service procedure, refer to section S of the 1994 626/MX-6
Body Electrical Troubleshooting Manual for air bag system service warnings.
FRONT AND REAR AXLES
INDEX.............................................................M - 2
OUTLINE........................................................ M - 3
SPECIFICATIONS.........................................M - 3
TROUBLESHOOTING GUIDE........................ M - 3
FRONT AXLE................................................. M - 4
PREPARATION............................................ M - 4
WHEEL HUB, STEERING KNUCKLE.......... M - 5
REAR AXLE................................................... M-11
PREPARATION............................................ M-11
DRUM BRAKE TYPE................................... M-12
DISC BRAKE TYPE..................................... M-15
DRIVE SHAFT................................................ M-18
PREPARATION............................................ M-18
JOINT SHAFT............................................. M-19
DRIVE SHAFT............................................. M-23
DOUBLE OFFSET TYPE (MTX)....................M-28
TRIPOD TYPE (ATX).................................... M-33
36U0MX-001
M INDEX
INDEX
FRONT AXLE
REAR AXLE
(Drum Brake Type)
(Disc Brake Type)
46U0MX-066
1. Front axle (Disc brake type)

Wheel hub, Steering Knuckle Preinspection........................... page M-15
Preinspection........................... page M - 5 Removal / Inspection
Removal / Installation............... page M - 5 Installation..............................page M-15
D is a s s e m b ly / In s p e c tio n / D is a s s e m b ly / A s s e m b l y ........... p a g e M - 1 6
Assembly............................... page M- 7 3. Joint shaft
2. Rear axle Preinspection........................... page M-19
(Drum brake type) Removal / Installation............... page M-19
Preinspection........................... page M-12 Overhaul..................................page M-22
Removal / Inspection / 4. Drive shaft
Installation.............................. page M-12 Preinspection........................... page M-23
Disassembly / Assembly...........page M-14 Removal / Installation............... page M-24
Overhaul
(Double offset type)............... page M-28
(Tripod type).......................... page M-33
M—2
OUTLINE, TROUBLESHOOTING GUIDE M
OUTLINE
SPECIFICATIONS
Engine FS KL
-— ____Transaxle
Item MTX ATX MTX ATX
Front axle
Maximum wheel bearing play mm (in) 0.05 (0.002)
Rear axle
Maximum wheel bearing play mm (in) 0.05 (0.002)
Drive shaft
Wheel side Birfield joint (BJ)
Joint type
Differential side DOJ TJ DOJ TJ
Length of joint 387.0 380.0 382.0 380.0
Right side
(between center of joint) (15.24) (14.96) (15.04) (14.96)
mm (in) 387.0 380.0 382.0 380.0
Left side
(15.24) (14.96) (15.04) (14.96)
Right side 24.0 0.94) 26.0 (1.02) 26.3 (1.03)
Shaft diameter mm (in)
Left side 24.0 (0.94) 26.0 (1.02) 26.3 (1.03)
Length of joint shaft mm (in) 376.0 14.80)
Joint shaft diameter mm (in) 26.0 1.02)
46UOMX-067
* TJ: Tripod joint
DOJ: Double offset joint

Steering wheel Excessive wheel bearing play Tighten or replace M- 5
vibration Worn or damaged wheel bearing Replace M- 7
Steering wheel pulls Excessive wheel bearing play Tighten or replace M- 5
or one-sided braking Worn or damaged wheel bearing Replace M- 7
Excessive steering Excessive wheel bearing play Tighten or replace M- 5
wheel play
Abnormal noise Worn or damaged wheel bearing Replace M- 7
Insufficient grease in joint or splines of joint shaft Add or replace M -19
Bent drive shaft or joint shaft Replace M-19, 23
Worn drive shaft or joint shaft splines Replace M-19, 23
Insufficient grease in joint or on splines of drive shaft Replenish or replace M-23, 28
Worn drive shaft Replace M-24
Grease leakage from Damaged or broken boot Replace M-28, 33
boot Faulty boot band Replace M-28, 33
Excessive grease Repair M-28, 33
36UQMX-004
Rear Axle

Steering wheel Worn or damaged wheel bearing Replace M-12, 15
vibration Excessive wheel bearing play Tighten or replace M-12, 15
Steering wheel pulls Worn or damaged wheel bearing Replace M -12, 15
or one-sided braking Excessive wheel bearing play Tighten or replace M -12, 15
Excessive steering Excessive wheel bearing play Tighten or replace M-12, 15
wheel play
Abnormal noise Worn or damaged wheel bearing Replace M -12, 15
36U0MX-005
M -3
M FRONT AXLE
FRONT AXLE
PREPARATION
SST
49 0118 850C For 49 G030 797 For

removal of tie rod installation of
Puller, ball joint u jS c U ^ end Handle wheel bearing
49G030 795)
49G033 1A1 For /in p n o c -mo For

disassembly and <4 disassembly of
Puller, wheel hub assembly of Puller, wheel hub wheel bearing
wheel hub D— U ~
49 G033 105 ✓ '“ "N . For 49 G033 102 For

installation of removal of front
Attachment 1vs— front wheel hub Handle n /V wheel hub
(Part of (Part of \ \
49G0331A1) ^ 49G033 1A1) N ? /}
49 F027 0A1 For 49 G033 107 / ^ ^ J \ For

installation of installation of dust
Installer set, II bearing Installer, dust V\ y \ \ cover
hearing 0 @ @ \ j/ cover % \^ J |] )
49 F027 004 For 49 V001 795 For

removal of wheel installation of oil
Attachment 80 bearing Installer, oil seal
(Part of
49F027 0A1)
49 F027 009 ^ = = :> ^ \ For 49 G033 106 For

instalation of dust removal of front
Attachment cover Attachment wheel hub
68 & 77 VV-
(Part of — ~ ^y 49G033 1A1) ^
49 F027 0A1)
49 G030 795 For

installation of
Installer, oil wheel bearing — —
36U0MX-057
M—4
FRONT AXLE M
WHEEL HUB, STEERING KNUCKLE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Remove the brake caliper assembly and disc plate.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and meas
ure the wheel bearing play.
4. If the bearing play exceeds the specification, check and ad
just the locknut torque or replace the wheel bearing if
necessary.
Maximum wheel bearing play: 0.05mm {0.002 in)
4. Loosely tighten the stabilizer and shock absorber bolts and nuts. Lower the vehicle and tighten all bolts
and nuts to the specified torque with the vehicle unladen.
5. After installation, check the wheel alignment. (Refer to Section R.)
46U0MX-001
1. Wheel nut 7. Tie rod end

2. Wheel and tire Removal Note............................ page M-6
3. Locknut Installation Note......................... page M-6
Removal Note............................ page M-6 8. Stabilizer control link
Installation Note......................... page M-6 9. Lower arm ball joint
4. Brake caliper assembly 10. Steering knuckle, wheel hub and dust cover
Service........................................Section P Inspect dust cover for damage and
5. Disc plate distortion
Service........................................ Section P Disassembly / Inspection I
6. Wheel speed sensor (ABS) Assembly.................................page M-7
Service........................................Section P
M—5
M FRONT AXLE
Removal Note
Locknut
1. Knock the crimped portion of the locknut outward by us
ing a small chisel and hammer.
2. Lock the hub by applying the brakes.
46U0MX-002
Tie rod end
Caution
are between the dust boot and tie rod end.
Losen the nut and disconnect the tie rod end by using the
SST.
Installation Note
Tie rod end
1. Position the tie rod end and dust boot directly over the
knuckle hole.
2. Install the nut to the tie rod end and tighten.
Tightening torque:
32—44 N m {3.2—4.5 kgf-m, 24—32 ft lbf]
46U0MX-004
Locknut
Install a new locknut and stake it, as shown.
Tightening torque: 236—318 Nm

{24.0—32.5 kgf m, 173.6—235.0 ft lbf)
16A0MX-018
M—6
FRONT AXLE M
REPLACE
46UQMX-068
1. Oil seal 5. Dust cover

Assembly Note........................ page M-10 Disassembly Note.................... page M- 8
2. Front wheel hub assembly Assembly Note........................ page M- 9
Disassembly Note............................. below 6. Steering knuckle
Assembly Note........................ page M - 9 7. Hub bolt
3. Retaining ring Disassembly Note.................... page M- 8
4. Wheel bearing Assembly Note........................ page M- 9
Disassembly Note.................... page M - 8
Assembly Note........................ page M - 9
Disassembly Note
Front wheel hub assembly
1. Remove the front wheel hub assembly by using the SST.
46U0MX-005
M—7
M FRONT AXLE
2. If the bearing inner race remains on the front wheel hub
assembly, grind a section of the bearing inner race until ap
prox. 0.5mm [0.020 in} remains. Then remove it with a
chisel.
46U0MX-006
Wheel bearing
Using the SST, remove the wheel bearing.
36U0MX-007
Dust cover
Note
• The dust cover does not need to be removed unless you
are replacing it.
1. Mark the dust cover and steering knuckle for proper reas
sembly.
46U0MX-007
2. Remove the dust cover by using a chisel.
16E0MX-018
Hub bolt
Note
• The hub bolts do not need to be removed unless you
are replacing them.
Remove the hub bolts by using a press.
46U0MX-008
M—8
FRONT AXLE M
Assembly Note
Hub bolt
Press in new hub bolts.
16E0MX-020
Dust cover
1. Mark the new dust cover as the one removed.
16E0MX-021
2. Align the marks of the new dust cover and the steering
knuckle.
3. Using a steel plate and the SST, install the dust cover.
46U0MX-009
Wheel bearing
Using the SST, install the new wheel bearing.
36U0MX-009
Front wheel hub assembly
Using the SST, install the front wheel hub assembly.
49 G033 105
49 F027 009
36U0MX-010
M -9
M FRONT AXLE
Oil seal
1. Using the SST and a hammer, tap a new oil seal in evenly
until the SST contacts the steering knuckle.
2. Coat the lip of the oil seal with grease.
46U0MX-010
M—10
REAR AXLE M
REAR AXLE
PREPARATION
SST
36U0MX-011
M -1 1
M REAR AXLE
DRUM BRAKE TYPE
Wheel Hub, Hub Spindle
Preinspection
Wheel bearing play
2. Position a dial indicator against the brake drum. Push and
pull the rear brake assembly by hand in the axial direction
and measure the wheel bearing play.
3. If the bearing play exceeds specification, check and ad
just the locknut torque or replace the hub bearing
assembly if necessary.
Maximum wheel bearing play: 0.05mm (0.002 in)

4. Loosely tighten the lateral link , trailing link and shock absorber bolts and nuts. Lower the vehicle and
tighten all bolts and nuts to the specified torques with the vehicle unladen.
5. After installation check the rear wheel alignment. (Refer to Section R.)
1. Wheel and tire 6. Parking brake cable bracket

2. Hub cap 7. Clip
3. Locknut 8. Rear brake assembly
Removal Note.......................... page M-13 Service........................................ Section P
Installation Note...................... page M-13 9. Rear hub spindle
4. Brake drum Inspect for cracks and damage
5. Hub bearing assembly
Inspect for cracks and damage
Disassembly / Assembly.......... page M-14
M -1 2
REAR AXLE M
Removal Note
Locknut
1. Raise the staked portion of the locknut using a small cape
chisel.
36U0MX-014
Installation Note
Locknut
Tightening torque: 177—235 N-m

{18.0—24.0 kgf-m, 130.1—173.6 ftlbf)
36U0MX-017
M -1 3
M REAR AXLE
Caution
• The wheel hub and bearing are one assembly and do not need to be disassembled.
46U0MX-011
1. Hub bolt 2. Hub bearing assembly

Disassembly Note. page M-14
Assembly Note..... page M-14
Disassembly Note
Hub bolt
Note
• The hub bolts do not need to be removed unless you
are replacing them.
Remove the hub bolts with a press.
46U0MX-012
Assembly Note
Hub bolt
36U0MX-020
M -1 4
REAR AXLE M
DISC BRAKE TYPE
Wheel Hub, Hub Spindle
Preinspection
Wheel bearing play
2. Remove the brake caliper assembly.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and
measure the wheel bearing play.
4. If the bearing play exceeds the specification, check and
adjust the locknut torque or replace the hub bearing
assembly if necessary.
Maximum wheel bearing play: 0.05mm {0.002 in)

4. Loosely tighten the lateral link , trailing link and shock absorber bolts and nuts. Lower the vehicle and
tighten all bolts and nuts to the specified torques with the vehicle unladen.
5. After installation, check the rear wheel alignment. (Refer to Section R.)
1. Wheel and tire 6. Hub bearing assembly

2. Hub cap Inspect for cracks and damage
3. Locknut Disassembly / Assembly...........page M-16
Removal Note......................... page M-16 7. Allen bolt or flange bolt
Installation Note........................page M-16 8. Dust cover
4. Brake caliper assembly Inspect for damage and distortion
Service........................................ Section P 9. Wheel speed sensor (ABS)
5. Disc plate 10. Hub spindle
Inspection................................... Section P Inspect for cracks and damage
M -1 5
M REAR AXLE
Removal Note
Locknut
ing a small chisel and a hammer chisel.
46U0MX-013
Installation Note
Locknut
Install a new locknut and stake it as shown.
Tightening torque: 177—235 N m

{18.0—24.0 kgf m, 130.1—173.6 ft lbf)
36U0MX-023
Caution
• The wheel hub and bearing are one assembly and do not need to be disassembled.
46U0MX-014
1. ABS sensor rotor 2. Hub bolt

Disassembly Note.................... page M-17 Disassembly Note.................... page M-17
Assembly Note........................ page M-17 Assembly Note........................ page M-17
3. Hub bearing assembly
M—16
REAR AXLE M
Disassembly Note
ABS sensor rotor
Note
• The sensor rotor does not have to be removed unless
Remove the sensor rotor by using a chisel.
Hub bolt
Note
• The wheel hub and bearing are one assembly and do
not to be disassembled.
Remove the hub bolts by using a press.
46U0MX-016
Assembly Note
Hub bolt
ABS sensor rotor

1. Install a new rear ABS sensor rotor on to the wheel hub.
2. Using a steel plate and the SST, press the rotor until it is
flush with the wheel hub.
Note
• The ABS sensor rotor can be installed in either direction.
36UQMX-025
M -1 7
M DRIVE SHAFT
DRIVE SHAFT
PREPARATION
SST
49 H034 2A0 For 49 H034 201 For

Lower arm bracket Support block (( V bracket
bushing puller & (Part of \ \ >
installer 49 H034 2A0) \J ^
49 F026102 For 49 G030 795 For

Installer, bearing bearing and left Installer, oil seal right side dust
side dust seal seal and bearing
49 0118 850C For 49 W027 003 For
Puller, ball joint

removal of tie rod
end Installer, oil seal
O installation of
left side dust seal
49 G025 001 For 49 G017 503 < 2 = ^, For

installation of support of
Installer, sensor sensor rotor Hook engine
(Part of
49G017 5A0)
49 G017 5A0 P * For 49 G017 502 For

Support, engine engine Support ' engine
(Part of
49G017 5A0)
49 G017 501 For 49 G030 797 For

support of installation of
Bar \N . engine right side dust
(Part of \ \ seal and bearing
49G017 5A0) 49 G030 795)
49 G030 796 /^ > \ For

installation of
right side dust — —
(Part of f tf/J r seal and bearing
49 G030 795)
16E0MX-036
M -1 8
DRIVE SHAFT M
JOINT SHAFT
Preinspection
Joint shaft
1. Verify that the joint shaft is not twisted or cracked. Replace
it if necessary.
2. Turn the joint shaft by hand and verify that the bearing ro
tates smoothly and freely. Replace it if necessary.
16E0MX-037
1. Drain the transaxle oil.
4. After installation, fill the transaxle with the specified amount of the specified transaxle oil or ATF and in
spect for oil leakage.
89—117 (9.0—12.0, 66—86.7)
N-m [kgfm , ft-lbf)
46U0MX-017
1. Wheel and tire 6. Right drive shaft and axle

2. Drain plug Removal Note.......................... page M-20
3. Stabilizer control link Installation Note....................... page M-21
4. Tie rod end 7. Joint shaft
Removal Note.......................... page M-20 Removal Note.......................... page M-20
Installation Note....................... page M-21 Installation Note....................... page M-21
5. Lower arm ball joint Overhaul..................................page M-22
M -1 9
M DRIVE SHAFT
Removal Note
Tie rod end
Caution
boot. Install the SST so that the sharp edges are be
tween the dust boot and tie rod end.
Loosen the nut and disconnect the tie rod end by using the
SST
46U0MX-018
Right drive shaft and axle
Caution
• Be careful not to damage the ball joint dust boot.
36U0MX-027
4. As shown in the figure, insert a pry bar between the right

drive shaft and the joint shaft and tap on the bar to uncou
ple them.
Joint shaft
Pull the joint shaft straight out.
46U0MX-021
M—20
DRIVE SHAFT M
Installation Note
Joint shaft
Caution
• Do not damage the transaxle oil seal.
1. Install the joint shaft with the end-gap of a new clip facing
upward.
Tightening torque:
43—61 N m {4.3—6.3 kgf m, 32—45 ft-lbf]
Right drive shaft and axle

1. Push the drive shaft into the joint shaft.
2. After installation, pull the front hub outward to verify that the
drive shaft is securely held by the clip.
46U0MX-023
through bolt.
Tightening torque:
35—56 N m {3.5—5.8 kgf m, 26—41 ft lbf)
46U0MX-024
Tie rod end
Caution
• Do not damage the dust boot.
knuckle hole.
Tightening torque:
32—44 N m (3.2—4.5 kgf m, 24—32 ft lbf)
M DRIVE SHAFT
Overhaul
REPLACE
46U0MX-O69
1. Clip 4. Bearing
2. Joint shaft Disassembly Note. ........ below
Inspect splines for damage and wear Assembly Note.... page M-23
Disassembly Note............................. below 5. Dust seal (right)
Assembly Note........................ page M-23 Assembly Note.... page M-23
3. Dust seal (left) 6. Bracket
Disassembly Note............................. below
Assembly Note........................ page M-23
Disassembly Note
Joint shaft
Remove the joint shaft by using the SST.
Dust seal (left)/Bearing

Remove the left side dust seal and bearing by using the
SST
36U0MX-032
M—22
DRIVE SHAFT M
Assembly Note
Dust seal (right)
Using the SST, install the new right side dust seal.
16E0MX-051
Bearing
Using the SST, install the new bearing.
49 G030 795
49 H034 201
36U0MX-033
Dust seal (left)
49 W027 003
STEEL Using a steel plate and the SST, install the new left side
dust seal.
36U0MX-034
Joint shaft
SHAFT Using a press and the SST, install the joint shaft.
49 H034 201
36U0MX-035
DRIVE SHAFT
Preinspection
Drive shaft
1. Check the dust boot on the drive shaft for cracks, damage,
leaking grease, and a loose boot band.
2. Check the drive shaft for bending, cracks, and wear of joints
or splines.
3. Repair or replace the drive shaft if necessary.
36U0MX-036
M -2 3
M DRIVE SHAFT
1. Drain the transaxle oil.
4. After installation, fill the transaxle with the specified amount of the specified transaxle oil or ATF and in
spect for oil leakage.
5. Check the front wheel alignment. (Refer to Section R.)
N m (kgf m, ft Ibf |
46U0MX-026
1. Wheel and tire 7. Transverse member

2. Splash shield 8. Lower ball joint
3. Drain plug Removal Note.................. page M-25
4. Locknut 9. Engine mount member
Removal Note.......................... page M-25 (Only for ATX at left side drive shaft)
Installation Note....................... page M-27 Removal Note.................. page M-25
5. Stabilizer and control link 10. Drive shaft
6. Tie rod end Removal Note.................. page M-26
Removal Note.......................... page M-25 Installation Note............... page M-26
Installation Note....................... page M-27 Overhaul.......................... pages M-28, 33
M—24
DRIVE SHAFT M
Removal Note
Locknut
ing a chisel and a hammer.
46U0MX-027
Tie rod end
Caution
are between the dust boot and tie rod end.
Loosen the nut and disconnect the tie rod end by using the
SST
Lower ball joint

46UQMX-029
46U0MX-030
Engine mount member
Suspend the engine by using the SST and remove the en
gine mount member.
16E0MX-059
M—25
M DRIVE SHAFT
Drive shaft
Caution
• The sharp edges of the drive shaft can slice or punc
ture the oil seal. Be careful when removing the drive
shaft from the transaxle.
1. Separate the left-side drive shaft from the transaxle by pry

2. Separate the right-side drive shaft from the joint shaft by

hammering on a bar inserted between them.
46U0MX-032
Note
• If the drive shaft will not come out of the front wheel hub
easily, install an already discarded nut onto the drive shaft
so that the nut is flush with the end of the drive shaft. Tap
the nut with a copper hammer to loosen the drive shaft
from the front wheel hub.
46U0MX-033
Installation Note
Drive shaft
Caution
• The sharp edges of the drive shaft can slice or punc
ture the oil seal. Be careful when installing the drive
shaft to the transaxle.
1. Turn the clip with the opening facing upward.
46U0MX-034
2. A p p ly g r e a s e to the e n d s of the d rive shafts.
Caution
• The oil seals are damaged easily it this procedure
is not done correctly.
3. Push the drive shaft into the transaxle (left side) or joint shaft
(right side).
46U0MX-035
M—26
DRIVE SHAFT M
4. After installation, pull the front hub outward to confirm that
the drive shaft is securely held by the clip.
46U0MX-036
through bolt.
Tightening torque:
35—56 Nm [3.5—5.8 kgf m, 26—41 ft lbf}
46U0MX-037
Tie rod end
knuckle hole.
Tightening torque:
32—44 Nm (3.2—4.5 kgf m, 24—32 ft lbf}
Locknut
Tightening torque: 236—318 Nm

{24.0—32.5 kgf m, 173.6—235.0 ft Ibf}
16A0MX-025
M -2 7
M DRIVE SHAFT
DOUBLE OFFSET TYPE (MTX)

Overhaul
3. Verify that all parts are free of dust, dirt and other foreign material immediately before reassembly.
46U0MX-O39
1. Boot bands 7. Cage

Disassembly Note.................... page M-29 Disassembly Note............. page M-29
Assembly Note........................ page M-32 Assembly Note................ page M-31
2. Clip 8. Boot (transaxle side)
Disassembly Note.................... page M-29 Disassembly Note.............page M-30
Assembly Note........................ page M-31 Inspect for cracks and damage
3. Outer ring Assembly Note................ pages M-30, 31
Inspect inside bore for wear, 9. Boot (wheel side)
c o rro sio n , a n d s c o r in g Disassembly..................... page M-30
Assembly Note........................ page M-31 Inspect for cracks and damage
4. Snap ring Assembly Note................ page M-31
Disassembly Note.................... page M-29 10. ABS sensor rotor
Assembly Note........................ page M-31 Disassembly Note............ page M-30
5. Balls Assembly Note................ page M-30
Disassembly Note.................... page M-29 11. Shaft and ball joint assembly
Assembly Note........................ page M-31 Inspect splines for damage and wear
6. Inner ring Inspect wheel side joint for excessive play
Disassembly Note.................... page M-29 and rough rotation
Assembly Note........................ page M-31 12. Clip
M—28
DRIVE SHAFT M
Disassembly Note
Rotate the joint by hands as shown in the inset. If the joint
does not move smoothly or if a problem is found, repair the
necessary parts or replace the drive shaft.
46U0MX-040
Boot bands
1. Pry up the locking clips by using a screwdriver.
2. Pull back the end of the band.
46U0MX-041
Clip
1. Use paint to mark the drive shaft and outer ring for proper
reassembly.
2. Remove the clip.
46U0MX-042
Snap ring
1. Use paint to mark the drive shaft and inner ring for proper
reassembly.
2. Remove the snap ring by using snap ring pliers.
46U0MX-043
Cage, inner ring, and balls
1. Use paint to mark the inner ring and cage for proper reas
sembly.
2. Turn the cage approximately 30 degrees and pull the cage
and balls away from the inner ring.
46U0MX-044
M—29
M DRIVE SHAFT
Boot
1. Wrap the shaft splines with-tape to protect the boot.
TAPE 2. Remove the boot.
16E0MX-077
ABS sensor rotor
Note
• The sensor rotor does not need to be removed unless
Tap the ABS sensor rotor off the drive shaft with a chisel.
46U0MX-045
Assembly Note
ABS sensor rotor
Set a new ABS sensor rotor on the drive shaft in the direc
tion as shown, and press it onto the shaft assembly by us
ing the SST.
Boot
1. Wrap the shaft splines with tape.
2. Install the wheel-side and transaxle-side boots, noting the

shape and size of each one in the figure.
46U0MX-048
M -3 0
DRIVE SHAFT M
Boot (wheel side)
1. Fill the boot with the grease supplied in the boot kit.
Grease amount
FS engine: 90—110 g {3.18—3.88 oz}
KL engine: 130—150 g {4.59—5.29 oz]
2. Slide the boot onto the shaft.
46U0MX-049
Cage, inner ring and balls/Snap ring
1. Align the marks, and install the balls and cage to the inner
ring in the direction shown in the figure.
46UOMX-050
Boot (differential side), outer ring, clip
1. Fill the boot and outer ring with the grease supplied in the
boot kit and joint kit.
Grease amount
FS engine: 120—140 g {4.24—4.94 oz}
KL engine: 140—160 g {4.94—5.64 oz}
46U0MX-051
2. Align the marks, and install the outer ring onto the shaft.
MARKS
3. Install a new clip.
4. Install the boot.
16E0MX-083
5. S e t the d rive sh aft to the s ta n d a r d length.
Standard length
mm (in)
Engine Left side Right side
FS 649.2-659.2 (25.56-25.95) 600.2-610.2 (23.63-24.02)
KL 650.7-660.7 (25.62-26.01) 600.7-610.7 (23.65-24.04)
36U0MX-048
M—31
M DRIVE SHAFT
6. Release trapped air from inside the boot (differential side)
by using a screwdriver covered with a rag.
7. Verify the drive shaft length.
8. If not within specification, return to Step 5.
16E0MX-085
Boot bands
1. Fold the band back in the direction opposite the forward
revolving direction of the drive shaft and use pliers to pull
it tight.
2. Lock the end of the band by bending the locking clips.
46U0MX-052
DRIVE SHAFT M
TRIPOD TYPE (ATX)
Overhaul
3. Verify that all parts are free of dust, dirt, and other foreign material immediately before reassembly.
DO NOT DISASSEMBLE
(8 ) REPLACE
LEFT SIDE
(2 ) REPLACE
RIGHT SIDE
46U0MX-053
1. Boot bands 6. Boot

Disassembly Note.................... page M-34 Inspect for damage
Assembly Note........................ page M-36 Assembly Note........................ page M-35
2. Clip 7. ABS sensor rotor
3. Outer ring Disassembly Note.................... page M-34
D is a s s e m b ly N o t e ..................... p a g e M — 3 4 A s s e m b ly N o t e ......................... p a g e M - 3 5
Inspect inside bore for wear, 8. Shaft and ball joint assembly
corrosion, and scoring Inspect splines for damage and wear
Assembly Note........................ page M-35 Inspect wheel-side joint for excessive play
4. Snap ring and rough rotation
Disassembly Note.................... page M-34
5. Tripod joint
Disassembly Note.................... page M-34
Inspect for damage and wear
M—33
M DRIVE SHAFT
Disassembly Note
Boot band
Note
• The boot band does not need to be removed unless you
are replacing it.
Remove the boot clamp with end clamp pliers as shown

and discard the clamp.
46U0MX-054
Outer ring
Mark the outer ring and the shaft for proper reassembly.
36U0MX-051
Snap ring/Tripod joint
1. Marks the shaft and tripod joint for proper reassembly.
2. Remove the snap ring with snap ring pliers.
3. Remove the tripod joint from the shaft with a bar and a
hammer.
46U0MX-Q55
Note
• The wheel-side boot does not need to be removed un
less you are replacing it.
Wrap the splines of the shaft with tape to prevent damag

ing the boot.
46U0MX-056
ABS sensor rotor
Note
• The sensor rotor does not need to be removed unless
Tap the ABS sensor rotor off the drive shaft by using a chisel.
46UOMX-057
M—34
DRIVE SHAFT M
Assembly Note
ABS sensor rotor
Caution
• Verify the direction of the sensor rotor.
tion shown, and press it onto the shaft assembly by using
the SST.
Boot
WHEEL SIDE TRANSAXLE SIDE
1. Wrap the splines of the transaxle side shaft, and install the
wheel-side and transaxle side boots, noting the shape and
size of each one in the figure.
46U0MX-059
2. Fill the wheel side boot with the grease supplied in the boot
kit.
Grease amount: 125—145 g {4.41—5.11 oz)
36U0MX-060
Tripod joint/Snap ring
1. Align the marks and install the tripod joint.
2. Install the new snap ring with snap-ring pliers.
46U0MX-060
Outer ring
Fill the outer ring and transaxle-side boot with the grease
supplied in the boot kit.
Grease amount: 185—215 g {6.52—7.58 oz)
46U0MX-061
M -3 5
M DRIVE SHAFT
Boot band
1. Verify that the boots are not dented or twisted.
46U0MX-062
2. Set the drive shaft to the standard length.
Standard length m m ( in )
Left sid e R ig h t sid e

6 4 8 .7 — 6 5 8 .7 (2 5 .5 4 — 2 5 .9 3 ) 5 9 8 .7 - 6 0 8 .7 ( 2 3 . 5 7 - 2 3 . 9 6 )
3. Release any trapped air from inside the boot by using a

rag-covered screwdriver.
4. Verify that the drive shaft length is within the standard.
5. If the drive shaft length is not within the standard, return to
Step 1.
6. Install a new boot band on the boot so that the slot end of
the boot band is pointing opposite the forward revolving
direction of the drive shaft.
7. Slide the hook into the end slot, and fit the tabs into the re
maining two slots.
46U0MX-064
8. Crimp the clamp securely by using clamp pliers.
Caution
• Do not overcrimp the boot band clamp. Overcrimp
ing could damage the clamp bridge.
46U0MX-065
M—36
STEERING SYSTEM
INDEX................................................................. N - 2
OUTLINE............................................................ N - 3
SPECIFICATIONS........................................... N - 3
ENGINE SPEED SENSING POWER
STEERING....................................................... N - 3
PREPARATION...............................................N - 3
TROUBLESHOOTING GUIDE....................... N - 4
AIR BLEEDING...............................................N - 5
POWER STEERING FLUID............................ N - 6
STEERING WHEEL AND COLUMN..............N - 9
STEERING GEAR AND LINKAGE................ N-14
POWER STEERING OIL PUMP..................... N-18
DRIVE BELT................................................... N-22
36U0NX-001
N INDEX
INDEX
ENGINESPEED SENSINGPOWER STEERING(ESPS)
FS ENGINE
STEERING WHEEL
FREE PLAY:
0—30mm (0— 1.18 in)
POWER STEERING FLUID

SPECIFICATION:
ATF Dexron®H or M-III
AT 98 N (10 kgf, 22 Ibf)

NEW: 7.5—9.0mm (0.30—0.35 in)
USED: 8.0—9.5mm (0.32—0.37 in)
LIMIT: 11.0mm (0.43 in)
KL ENGINE

SPECIFICATION:
ATF Dexron®!! or M-III
NEW: 6.0—7.0mm (0.24—0.28 in)

USED: 7.0—8.0mm {0.28—0.31 in)
LIMIT: 9.0mm {0.35 in)
1. Steering wheel and column 3. P o w e r ste e rin g oil p u m p

On-vehicle inspection............... page N- 9 Removal / Installation................ page N-18
Removal / Installation................ page N-10 Disassembly / Assembly /
Disassembly / Assembly / Inspection...............................page N-20
Inspection............................... page N-12 Air bleeding..............................page N- 5
2. Steering gear and linkage Power steering fluid................. page N- 6
Removal / Installation.................page N-14 4. Drive belt
Disassembly / Inspection/ Inspection.................................page N-22
Assembly................................ page N-16 Adjustment............................... page N-23
Air bleeding.............................. page N- 5 Replacement............................ page N-23
N—2
OUTLINE, ENGINE SPEED SENSING POWER STEERING N
OUTLINE
SPECIFICATIONS
Enaine FS KL
Item
O u te r d ia m e te r m m ( in ) 3 8 0 ( 1 5 .0 )
S te e rin g w h e e l
L o c k -to -lo c k tu rn s 3.1
Type R a ck-a n d -p in io n
S te e rin g g e a r G e a r ratio o o (infinite)

R a ck s tro k e m m ( in ) 137 (5 .3 9 )
S te e rin g c o lu m n a n d
S h a ft ty p e C o lla p sib le
shaft
P o w e r assist syste m E n g in e s p e e d se n sin g
Type ATF D e xro n ® n o r M -H I
P o w e r s te e rin g flu id
C a p a c ity L (U S qt, Im p q t) 1 .2 5 (1 .3 2 , 1 .1 0 ) 1 .3 0 (1 .3 7 , 1 .1 4 )
36U0NX-003
ENGINE SPEED SENSING POWER STEERING

PREPARATION
SST
49 0118 850C For 49 0180 510B For

re m o va l o f tie rod in s p e c tio n o f
Puller, b all jo in t e n d ball jo in t A tta ch m e n t, p in io n p re lo a d
p re lo a d —
4 9 1232 670A For 4 9 1 232 6 7 2 — F or

in s p e c tio n of in s p e c tio n of
G a u g e set, p o w e r ste e rin g p o w e r ste e rin g
p o w e r s te e rin g flu id p re ssu re flu id p re s s u re
4 9 *1 2 3 2 6 7 0 A )
4 9 1232 673 For 4 9 H 0 0 2 671 For

B o d y , v a lv e PB1 p o w e r ste e rin g A d a p te r, p o w e r p o w e r s te e rin g
flu id p re ssu re ste e rin g g a u g e ^ na— « = o a » > flu id p re ssu re
49 1232 670A )
4 9 G 0 17 5 A 0 For 49 9200 020 < v S \ For

s u p p o rt o f e n g in e in s p e c tio n o f
S u p p o rt, e n g in e T en sio n g a u g e , d riv e b e lt te n sio n
V -rib b e d belt
v
49 H032 321A For 49 D032 316 / g v

re m o va l / For
W re n c h , h e x a g o n Sffaj 1 in sta lla tio n of P ro tra cto r [1 1 -j in sta lla tio n o f
a d ju s tin g c o v e r a d ju s tin g c o v e r
N -3
N ENGINE SPEED SENSING POWER STEERING
49 G 032 3A4 F or 4 9 G 0 3 2 351 For

A d a p te r, p o w e r © © (p ) _ p o w e r ste e rin g A d a p te r t: p o w e r ste e rin g
s te e rin g g a u g e ^ W O flu id p re ssu re (Part o f ( f t. D > p re ssu re
49 G 032 3A4) U U
49 G 032 352 F or 49 G 032 353 ^ ^ For

in s p e c tio n of in sp e ctio n of
A d a p te r IT p o w e r ste e rin g Bo|t p o w e r ste e rin g
(P a rt o f J-L flu id p re ssu re (P art o f fi==3) flu id p re ssu re
49 G 032 3A4) |g 9 4 9 G 0 3 2 3A 4)
4 9 F 0 3 2 301 F or
d is a s s e m b ly /
H a n g e r, p o w e r a s s e m b ly of — —
s te e rin g p u m p U' p o w e r ste e rin g
oil p u m p
36U0NX-004
Problem Possible Cause Action Page/Section

Steering feels heavy P o o r lu b ric a tio n o r a b n o rm a l w e a r o f ste e rin g a sse m b ly R e p la ce N -1 6
ball jo in t
S tu c k o r d a m a g e d lo w e r a rm ball jo in ts R e p la ce S e ctio n R
Im p ro p e r ste e rin g p in io n p re lo a d A d ju s t N -1 7
D a m a g e d ste e rin g g e a r R e p la ce g e a r N -1 4
M a lfu n c tio n in g s te e rin g sh a ft jo in t R e p la ce N -1 0
Im p ro p e rly a d ju s te d w h e e l a lig n m e n t A d ju s t S ection R
In c o rre c t tire p re ssu re A d ju s t S ection Q
L o o se o r d a m a g e d oil p u m p d riv e belt A d ju s t o r re p la ce N -2 3
L o w flu id level o r a ir in flu id A d d flu id o r b le e d air N -5 , 6
L e a k a g e o f flu id R e p a ir o r re p la ce
In su fficie n t P/S oil p u m p p re ssu re R e p la ce N -1 8
Steering wheel pulls In c o rre c t tire p re ssu re A d ju s t S e ctio n Q

to one side U n e v e n ly w o rn tires R e p la ce S e ctio n Q
W e a k fro n t s p rin g R e p la ce S ection R
W o rn o r d a m a g e d sta b ilize r a n d /o r lo w e r a rm b u sh in g R e p la ce S e ctio n R
D ra g g in g b ra ke R epair S ection P
L o o se lo w e r a rm T ig h te n o r re p la c e S ection R
General instability In c o rre c t tire p re ssu re A d ju s t S ection Q

while driving D a m a g e d o r u n b a la n c e d w heel A d ju s t o r re p la ce S ection Q
W o rn o r d a m a g e d s te e rin g shaft joint(s) R e p la ce N -1 0
Im p ro p e r s te e rin g p in io n p re lo a d A d ju s t N -1 7
W e a k fro n t co il s p rin g R e p la ce S e ctio n R
W o rn o r d a m a g e d sta b ilize r a n d /o r lo w e r a rm b u sh in g R e p la ce S e ctio n R
D a m a g e d s h o c k a b s o rb e r R e p la ce S ection R
Shake E xce ssive tire a n d /o r w h e e l ru n o u t R e p la ce S ection Q

(steering wheel L o o se lu g nuts T igh te n S ection Q
vibrates up/down) U n b a la n c e d w heel(s) A d ju s t o r re p la ce S ection Q
C ra c k e d o r w o rn e n g in e m o u n t ru b b e r R e p la ce Sections B1, B2
C ra c k e d o r w o rn tra n s a x le m o u n t ru b b e r R e p la ce Sections J, K
N—4
ENGINE SPEED SENSING POWER STEERING N
TROUBLESHOOTING GUIDE (Cont’d)
Problem Possible Cause Action Page/Section

Shimmy C ra c k e d o r w o rn s te e rin g g e a r m o u n t ru b b e r R e p la ce N -1 6
(steering wheel vibrates L o o se ste e rin g g e a r m o u n tin g bolts T ig h te n N -1 4
circumferentially) S tu ck o r d a m a g e d s te e rin g ball jo in t R e p la ce N -1 6
E xce ssive tire a n d /o r w h e e l ru n o u t R e p la ce S e ctio n Q
L o o se lu g n u ts T ig h te n S e ctio n Q
U n b a la n c e d w heel(s) A d ju s t o r re p la ce S e ctio n Q
In c o rre c t tire p re ssu re A d ju s t S e ctio n Q
U n e v e n ly w o rn tires R e p la ce S e ctio n Q
D a m a g e d s h o c k a b s o rb e r R e p la ce S e ctio n R
L o o se s h o c k a b s o rb e r m o u n tin g bolts T ig h te n S e ctio n R
S tu c k o r d a m a g e d lo w e r a rm ball jo in t R e p la ce S e ctio n R
C ra c k e d o r w o rn su s p e n s io n b u sh in g R e p la ce S e ctio n R
D a m a g e d o r w o rn fro n t w h e e l b e a rin g R e p la ce S e ctio n M
im p ro p e rly a d ju s te d fro n t w h e e l a lig n m e n t A d ju s t S e ctio n R
Excessive steering W o rn s te e rin g g e a r R e p la ce g e a r N -1 4

wheel play W o rn o r d a m a g e d s te e rin g sh a ft jo in ts R e p la ce N -1 0
W o rn o r d a m a g e d lo w e r a rm b u sh in g R e p la ce S e ctio n R
L o o se s te e rin g g e a r m o u n tin g b o lts T ig h te n N -1 4
W o rn lin k a g e o r tie ro d ball jo in t R e p la ce N -1 6
Poor steering wheel In c o rre c t tire p re ssu re A d ju s t S e ctio n Q

return S tu c k o r d a m a g e d s te e rin g sh a ft jo in ts R e p la ce N -1 0
Im p ro p e rly a d ju s te d fro n t w h e e l a lig n m e n t A d ju s t S e ctio n R
Im p ro p e rly a d ju s te d s te e rin g p in io n p re lo a d A d ju s t N -1 7
Ball jo in t stic k in g R e p la ce N -1 6
O b s tru c tio n n e a r ste e rin g shaft R e p a ir N -1 0
Abnormal noise from L o o se P/S oil p u m p o r b ra c k e t T ig h te n N -1 8

steering system L o o se ste e rin g g e a r T ig h te n N -1 4
D rive belt to o lo o s e /tig h t A d ju s t N -2 3
A ir in syste m B le e d air N - 5
M a lfu n c tio n in g s te e rin g g e a r R e p la ce g e a r N -1 4
M a lfu n c tio n in g P/S oil p u m p R e p la ce N -1 8
O b s tru c tio n n e a r s te e rin g sh a ft o r p re ssu re p ip e R e p a ir o r re p la ce N -1 0
L o o se ste e rin g lin k a g e T ig h te n o r re p la ce N -1 4
W o rn ste e rin g shaft jo in ts R e p la ce N -1 0
36U0NX-005
AIR BLEEDING
1. Check the fluid level. (Refer to page N-6.)
2. Turn the steering wheel fully left and right several times with
the engine not running.
3. Recheck the fluid level. If it has dropped, add fluid.
4. Repeat Steps 2 and 3 until the fluid level stabilizes.
6 .Turn the steering wheel fully left and right several times.
36UQNX-006
7. Verify that the fluid is not foamy and that the fluid level has
not dropped.
8. Add fluid if necessary and repeat Steps 6 and 7.
16E0NX-009
N -5
Inspection
Fluid level
Check the power steering fluid level. Add the specified pow
er steering fluid if necessary.
Fluid specification: ATF Dexron®n or M-m
46U0NX-001
Fluid leakage
Caution
• Never hold the steering wheel to the exreme left or right for more than five seconds with the
engine running. This could damage power steering pump.
Start the engine and let it idle. Turn the steering wheel fully left and right to apply fluid pressure. Inspect
the points shown in the figure for fluid leakage.
FS ENGINE
46U0NX-002
N -6
Fluid pressure
1. Assemble the SST as shown in the figure. Remove the trans
verse member. (KL engine) (Refer to Section R.)
Tightening torque:
39—49 Nm {4.0—5.0 kgfm, 29—36 ftlbf)
16E0NX-012
2. Mark both hose connections to ensure that the hose is rein
stalled in its original position.
3. Disconnect the pressure hose from the oil pump. Attach the
SST (adapters).
4. Connect the SST (gauge set) to the SST (adapters).
5. Bleed the air from the system. (Refer to page N-5.)
46U0NX-003
6. Open the gauge valve fully. Start the engine and turn the
steering wheel fully left and right to raise the fluid tempera
ture to 50—60°C {122—140°F).
46U0NX-004
-THERMOMETER Caution
[50—60°C 'GAUGE • Do not let the valve stay closed for more than 5 sec
{122— 140oF ]]y iC L O S E VALVE onds. The increase in fluid tamperature will dam
COMPLETELY age the oil pump.
7. Close the gauge valve completely. Increase the engine

speed to 1,000—1,500 rpm and measure the fluid pres
sure generated by the oil pump. If the pressure is not with
in specification, replace the oil pump assembly.
(Refer to page N-18.)
46U0NX-005
Oil pump fluid pressure: 8,340—8,820 kPa
-T H E R M O M E T E R
{85.0—90.0 kgf/cm2, 1,210—1,280 psi)
[50—60°C GAUGE
(122— 140°F)] / OPEN VALVE
COMPLETELY 8. Open the gauge valve fully and increase the engine speed
to 1,000—1,500 rpm.
46U0NX-006
N -7
Caution
• Do not let the valve stay closed for more than five
seconds. The increase in fluid temperature will dam
age the oil pump.
9. Turn the steering wheel fully left and right and measure the
fluid pressure generated within the gear housing. If the pres
sure is not within specification, repair or replace the steer
ing gear assembly.
Gear housing fluid pressure: 8,340—8,820 kPa

{85.0—90.0 kgf/cm2, 1,210—1,280 psi)
10. Remove the gauge set. Install and tighten the pressure hose
to the specified torque.
Tightening torque:
24—35 N-m {2.4—3.6 kgfm, 17—26 ftlbf)
11. Install the transverse member. (Refer to Section R.)

12. Bleed the air from the system. (Refer to page N-5.)
46U0NX-008
STEERING WHEEL AND COLUMN
On-vehicle inspection
Steering wheel play
With the wheels in the straight-ahead position, gently turn
the steering wheel left and right and verify that the play is
within specification.
Play: 0—30mm (0—1.18 in)
If the play exceeds specification, either the steering joints

are worn or the backlash of the steering gear is excessive.
Looseness or play of steering wheel

Move the steering wheel in the directions shown to check
for column bearing and bushing wear, steering shaft joint
play, steering wheel looseness, and column looseness.
16E0NX-025
Steering wheel effort
1. With the vehicle on a hard, level surface, put the wheels
in the straight-ahead position.
2. Start the engine and warm the power steering fluid to
50—60°C (122—140°F}.
16E0NX-026
3. With the engine running at idle, attach a pull scale to the
outermost point of the steering wheel spoke.
Then, starting with the wheels in the straight-ahead posi
tion, measure the effort required to turn the steering wheel
to the left and to the right.
Steering wheel effort:

28—29 N (2.8—3.0 kgf, 6.2—6.6 Ibf}
[during one turn of the steering wheel]
4. If not within specification, check the following: fluid level,

16E0NX-027 air in system, fluid leakage at hose or connections, func
tion of oil pump and steering gear, and tire pressure.
N—9
Warning
• Refer to the 1994 626/MX-6 Body Electrical Troubleshooting for removal and installation of
the airbag module.

4. Tighten all necessary nuts and bolts to the specified torque.
1. Air bag module 9. Dynamic damper (FS engine MX-6 with ATX)
Service....... 1994 626/MX-6 Body Electrical 10. Intermediate shaft
Troubleshooting Manual Installation Note........................ page N—11
2. Locknut Inspect for damage
3. Steering wheel Inspect universal joint for looseness, abnor
Removal Note.......................... page N -11 mal noise, and sticking
Installation Note........................ page N -11 11. Shaft seal
4. Column cover Inspect for damage and cracks
5. Combination switch 12. Set plate
Service....... 1994 626/MX-6 Body Electrical 13. Dust cover
Troubleshooting Manual 14. Universal joint
6. Lower panel Inspect for looseness, abnormal noise, and
7. Key interlock cable (ATX) sticking
8. Steering shaft assembly
Installation Note........................ page N -11
Assembly................................ page N-12
N—10
Removal note
Steering wheel
Caution
• Do not try to remove the steering wheel by hitting
the shaft with a hammer. The column will collapse.
Remove the steering wheel by using a suitable puller.
16E0NX-029
Installation note
Intermediate shaft and steering shaft assembly
1. Tighten bolt A after tightening bolt B.
2. Tighten bolt C with the steering shaft at its upper most tilt
position.
3. After installation, lightly tap the lower bracket at the point
shown by using a hammer to verify correct installation.
Caution
• Do not apply the shock in the axial direction of the
shaft.
Note
• If the tilt lever does not move easily, loosen the D nuts,
tap the lower bracket at the point shown and retighten.
16E0NX-030
Steering wheel
Set the wheels in the straight-ahead position, and install the
steering wheel.
16E0NX-031
Disassembly / / Inspection / Assembly
1. Steering lock mounting bolts and bracket 2. Steering lock assembly

Disassembly Note............................. below Inspection.................................page N-13
Assembly Note......................... page N-13 3. Steering shaft assembly
Inspection.................................page N-13
Disassembly note
Steering lock mounting bolts and bracket
1. Use a chisel and a hammer to make a groove in the heads
of the steering lock mounting bolts.
2. Remove the bolts by using a screwdriver.
3. Remove the steering lock assembly.
N -1 2
Inspection
Steering lock assembly (Automatic transaxle only)
Verify that the cable connector does not move when the
key is in the LOCK position and that it moves freely with
the key in other positions.
36UONX-030
Steering shaft assembly
Check for the following and replace the steering shaft assem
bly if necessary.
1. Column bushing damage.
2. Column bearing damage.
36U0NX-031
3. Steering shaft length.
Length: 567.6—569.6mm (22.35—22.42 in)
36U0NX-012
4. Tilt operation.
(1) Verify that the adjusting lever moves smoothly from un
lock position to lock position.
(2) Verify that the steering shaft is fixed firmly when the ad
justing lever is locked.
16E0NX-037
Assembly note
Steering lock mounting bolts and bracket
1. Install the steering lock assembly on the jacket.
2. Verify that the lock operates correctly.
3. Install new steering lock mounting bolts.
4. Tighten the bolts until the heads break off.
16E0NX-263
N—13
S T E E R IN G G EA R A N D L IN K A G E
R em o val / In stallatio n
1. Remove the wheels.
2 .Jack up the front of the vehicle and support it on safety stands.
5. Install the wheels.
T ig h te n in g to rq u e : 8 8 — 118 N-m {9 — 12 k g fm , 6 5 — 8 7 ft lb f )
6. After Installation:
(1) Check for fluid leakage. (Refer to page N-6.)
(2) Bleed air from the system. (Refer to page N-5.)
(3) Check the steering angle and toe-in, and adjust if necessary. (Refer to Section R.)
85—117 (8.7—11.9, 63—86.1) [6.B -9.5, 4 9 -6 9 )

67—93 (6.8—9.5, 49—69) 39—59 (4.0—6.0, 29—43)
DO NOT FACE TANGS

OF CLAMP UPWARD
18—26 (1.8—2.7, 13—20)
64—89 ( 6.5—9.1, 47—66

NUT, REPLACE (3.5—4.5, 26—32)
6.9—9.81 Nm 170—100 kgf-cm, 61—86.8 ln-lbf)
31—44 (3.2—4.S, 23—33)

NUT, REPLACE
3 7 -5 2 I
93—131 (
N-m (kgf-m, ft-lbf)

46U0NX-011
1. Cotter pin 7. Pressure pipe

2. Nut 8. Return hose and clamp
3. Tie rod end ball joint 9. Bolt (Intermediate shaft)
Removal Note.......................... page N-15 10. Mounting bracket nut and bolt
4. Transverse member (KL engine) Installation Note................... . page N-15
Service........................................ Section R 11. Steering gear and linkage
5. Front exhaust pipe and catalytic converter Removal Note.......................... page N-15
(KL engine) Disassembly / Assembly /
Service....................................... Section F2 Inspection............................... page N-16
6. Engine mount
Removal Note.......................... page N-15
N -1 4
R em oval no te
T ie rod en d ball jo in t
1. Loosen the tie rod nut.
2. With the nut protecting the tie rod end stud, separate the
tie rod end from the steering knuckle by using SST.
49 0118 850C
36U0NX-014
Engine m ount
1. Use the S S T
as shown.
2. Remove the engine mount.
S te e rin g g e a r an d linkage
Pull the steering gear from the right side to remove it.
In s ta lla tio n note

M o u n tin g b racket nut and bolt
1. Loosely tighten nuts 4 and 3.
2. Tighten the mounting brackets nuts and bolts to the speci
fied torque in the order shown.
3 8 — 51 N m (3 .8 — 5 .3 kgf-m, 2 8 — 38 f t lb f)
46U0NX-012
D isasse m b ly / A s s e m b ly / In sp ectio n
1. Disassemble in the order shown in the figure, referring to D isassem b ly Note.
2. Inspect all parts and replace as necessary.
3. Install in the reverse order of removal, referring to A ssem b ly Note.
N-m |kgf-m, ft-lbf)
36U0NX-016
1. Oil pipe and pipe clip 10. L o c k n u t (a d ju stin g c o v e r)

2. Mounting bracket 11. Adjusting cover
3. Mounting rubber Assembly Note......................... page N -17
4. Tie rod end 12. Spring
Inspection................................. page N -17 Inspect for damage
5. Locknut (tie rod end) 13. Pressure pad
6. Clamp Inspect for damage
7. Boot wire 14. Steering gear assembly
8. Boot Inspect for damage and poor operation
9. Tie rod (Not repairable, replace steering gear
Inspection................................. page N -17 assembly)
N -1 6
In sp ectio n
T ie rod end
1. Inspect the tie rod end for damage and boot cracks. Re
place it as necessary.
2. Inspect the ball joint for looseness. Replace the tie rod end
as necessary.
3. Rotate the ball joint five times.
4. Measure the rotation torque of the ball joint by using the
S S T and a pull scale.
R o tatio n torque:
0 .3 — 2 .9 N m {3 — 30 kgf-cm, 2 .6 — 26 in-lbf}
P ull scale reading:
3 — 29 N ( 0 .3 — 3 kgf, 0 .7 — 6 .6 Ibf}
5. If not within specification, replace the tie rod end.
T ie rod
1. Inspect the tie rod for bending and damage. Replace it if
necessary.
2. Inspect the ball joint for looseness. Replace the tie rod as
necessary.
3. Swing the tie rod five times.
4. Measure the swinging torque by using a pull scale.
S w in g in g to rq u e:
0.1—3.4 N m (1 —35 k g fc m , 0.9—30 in-lbf}
P ull scale reading:
0.7—21 N (0.07—2.2 kgf, 0.16—4.8 Ibf}
5. If not within specification, replace the tie rod.

A ss em b ly note
A d ju stin g co ver
1. Set the rack in the center position.
2. Tighten the adjusting cover to 9.8 N-m (100 kgf-cm, 87
in-lbf}, then loosen it.
3. Tighten again to 4.4—5.4 N-m (45—55 kgf-cm, 39—48
in-lbf}, and then return it 2 0 degrees.
4. Apply thread-locking compound to the exposed threads of
49 D032 316 the adjusting cover.
49 H032 321A
5. Attach the S S T and a pull scale to the pinion shaft.
6. Measure the pinion preload.
36U0NX-032
R ack position: C e n te r ± 9 0 °
49 0180 510B
P in ion preload:
1.0— 1.3 N-m (10— 14 kgf-cm, 8.7— 12.1 in-lbf} m ax.
Pull scale reading: 7.8 N (0.8 kg, 1.8 lb} m ax.
7. If not within specification, repeat Step 2—6.

8. Tighten the locknut while holding the adjusting cover by us
ing the SST.
49—59 N m (5.0—6.0 kgf-m, 36—43 ftlb f}
36U0NX-019
Revised 5/94 (1994 626/MX-6) N—17
P O W E R S T E E R IN G O IL P U M P
R em o val / In s ta lla tio n
1. Remove the transverse member. (Refer to Section R.)
4. Install in the reverse order of removal, referring to In stallatio n N ote.
5. Install the transverse member. (Refer to Section R.)
6. After installation:
(1) Adjust the belt deflection. (Refer to page N-23.)
(2) Bleed air from the system. (Refer to page N-5.)
(3) Check all connections for fluid leakage. (Refer to page N-6.)
KL ENGINE
6.9—9.81 N-m
'( 7 0 — 100 kgf-cm,
61—86.8 ln-lbf |
WASHER, REPLACE
FACE TANGS OF
CLAMP AWAY FROM PULLEY
6.9—9.81 N-m (70— 100 kgf-cm,

61—86.8 In-lbf |
N fli (kgf-m, ft-lbf |

46UQNX-013
1. Locknut 6. Pulley
2. Idller pulley and bearing 7. Hose bracket
3. Adjusting bolt 8. Pump bracket
4. Drive belt 9. SPS connector
Inspection................................. page N-22 • 10. Pressure pipe
Adjustment............................... page N-23 11. Return hose
Replacement............................ page N-23 12. Power steering oil pump
5. Nut Disassembly / Inspection /
Removal / Installation Note........page N-19 Assembly................................page N-20
N -1 8
FS ENGINE
N-m ( kgf-m, ft lbf |

36U0NX-022
1. Lock bolt 5. Pulley

2. Adjusting bolt 6. SPS connector
3. Drive belt 7. Pressure pipe
Inspection................................. page N-22 8. Return hose
Adjustment............................... page N-23 9. Pulley cover
Replacement............................ page N-23 10. Power steering oil pump and bracket
4. Nut Disassembly / Inspection /
Removal / Installation Note................ below Assembly................................ page N-20
Removal / Installation note
Nut
Insert a screwdriver through a hole of the pulley, and while
holding the pulley, loosen/tighten the nut.
16EQNX-096
N—19
D isasse m b ly / In s p e ctio n / A ss em b ly
1. The following procedure is for replacement of the O-rings only. Replace the oil pump assembly if other
repairs are necessary.
2. Disassemble in the order shown in the figure, referring to D isassem bly Note.
3. Assemble in the reverse order of disassembly, referring to A ssem b ly Note.
18—26 (1.8—2.7, 13—19
N-m | kgf-m, ft lbf |

36U0NX-023
1. Bracket (FS engine) 12. Gasket

2. Bracket 13. Pin
3. Suction pipe 14. Cam ring
4. O-ring Assembly Note......................... page N-21
5. P re ssu re sw itch a s s e m b ly In sp e c t for w e a r a n d d a m a g e
6. O-ring 15. Rotor
7. Connector Inspect for wear and damage
8. O-ring 16. Blade
9. Control valve Assembly Note......................... page N-21
Inspect for clogging, cracks, and damage Inspect for wear and damage
10. Spring 17. Side plate
Inspect for weakness Inspect for wear and damage
11. Pump body (Rear) 18. O-ring
Assembly Note......................... page N-21 19. Pump body (Front)
Inspect for cracks, wear, and damage Inspect for cracks, wear, and damage
N—20
D isassem bly note
Oil pum p
Install the pump to the S S T and hold the pump and S S T
in a vise.
46U0NX-014
A ssem b ly note
Cam ring
Install the cam ring in the pump body (front) with the mark
facing upward.
16E0NX-099
B lade
Place the blades in the rotor with the rounded edges con
tacting the cam.
36U0NX-024
Pum p b o d y (R ear)
After installing the pump body (rear), manually turn the shaft
to verify that it rotates smoothly.
36U0NX-025
D R IV E B ELT
In sp ection
1. Check the drive belt for wear, cracks, and fraying. Replace
V-RIBBED BELT if necessary.
2. Verify that the drive belt is correctly mounted on the pulleys.
x o x
46U0NX-015
3. Check the belt deflection when the engine is cold, or at least
30 minutes after the engine has stopped. Applying moder
ate pressure 98 N {1 0 kg f, 22 Ib f) midway between the
pulleys.
46U0NX-016
D eflectio n
mm (in)
— -— ___ New Used Limit
6.0—7.0 7.0—8.0 9.0
KL engine
(0.24-0.28) (0.2 8-0 .31 ) (0.35)
7.5—9.0 8.0—9.5 11.0
FS engine
(0.30-0.35) (0.32-0.37) (0.43)
4. If the deflection is not within specification, adjust it.
36U0NX-026
D rive belt te n sio n ch eck
Check the drive belt tension when the engine is cold, or
T en sio n
N (kgf, Ibf)
New Used Limit
540-680 400-530 340
KL engine
(55-70, 130-150) (40-55, 110-150) (35, 77)
590-780 500-680 390
FS engine (40, 88)
160-80, 140-170) (50-70, 110-150)
Adjustment
Loosen idler pulley locknut (bolt) A, and adjust the belt
deflection by turning adjusting bolt B.
Tightening torque
A: 37—52 N-m (3.8—5.3 kgf-m, 27—38 ftlbf)
Replacement
1. Remove the alternator A/C drive belt. (KL engine)
Manual.)
2. Loosen locknut (bolt) A and adjusting bolt B.
3. Remove and replace the drive belt.
4. Adjust the deflection (tension). (Refer to above.)
5. Install the alternator A/C drive belt. (KL engine)
Manual)
N -2 3
BRAKING SYSTEM
INDEX.................................................. P - 2 PARKING BRAKE SYSTEM................. P-36

OUTLINE..............................................P - 4 TROUBLESHOOTING GUIDE...........P-36
SPECIFICATIONS............................. P - 4 PARKING BRAKE SHOE................... P-36
CONVENTIONAL BRAKE SYSTEM ... P - 5 PARKING BRAKE (LEVER TYPE)..... P-36
PREPARATION................................. P - 5 PARKING BRAKE CABLE................ P-37
TROUBLESHOOTING GUIDE...........P - 6 PARKING BRAKE LEVER................ P-38
AIR BLEEDING.................................P - 7 ANTI-LOCK BRAKE SYSTEM (ABS).. P-39
BRAKE HYDRAULIC LINE............... P - 7 DESCRIPTION................................... P-39
BRAKE FLUID.................................. P - 9 PREPARATION .t....................... P-39
VACUUM LINE.................................P - 9 TROUBLESHOOTING GUIDE...........P-39
BRAKE PEDAL................................. P-10 WIRING DIAGRAM........................... P-40
MASTER CYLINDER.........................P-12 RELATIONSHIP CHART.................... P-41
POWER BRAKE UNIT...................... P-18 DIAGNOSTIC CHART....................... P-41
DUAL PROPORTIONING VALVE......P-22 DIAGNOSTIC INDEX.........................P-41
FRONT BRAKE (DISC)...................... P-24 SYMPTOM TROUBLESHOOTING..... P-42
DISC PAD......................................... P-25 SELF-DIAGNOSIS FUNCTION...........P-45
DISC PLATE...................................... P-26 INSPECTION BY DIAGNOSIS TEST
CALIPER........................................... P-26 MODE............................................ P-45
REAR BRAKE (DISC).........................P-28 OUTLINE.......................................... P-45
DISC PAD......................................... P-29 HYDRAULIC UNIT............................ P-61
DISC PLATE......................................P-30 ABS CONTROL UNIT....................... P-64
CALIPER........................................... P-31 ABS RELAY...................................... P-65
REAR BRAKE (DRUM)..................... P-33 ABS WHEEL SPEED SENSOR
WHEEL CYLINDER........................... P-35 (FRONT).......................................... P-67
ABS SENSOR ROTOR (FRONT)....... P-68
ABS WHEEL SPEED SENSOR (REAR) P-70
ABS SENSOR ROTOR (REAR)......... P-71
36U0PX-001
p INDEX
INDEX
46U0PX-Q66
1. Brake hydraulic line 11. Caliper

Inspection / Removal / Disassembly / Inspection /
Installation............................... page P- 8 Assembly........................... page P-26
2. Brake fluid 12. Rear brake (disc)
Inspection................................. page P- 9 Inspection (on-vehicle)......... page P-28
Replacement............................. page P- 9 Removal / Inspection /
3. Vacuum line Installation.......................... page P-28
Inspection................................. page P- 9 13. Disc pad
4. Brake pedal Replacement........................ page P-29
Inspection (on-vehicle).............. page P-10 14. Disc plate
Removal / Inspection / Inspection............................ page P-30
Installation............................... page P—11 15. Caliper
5. Master cylinder Disassembly / Inspection /
Removal / Installation.................page P-12 Assembly........................... page P-31
Disassembly / Inspection / 16. Rear brake (drum)
Assembly................................ page P-16 Inspection (on-vehicle).......... page P-33
6. Power brake unit Removal / Inspection /
Inspection (on-vehicle).............. page P-18 Installation.......................... page P-33
Removal / Installation................ page P-20 17. Wheel cylinder
7. Dual proportioning valve Disassembly / Inspection /
Inspection................................. page P-22 Assembly........................... page P-35
Replacement............................. page P-22 18. Parking brake (lever type)
8. Front brake (disc) Inspection (on-vehicle).......... page P-36
Inseparable (on-vehicle)............page P-24 Adjustment........................... page P-36
Removal / Inspection / 19. Parking brake cable
Installation............................... page P-24 Removal / Inspection /
9. Disc pad Installation........................... page P-37
Replacement............................. page P-25 20. Parking brake lever
10. Disc plate Removal / Inspection /
Inspection................................. page P-26 Installation........................... page P-38
P—2
INDEX P
ANTI-LOCKBRAKE SYSTEM (ABS)
LEVER STROKE 5—7 NOTCHES
46U0PX-O67
21. Hydraulic unit 25. ABS sensor rotor (front)

Inspection................................. page P-61 Removal / Inspection................ page P-68
Removal / Installation.................page P-62 Installation.................................page P-69
22. ABS control unit 26. ABS wheel speed sensor (rear)
Removal / Installation................ page P-64 Removal / Inspection /
23. ABS relay Installation...............................page P-70
Removal / Inspection / 27. ABS sensor rotor (rear)
Installation............................... page P-65 Removal / Installation................ page P-71
24. ABS wheel speed sensor (front)
Installation............................... page P-67
P -3
p OUTLINE
OUTLINE
SPECIFICATIONS
--------------------- Engine FS KL
Item " _ non ABS ABS non ABS ABS
Type Suspended
Brake pedal Pedal lever ratio 4.1
Max. stroke mm {in) 125 (4.92)
Tandem (with level sensor)
Type
Master cylinder Conventional Port-less Conventional Port-less
Cylinder inner diameter mm {in) 23.81 (0.937)
Type Ventilated disc
Cylinder bore mm (in) 57.15 (2.250)
Front disc brake Pad dimensions (area x thickness)

mm2 (in2) xm m (in) 4800 (7.44) x 10 (0.39)
Disc plate dimensions mm (in)

(outer diameter x thickness) 2 58x24 (10.16x0.94)
Type — Solid disc

Cylinder bore mm (in) — 30.16 (1.187)
Rear disc brake Pad dimensions (area x thickness)

— 2900x8.0 (4.49x0.31)
mm2 (in2) xm m (in)
Disc plate dimensions mm (in)
— 261 x 10.0 (9.88x0.39)
(outer diameter x thickness)
Type Leading-trailing —
Wheel cylinder inner diameter mm (in) 17.46 (0.687) —
Rear drum Lining dimensions mm (in) 30x219.3x4.5
-
brake (width x length x thickness) (1.18x8.63x0.18)
Drum inner diameter mm (in) 228.6 (9.000)
Shoe clearance adjustment Automatic adjuster
Vacuum multiplier
Power brake Type
Single diaphragm Tandem diaphragm
unit
Diameter mm (in) 239 (9.4) 188 + 215 (7.4 + 8.5)
Braking force
Type Dual proportioning valve
control device
Brake fluid FMVSS116, DOT-3
Type Mechanical two-rear-wheel control
Parking brake
Operation system Center lever
36U0PX-004
P—4
CONVENTIONAL BRAKE SYSTEM

PREPARATION
SST
49 0259 770B For 49 F043 001 For

removal of adjustment of
Wrench, flare nut brake pipe Adjust gauge push rod
clearance
49 0208 701A For 49 0221 600C For

Air-out tool, boot piston seal Espand tool, disc brake pads
brake (Front disc brake)
49 B043 001 For 49 E043 003 For

9
Adjust gauge push rod Lock tool, turning — push rod
clearance clearance
49 B043 004 For 49 U043 0A0 For

adjustment of inspection of
Socket wrench push rod Gauge set, oil brake fluid
clearance pressure pressure
49 U043 004 For 49 U043 005 For

Gauge, oil brake fluid Joint brake fluid
pressure pressure (Part of pressure
(Part of 49 U043 0A0)
49 U043 0A0)
49 U043 006 For

inspection of
Hose brake fluid
(Part of pressure
49 U043 0A0)
36U0PX-005
P -5
p CONVENTIONAL BRAKE SYSTEM

Poor braking Leakage of brake fluid Repair
Air in system Bleed air P- 7
Worn disc pad or brake shoe Replace P-25, 29, 33
Brake fluid, grease, oil or water on disc pad or brake Clean or replace P-25, 29, 33
shoe
Hardening of disc pad or brake shoe surface or poor Grind or replace P-25, 29, 33
contact
Malfunction of caliper piston or wheel cylinder Replace P-26, 31, 33
Malfunction of master cylinder or wheel cylinder Repair or replace P-12, 16, 33
Malfunction of power brake unit Replace P-20
Malfunction of check valve (vacuum hose) Replace P- 9
Damaged vacuum hose Replace P- 9
Deterioration of flexible hose Replace P- 8
Malfunction of dual proportioning valve Replace P-22
Brakes pull to one Worn disc pad or brake shoe Replace P-25, 29, 33
side Brake fluid, grease, oil or water on disc pad or brake Clean or replace P-25, 29, 33
shoe
Hardening of disc pad brake shoe surface or poor Grind or replace P-25, 29, 33
contract
Abnormal wear, distortion of disc plate or drum Repair or replace P-24, 28, 33
Malfunction of automatic adjuster Replair or replace P-31, 33
Loose or damaged dust cover/backing plate mounting Tighten or replace Section M
bolt
Malfunction of caliper piston or wheel cylinder Replace P-26, 31, 33
Worn or improperly adjusted wheel bearing preload Adjust or replace Section M
Improper adjustment of wheel alignment Adjust Section R
Unequal tire air pressure Adjust Section Q
Brakes do not No brake pedal play Adjust P-10
release Improper adjustment of push rod clearance Adjust P-13
Clogged master cylinder return port Clean
Brake pad not returning properly Repair
Improper return or malfunction of caliper piston or wheel Repair or replace P-26, 31, 35
cylinder piston
Excessive runout of disc plate Repair or replace P-24, 28
Improper adjustment of wheel bearing preload Adjust or replace Section M
Pedal goes too far Air in system, insufficient brake fluid Add fluid and bleed air P—7, 9
(Excessive pedal Improper adjustment of pedal play Adjust P-10
stroke) Worn disc pad or brake shoe Replace P-25, 29, 33
Abnormal noise or Worn disc pad or brake shoe Replace P-25, 29, 33
vibration during Damaged pad or brake shoe Grind or replace P-25, 29, 33
braking Brakes do not release Repair
Foreign material or scratches on disc plate or drum con Clean
tact surface
Loose backing plate/dust cover or caliper mounting bolt Tighten P-24, 28, 33
Damaged disc plate or drum contact surface Replace P-24, 28, 33
Poor contact of pad or brake shoe Repair or replace P-25, 29, 33
Insufficient grease on sliding parts Apply grease
36U0PX-006
P—6
CONVENTIONAL BRAKE SYSTEM P
AIR BLEEDING
Note
• The brakes should be bled whenever a brake line is dis
connected. If a hydraulic line is disconnected at the mas
ter cylinder, start at the slave cylinder farthest from the
brake master cylinder, and move to the next closest slave
cylinder until all four cylinders have been bled. If the dis
connection point is anywherer except the master cylin
der, start at the point closest to the disconnection, and
move to the next farthest slave cylinder until all four
cylinders have been bled.
1. Jack up the vehicle and support it with safety stands.
2. Remove the bleeder cap and attach a vinyl hose to the

bleeder plug.
3. Place the other end of the vinyl tube in a clear container.
4. One person should depress the brake pedal a few times,
and then hold it in the depressed position.
5. A second person should loosen the bleeder screw, drain
out the fluid, and retighten the screw by using the SST.
6. Repeat Steps 4 and 5 until no air bubbles are seen. The

reservoir should should be kept about 3/4 full during bleed
ing to prevent air from reentering the lines.
7. Check for correct brake operation.
8. Verify that there is no fluid leakage. Wipe off any spilled flu
id immediately.
9 .After bleeding the air, add brake fluid to the reservoir up
to the specified level.
Tightening torque:
5.9—8.8 N m (60—90 kgf cm, 53—78 in-lbf}
BRAKE HYDRAULIC LINE
16E0PX-010
1. Brake pipe 2. Flexible hose

Inspection / Removal / Inspection / Removal /
Installation................................. page P-8 Installation.................................page P-8
P—7
Brake pipe
Check for cracks, damage, and corrosion of the brake pipe.
Replace the pipe or flare nut(s) if necessary.
Flexible hose
Check for scars, cracks, and swelling of the flexible hose.
Replace the hose if necessary.
Removal
1. Remove the brake pipe by using the SST.
2. Disconnect the clip and remove the flexible hose from the
bracket.
Installation
1. Secure the flexible hose in the bracket and connect the clip
to it.
2. Connect the flexible hose to the brake pipe. Verify that the
hose is not twisted.
3. Tighten the flare nut by using the SST. Verify that the hose
can not come in contact with any other parts of vehicle.
Tightening torque:
12.8—21.5 N m {130—220 kgf cm, 113—190 in Ibf}
P -8
BRAKE FLUID
Inspection
1. Depress the brake pedal several times, and inspect for leak
age of the brake line system.
16E0PX-016
2. Verify that the fluid level in the reservoir is between the MAX
and MIN lines on the reservoir.
3. If the fluid level is extremely low, check the brake system
for leakage.
Fluid specification: FMVSS116, DOT-3
Replacement
Caution
mediately.

tion pump.
2. Fill the reservoir with clean brake fluid.
3. Attach a vinyl tube to the farthest bleeder screw and place
the other end of the tube in a clear container.
4. Remove all old brake fluid from the brake lines by loosen
ing the bleeder screw and pumping the brake pedal until
only clean fluid is seen. The reservoir should be kept about
3/4 full during bleeding to prevent air from reentering the
lines.
5. Perform the above for all bleeder screws.
6. Fill the reservoir to the specified levels.
VACUUM LINE
Inspection
1. Remove the clamps and the hose.
2. Apply both suction and pressure to engine-side of the hose,

and verify that air flows only toward that side. If air flows
in both directions or not at all, replace the vacuum hose.
P -9
BRAKE PEDAL
Brake pedal height
Inspection
Verify that the distance from the center on the pedal pad
to the floor mat is as specified.
Specification: 191.5—196.5 mm (7.54—7.74 in)
Adjustment
1. Loosen locknut B and turn bolt A until it does not contact
the pedal.
2. Loosen locknut D and turn rod C to adjust the height.
3. Adjust the pedal free play and tighten locknut D.
4. Turn bolt A until it contacts the pedal; then turn an addi
tional 1/2 turn.
5. Tighten locknut B.
Tightening torque:
9.81—14.7 N m (100—150 kgf cm, 86.9—130 In lbf)
36U0PX-014
Pedal Play
Inspection
1. Depress the pedal a few times to eliminate the vacuum in
the system.
2 Remove the snap pin, verify that the holes in the fork and
in the pedal are aligned, then reinstall the pin.
3. Gently depress the pedal by hand and check the free play
(until resistance is felt).
Pedal play: 4—12 mm (0.16—0.47 in]
36U0PX-015
Adjustment
1. Remove the spring pin and the clevis pin.
2. Loosen locknut D and turn rod C to align the holes in the
folk and in the pedal.
3. Install the clevis pin and a new spring pin.
4. Verify the pedal height and the stoplight operation.
Tightening torque:
24—34 N m (2.4—3.5 kgf m, 17—25 ft lbf]
Pedal-To-Floor Clearance
Inspection
Verify that the distance from the floor panel to the pedal pad
center is as specified when the pedal is depressed with a
force of 589 N (60 kgf, 132 Ibf].
Pedal-to floor clearance: 85 mm (3.35 in] min.
If the distance is less than specified, check for the following

problems:
1. Air in brake system
2. Malfunction of automatic adjuster
3. Worn pads
P -1 0
4. After installation, check and if necessary adjust the pedal height and free play.
N-m {kgf-m, ft-lbf)

36U0PX-017
1. Stoplight switch connector 5. Stoplight switch

2. Spring pin Inspection..........................................below
3. Clevis pin 6. Pedal pad
4. Steering shaft Inspect for wear and damage
Service......................... Section N 7. Brake pedal
Inspect for bending and damage
Inspection
Stoplight switch
1. Disconnect the stoplight switch connector.
2. Connect an ohmmeter between the terminals of the stop
light switch.
3. Confirm continuity between the terminals when the brake
pedal is depressed.
36U0PX-018
P-11
P CONVENTIONAL BRAKE SYSTEM
MASTER CYLINDER
3. After installation, add brake fluid, bleed air, and check for fluid leakage.
©ESI
> 1 2 .9 —21.5 N m
\ 1 1 3 0 —220 kgf-cm, >
113—190 in-lbf | ( 5 )
12.9—21.5 N m
(130—220 kgf-cm, 113—190 in-lbf)
9.81—15.6 N-m {100—160 kgf-cm, 87—138 in-lbf I
N-m (m-kgf, ft-lbf)

46U0PX-069
1. Brake fluid level sensor connector 5. Bracket

2. Brake pipe 6. Master cylinder
Removal Note................................... below Disassembly / Inspection /
Installation Note........................ page P-15 Assembly................................page P-16
3. Hose (MTX) Installation Note........................ page P-13
4. Nut 7. O-ring (Except MTX without ABS)
Removal Note
Brake pipe
Disconnect the brake pipe from the master cylinder by us
ing the SST.
Caution
mediately.
46U0PX-008
P -1 2
Installation Note
ADJUSTING BOLT Master cylinder (MTX without ABS)
Piston to push rod clearance
1. Place the SST atop the master cylinder. Turn the adjusting
bolt until it bottoms in the push rod hole in the piston.
36U0PX-019
2. Apply 66.7 kPa (500 mmHg, 19 inHg] vacuum to the
power brake unit with a vacuum pump.
3. Invert the adjustment gauge used in Step 1 and place it on
the power brake unit.
4. Measure the clearance between the end of the gauge and
the push rod of the power brake unit. If it is not 0 mm (0
in ] , loosen the push rod locknut and turn the push rod to
make the adjustment.
16E0PX-030
Note
• This adjustment produces the follwing clearance.
Vacuum applied to unit Push rod to piston clearance

0 kPa (0 mmHg, 0 inHg) 0.4—0.6 mm (0.016—0.024 in)
Approx. 66.7 kPa
0.1—0.4 mm (0.004—0.016 in)
{500 mmHg, 19.7 inHg)
C LEARANCE
46U0PX-009
Master cylinder (Except MTX without ABS)

Piston to push rod clearance
1. Turn the nut of the SST clockwise to fully retract the SST
gauge rod. Attach the SST to the power brake unit.
Tightening torque:
9.81—15.6 N m (100—160 kgf-cm, 87—138 in-lbf)
2. Apply 66.7 kPa (500 mmHg, 19.7 inHg) vacuum using

a vacuum pump.
36U0PX-097
3. Turn the adjusting nut of the SST counterclockwise until the
gauge rod just contacts the push rod end of the power brake
unit.
Push lightly on the end of the gauge rod to be sure it is seat
ed. Verify that there is no gap between the adjusting nut
and SST body.
46U0PX-010
P—13
4. Remove the SST from the power brake unit without disturb
CLEARANCE (B) ing the adjusting nut. Set the SST onto the master cylinder
5. Push lightly on the end of the SST gauge rod to be sure
it is bottomed in the master cylinder piston, but do not push
so hard that the piston moves. Note any clearance between
the SST body and the adjusting nut (clearance B) or be
tween the body and the master cylinder (clearance C). Ad
just the push rod as necessary as outlined in “ Adjustment”
below.
Measurement Push rod
Clearance at (B) Too short
Clearance at (C) Too long
No clearance at (B) or (C) OK
46U0PX-011
Adjustment
The threads of the push rod are specially designed so that
the bolt becomes harder to turn past a certain point. This
is to prevent the bold from coming loose. Turn the bolt only
within this range when adjusting.
Clearance at B
1. Push lightly on the end of the SST gauge rod, and meas
ure the clearance between the adjusting nut and the SST
body.
46U0PX-012
2. Using the SST, turn the nut to lengthen the power brake
unit push rod to an amount equal to the clearance meas
ured at B.
36UQPX-021
Clearance at C
1. Measure and record height D1 of the gauge rod.
16E0PX-037
P—14
2. Turn the adjusting nut until the SST body sets squarely on
the master cylinder. (Turn only enough for the body to
touch.)
3. Measure and record height D2 of the gauge rod.
16E0PX-038
4. Subtract D1 from D2 and using the SST, turn the nut to
shorten the power brake unit push rod an amount equal
to the sum.
16E0PX-039
Note
CLEAF
0
UJ
1i
• This adjustment produces the follwing clearance.
f o l ' Vacuum applied to unit Push rod to piston clearance
I
M__ 0 kPa (0 mmHg, 0 inHg) 0.4—0.6 mm {0.016—0.024 in)
3* *
Approx. 66.7 kPa {500 mmHg,
19.7 inHg)
0 .1 -0 .4 mm {0.004-0.016 in)
r
46U0PX-013
Brake pipe
Tighten the brake pipe flare nut with the SST.
Tightening torque:
12.9—21.5 Nm (130—220 kgf cm, 113—190 inlbf)
36UOPX-098
1. After removing the brake fluid, disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary. If the master cylinder body is damaged, replace the
unit as an assembly.
Caution
• The brake master cylinder is made of aluminum, and can be easily damaged by tightening
in a vise. When securing the master cylinder in a vise, tighten only the flange of the master
cylinder.
N-m {kgf-cm, in-lbf)

46U0PX-014
1. Brake fluid level sensor 12. Stopper

Inspection................................. page P-17 13. Primary piston assembly
2. C a p set In s p e c t for a b n o r m a l w ear, rust, a n d
3. Filter damage
4. Screw 14. Stop screw and O-ring (Non ABS model)
5. Reservoir Assembly Note......................... page P-17
Inspect for damage and deformation 14. Stop pin and O-ring (ABS model)
6. Bushings Assembly Note......................... page P-17
7. Snap ring 15. Secondary piston assembly
8. Spacer Inspect for abnormal wear, rust, and
9. Piston guide damage
10. O-ring 16. Master cylinder body
11. Cup Inspect inside of body for corrosion
P—16
Assembly Note
Stop screw and O-ring (NON ABS MODEL)
1. Push the secondary piston assembly in fully.
2. Install and tighten a new O-ring and stop screw.
3. Push and release the piston to verify that it is held by the
stop screw.
Stop pin and O-ring (ABS MODEL)

1. Install the secondary piston assembly with the piston hole
facing the stop pin.
2. Install and tighten the new O-ring and stop pin.
3. Push and release the piston to verify that it is held by the
stop pin.
Inspection
Fluid level sensor
1. Disconnect the sensor connector.
2. Connect an ohmmeter to the connector.
3. Starting with the fluid level above the MIN mark on the reser
voir, verify that there is no continuity.
4. Remove the brake fluid and verify continuity when the lev
el is below the MIN mark.
5. Replace the sensor if necessary.
P—17
POWER BRAKE UNIT
Quick Inspection (On-vehicle)
Power brake unit function check
(Simple method)
Step 1
1. With the engine stopped, depress the pedal a few times.
2. With the pedal depressed, start the engine.
3. If the pedal moves down slightly immediately after the en
gine starts, the unit is operating.
46U0PX-070
Step 2
2. Stop the engine after it has run for 1 or 2 minutes.
3. Depress the pedal with the usual force.
4. If the first pedal stroke is long and becomes shorter with
subsequent strokes, the unit is operating.
5. If a problem is found, inspect the check valve and vacuum
hose for damage and examine the installation. Repair if
necessary, and inspect it again.
\ T H IR D
FIR S T S E C O N D
46U0PX-071
Step 3
2. Depress the pedal with the usual force.
3. Stop the engine with the pedal depressed.
4. Hold the pedal down for about 30 seconds.
5. If the pedal height does not change, the unit is operating.
6. If there is a problem, check the check valve and vacuum
hose for damage, and check the connection. Repair if
30 necessary and check again.
SECONDS
If the nature of the problem is still not clear after the 3 steps
46U0PX-072 above, follow the more detailed check described in “ Inspec
49 U 043 004 tion using gauges’’ below.
49 U 043 005 (Inspection using gauges)

Connect the SST gauges, vacuum gauge (A), and pedal
depression force gauge (B) as shown. Bleed the air from the
SST gauges before performing the following tests.
46U0PX-015
a) Checking for vacuum loss
Unloaded condition
2. Stop the engine when the vacuum gauge reading reaches
66.7 kPa (500 mmHg, 19.7 inHg}.
3. Observe the vacuum gauge for 15 seconds. If the gauge
shows 63.3—66.7 kPa {475—500 mmHg, 18.7—19.7
inHg}, the unit is operating.
16E0PX-05Q
P—18
Loaded condition
2. Depress the brake pedal with a force of 196 N {20 kgf,
44 Ibf).
3. With the brake pedal depressed, stop the engine when the
vacuum gauge reading reaches 66.7 kPa {500 mmHg,
19.7 InHg).
4. Observe the vacuum gauge for 15 seconds. If the gauge
shows 63.3—66.7 kPa {475—500 mmHg, 18.7—19.7
InHg), the unit is operating.
b) Checking for hydraulic pressure

1. If the fluid pressure is within the specification the engine
stopped (vacuum 0 kPa {0 mmHg, 0 inHg)), the unit is
operating.
Pedal force N (kgf, Ibf) Fluid pressure kPa (kgf/cm2, psi)

196 (20, 44) 883 (9, 128) min.
2. Start the engine. Depress the brake pedal when the vacu
um reaches 66.7 kPa {500 mmHg, 19.7 inHg ). If the flu
id pressure is within the specification, the unit is operating.
Pedal force N (kgf, Ibf) Fluid pressure kPa (kgf/cm2, psi)
MTX: 7061 (72, 1024) min.
196 (20, 44)
ATX: 8826 (90, 1280) min.
36U0PX-025
3. After installation, perform the following.
(1) Add fluid and bleed the air. (Refer to page P-7.)
(2) Check and adjust the brake pedal height. (Refer to page P-10.)
(3) Check for fluid leakage. (Refer to page P-9.)
N-m {kgf-m, ft-lbf)

46UOPX-074
1. Brake fluid level sensor connector 7. O-ring (Except MTX without ABS)
2. Hose (MTX) 8. Vacuum hose
3. Brake pipe 9. Spring clip
Removal / Installation Note........page P-21 10. Clevis pin
4. Nut 11. Nut
5. Bracket 12. Fork
6. Master cylinder 13. Nut
Removal / Installation................ page P-12 14. Power brake unit
Disassembly / Inspection / 15. Gasket
Assembly................................ page P-16
P—20
Brake pipes
Caution
• Brake fluid will damage painted surfaces. If it does
get on a painted surface, wipe it off immediately.
Loosen and tighten the brake pipes by using the SST.
46U0PX-016
DUAL PROPORTIONING VALVE
Inspection
1. Connect the SST to the brake pipes with adapters as shown
in the figure.
Adapter and flare nut tightening torque:

12.9—21.5 N m [130—220 kgf-m, 113—190 ft lbf}
Note
• Connect the brake pipes with the SST (49 0259 770B).
2. Bleed the air from the brake system.

(Refer to page P-7.)
3. Depress the brake pedal until the master cylinder pressure
equals A; then record rear brake pressure A’.
4. Depress the brake pedal again, apply additional pressure
until the pressure equals B; then record pressure B’.
Fluid pressure
kPa (kgf/cm2, psi)
A B A A’ B B'
MASTER CYLINDER PRESSURE kPa (kgf/cm2, psi) non ABS 3400 (35,500) 4170 (42.5,600)
3400 (35,500) 5880 (60,850)
46U0PX-075 MODEL ±200 (2,30) ±294 (3,43)
ABS 3400 (35,500) 4410 (45,640)
3400 (35,500) 5880 (60,850)
MODEL ±200 (2,30) ±294 (3,43)
Replacement
3. After installation, add brake fluid, bleed air, and check for fluid leakage.
NON ABS MODEL ABS MODEL

FRONT/RIGHT
( D 12.9—21.5 N m
(130—220 kgf-cm,
113—190 In-lbf)
HU
(130—220 kgfcmv .
113-190 £ *
In-lbf)
\
<S>
19—23 11.9—2.3,
14—17)
REAR /
LE FT
(2) 19—23 12.9—21.5 N-m (130—220 /

(1.9—2 .3,14—17) kgf-cm, 113—190 in-lbf) *
N-m (kgf-m, ft-lbf)

16E0PX-059
1. Brake pipe 3. Dual proportioning valve

Removal / Installation Note........page P-23 Installation Note........................ page P-23
2. Bolts
P -2 2
Brake pipe
Loosen and tighten the brake pipe by using the SST.
Tightening torque:
12.5—21.9 N-m (130—220 kgf-cm, 113—190 in-lbf)
36U0PX-099
Installation Note
Dual proportioning valve
Install the dual proportioning valve with the R marks facing
the right side.
36U0PX-029
FRONT BRAKE (DISC)
Inspection (on-vehicle)
Disc pad
1. Jack up the front of the vehicle and support it with safety
stands.
3. Sight through the caliper inspection hole and inspect the
remaining thickness of the pads.
Thickness: 2.0 mm {0.08 In) min.
4. Replace the pads as a set (right and left wheels) if either

is at or less than the minimum thickness.

4. After installation, perform the following.
(3) Depress the pedal a few times, then verify that the brakes do not drag while rotating the wheel by hand.

46U0PX-077
1. Flexible hose 6. Outer shim

2. Bolt 7. Inner shim
3. Caliper 8. Guide plate
Disassembly / Inspection / 9. Mounting support
Assembly................................ page P-26 10. Disc plate
4. V-spring Inspection........ page P-26
5. Disc pad
Inspection......................................... above
Installation Note........................ page P-25
P -2 4
Installation Note
Disc pad
Before installing the disc pads, push the piston fully inward
by using the SST.
49 0221 600C
16E0PX-064
DISC PAD
Replacement
N-m (kgf-m, ft-lb f)

16E0PX-065
1. Bolt 5. Outer shim

2. Caliper 6. Inner shim
3. V-spring 7. Guide plate
4. Disc pad
Installation Note................................ above
P—25
DISC PLATE
Inspection
1. Measure the thickness of the disc plate.
Standard: 24 mm (0.94 in)

Minimum: 22 mm (0.87 in)
2. If the thickness is not within the specifications, replace the

disc plate.
Disc plate runout

1. Verify that there is no wheel bearing looseness.
2. Measure the runout at the outer edge of the contact sur
face of the disc pad.
Runout: 0.1 mm [0.004 in) max.
3. If the runout is not within the specification, repair or replace

the disc plate.
CALIPER
5.9—8.8 (60—90, 53—78)
REPLACE
T) REPLACE
N-m (kgf-cm, In-lbf)

36U0PX-032
1. Dust seal 4. Bleeder cap, bleeder screw

Inspect for damage and poor sealing Disassembly Note..................... page P-27
2. Piston Assembly Note......................... page P-27
Disassembly Note..................... page P-27 5. Caliper body
Inspect for wear and rust Inspect for damage, wear and rust
3. Piston seal 6. Boot
Disassembly Note..................... page P-27
P -2 6
Disassembly Note
Piston
1. Place a piece of wood in the caliper.
2. Gently blow compressed air through the pipe hole to force
the piston out of the caliper.
46U0PX-019
Piston seal
Remove the piston seal from the caliper by using the SST.
49 0 2 0 8 701 A
16E0PX-070
Bleeder screw
Loosen the bleeder screw by using the SST.
49 02 59 7 7 0B
16E0PX-071
Assembly Note
Bleeder screw
Tighten the bleeder screw by using the SST.
Tightening torque:
6.9—9.8 Nm {70—100 kgf cm, 61—87 inlbf)
46U0PX-020
P—27
REAR BRAKE (DISC)
Disc pad
1. Jack up the rear of the vehicle and support it with safety
stands.
2. Remove the wheel and tires.
3. Verify the remaining thickness of the pads.
Thickness: 1.0 mm [0.04 in] min.
16E0PX-073

4. After installation, check the following.
11.8—15.6 N-m (120—160 kgf-cm, 105—138 In-lbf)
23—29 {2.2—3.0, 1 6 -2 2 )
45—67 {4.6—6.8, 33—49)
N-m {kgf-m, ft-lbf)

36U0PX-Q33
1. Parking cable, clip 8. M-spring

Removal / Inspection / 9. Disc pad
Installation............................... page P-37 Inspection.........................................above
2. Connecting bolt 10. Outer shim
3. Brake hose 11. Inner shim
4. Screw plug 12. Guide plate
5. Manual adjustment gear 13. Bolt
Removal Note........................... page P-29 14. Mounting support
Installation Note........................ page P-29 15. Disc plate
6. Lock bolt Inspection.................................page P-30
7. Caliper
Assembly................................ page P-31
P -2 8
Removal Note
Manual adjustment gear
Turn the manual adjustment gear counterclockwise with an
Allen wrench to pull the brake caliper piston inward.
(Turn until it stops.)
16E0PX-075
Installation Note
Manual adjustment gear
1. Turn the manual adjustment gear clockwise until the brake
pads just touch the disc plate.
2. Return the manual adjustment gear 1/3-turn.
16E0PX-076
DISC PAD
Replacement
11.8—15.6 N-m (
N-m [kgf-m, ft-lbf)

36U0PX-034
1. Parking brake cable, clip 5. M-spring

2. Screw plug 6. Disc pad
3. Manual adjustment gear 7. Outer shim
Removal Note................................... above 8. Inner shim
Installation Note................................ above 9. Guide plate
4. Lock bolt
P—29
DISC PLATE
Inspection
1. Measure the thickness of the disc plate.
Standard: 10 mm (0.39 in)

Minimum: 8 mm {0.31 in)
2. If the thickness is not within the specifications, replace the

disc plate.
Disc plate runout

1. Verify that there is no looseness in the wheel bearing.
2. Measure the runout at the outer edge of the contact sur
face of the disc pad.
Runout: 0.1 mm {0.004 in) max.
3. If the runout is not within the specification, repair or replace

the disc plate.
46U0PX-021
CALIPER
REPLACE
36—54 {3.7—5.5,
27—40)
@ 5.9—8.8 N m
{60—90 cm-kgf, 53—78 In-lbf)
<0> REPLACE
REPUCE 0
N-m {kgf-m, ft-lbf)

36U0PX-037
1. Dust seal 9. Spring

2. Piston 10. Operating lever
Disassembly Note........... ........below 11. Boot
Assembly Note................ page P-32 12. Bleeder cap and bleeder screw
Inspect for wear and rust Disassembly Note..................... page P-32
3. Manual adjustment gear Assembly Note......................... page P-32
4. Snap ring 13. Boot
5. Adjusting bolt 14. Boot
6. O-ring 15. Caliper body
7. Connecting link Inspect for damage and cracks
8. Piston seal
Disassembly Note............ page P-32
Disassembly Note
Piston
Turn the adjustment gear clockwise with an Allen wrench
to remove the piston from the adjustment gear.
(Turn the adjustment gear until it becomes easy to turn.)
16E0PX-081
P-31
Piston seal
Remove the piston seal from the caliper by using the SST.
49 0 2 0 8 7 0 1 A
16E0PX-082
Bleeder screw
Loosen the bleeder screw by using the SST.
Assembly Note
Bleeder screw
Tighten the bleeder screw by using the SST.
16E0PX-084
Piston
Insert the piston into the caliper and turn the adjustment gear
counterclockwise with an Allen wrench to pull the piston in
ward. (Turn until it stops.)
16E0PX-085
P—32
REAR BRAKE (DRUM)
Brake shoe (lining)
1. Jack up the rear of the vehicle and support it with safety
stands.
3. Remove the brake drum. (See below)
4. Verify the remaining thickness of the lining.
Thickness: 1.0 mm (0.04 in} min.
36U0PX-038

1. Remove the lining in the order shown in the figure, referring to Removal Note.
4. After installation, check the following.
9.81—12.7 N-m (100—130 kgf-cm, 86.9—112 In-lbf)
1 /9 .8 1 —14.7 N-m
(100—150 kgf-cm,
^86.9—130 In-lbf)
36U0PX-039
1. Screw 9. Anti-rattle spring 17. Bolt
2. Brake drum 10. Brake shoe (leading side) 18. Wheel cylinder
Inspection........page P-34 Inspection.............. Above Disassembly / Inspection /
Installation Note 11. Brake shoe (trailing side) Assembly......page P-35
..................... page P-34 Inspection.............. Above 19. Wheel cylinder gasket
3. Hub cap 12. Operating lever 20. Insulator
4. Locknut 13. Quadrant 21. Bolt
5. Wheel hub assembly 14. Quadrant spring 22. Backing plate
6. Return spring (upper) 15. Parking brake cable Inspect for damage and
7. Return spring (lower) 16. Brake pipe cracks
8. Hold pin and spring Removal Note., page P-34
Removal Note
Brake pipe
Disconnect or connect the brake pipe from/to the wheel cyl
inder with the SST.
Tightening torque:
16—22 N m {1.6—2.2 kgf m, 12—16 ft lbf}
36U0PX-040
Inspection
Check for the following and repair or replace parts as
necessary.
Brake drum
1. Drum inner diameter
Standard diameter: 228.6 mm (9.000 in}

Diameter limit : 230.1 mm {9.059 in}
46U0PX-022
2. Scratches, uneven or abnormal wear inside drum
46U0PX-023
Grease points
(1) Shoe and cylinder contact points
(2) Shoe anchor points
(3) Projections of backing plate
36U0PX-101
Installation Note
Brake drum
1. Before installing the brake drum, depress the brake pedal
to verify operation of the automatic adjuster.
46U0PX-024
P—34
2. After installation:
(3) Depress the brake pedal a few times and check that
the rear brakes do not drag while rotating the wheel.
(4) Check the parking brake lever stroke.
WHEEL CYLINDER
1. Disassemble the wheel cylinder in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary. If any of the metal parts are damaged, replace the
wheel cylinder as an assembly.
(T) R E P L A C E
REPLACE © ,
N-m {kgf-cm, in-lbf)

46U0PX-026
1. Dust boot 4. Spring

2. Piston 5. Bleeder cap and bleeder screw
Inspect for corrosion and damage 6. Wheel cylinder body
3. Piston cup Inspect for corrosion and damage
P -3 5
PARKING BRAKE SYSTEM
Problem Possible cause Remedy Page

Brakes do not Improper return of parking brake cable or improper Repair or adjust P-36, 37
release adjustment
Parking brake does Excessive lever stroke Adjust P-36
not hold well Brake cable stuck or damaged Repair or replace P-37
Brake fluid or oil on pad or brake shoe Clean or replace
Hardening of pad or brake shoe surface or poor contact Grind or replace P-29, 33
36U0PX-045
PARKING BRAKE SHOE

Drum brake
Removal and Installation. (Refer to page P-33.)
Inspection. (Refer to page P-33.)
36U0PX-046
PARKING BRAKE (LEVER TYPE)

Check if the stroke is within the specification when the park
ing brake lever is pulled with a force of 98 N (10 kgf, 22
Stroke: 5—7 notches
46U0PX-078
Adjustment
1. Before adjustment, start the engine and depress the brake
pedal several times.
2. Stop the engine.
3. Remove the parking brake lever cover.
4. Turn the adjusting nut at the front of the parking cable.
5. After adjustment, check the following points:
(1) Turn the ignition switch ON, pull the parking brake le
ver one notch, and check that the parking brake warn
ing light illuminates.
(2) Verify that the rear brakes do not drag.
P -3 6
PARKING BRAKE CABLE
1. Remove the cable in the order shown in the figure.
2. Visually check each part, and replace it if necessary.
4. Depress the brake pedal a few times and check that the rear brakes do not drag while rotating the wheels.
5. Adjust the parking brake lever stroke.
DISC BRAKE TYPE
N-m fkgf-m, ft-lbf)

46U0PX-027
1. Rear console 5. Nut

Removal I Installation............. Section S 6. Clip
2. Adjusting nut 7. Screw
3. Return spring 8. Brake drum
4. Front parking cable 9. Rear parking cable
Inspect for damage and wear
P -3 7
P PARKING BRAKE SYSTEM
PARKING BRAKE LEVER
1. Block the wheels firmly.
4. Inspect all components and parts. Replace parts if necessary.
5. Install in the reverse order of removal. Install the parking brake switch so that it contacts the parking brake
lever when the lever is fully released.
6. Adjust the parking lever stroke. (Refer to page P-37.)
7. Turn the ignition switch to ON, and verify that the parking brake warning light comes on when the lever
is pulled up one notch.
ftlbf)
46U0PX-029
1. Rear console 4. Parking brake lever assembly

Removal / Installation. Section S Inspect for damage and wear
2. Adjusting nut 5. Parking brake switch
3. Bolt Inspection.............................. Section T
P—38
ANTI-LOCK BRAKE SYSTEM P
ANTI-LOCK BRAKE SYSTEM (ABS)
DESCRIPTION
There is the following distinctive characteristics in the ABS vehicles compared with the non-ABS vehicles.
Note that it does not indicate malfunction.
• When the brakes are applied rapidly or on a slippery road surface, the ABS will activate; the brake
pedal will pulsate slightly and the vehicle and the steering wheel will vibrate slightly.
16EQPX-092
PREPARATION
SST
Precaution
Conditions that are not malfunctions
1. Vibration can sometimes be felt in the steering wheel, body, and/or brake pedal when the ABS is function
ing; such vibration is simply an indication that the system is functioning.
2. The ABS warning light may illuminate under any of the following conditions:
• When the vehicle is travelling on snow or ice with the parking brake activated or a brake dragging at
one wheel.
• When different size tires are used.
• When tires of different gripping performance are used.
• When (while the vehicle is jacked up or stuck) the front wheels only are spun for 20 seconds or more.
• When there is insufficient battery voltage.
Note
• Under the above conditions, the warning light will not illuminate a second time when the ignition is switched
OFF then back ON, and there will be no problem entry made to the control unit memory.
Troubleshooting notes
The ABS is composed of electrical components, mechanical components (hydraulic unit), and the com
ponents of the standard brake system.
Fundamentally, malfunction of the ABS electrical or mechanical components is judged by the self-diagnosis
function within the ABS control unit. And malfunctions are indicated by the warning light in the instrument
panel. The location of a malfunction is indicated by the technician switching the system to the diagnosis-
indication mode.
The self-diagnosis and indication functions must be used when diagnosing malfunctions of the ABS.
46U0PX-030
P -3 9
■0 0 A N TI-LO C K BRAKE SYSTEM
I 3D
J*
o ABS WHEEL SPEED SENSORS
FEAR o
g
>
o
(S) / SHIELD
30
WIRE >
ANTI-LOCK BRAKE SYSTEM

0 -0 1 ABS CONTROL UNIT (F) 0 - 0 2 CHECK CONNECTOR(F) 0 - 0 3 ABS RELAY BOX (F)
2S 20 20 2M 2G 2E 2C 2A
W/G LG/B
> < B L/O L /B 0 Y/G R G
X * * * G/B B G/B
n R /Y
X L /R
n
* R /Y * B/W B BR Y/G Y Y /L W L L /Y B /L Y W/B * G/R * G/R Y L /Y LG/B B/W B /L B
0 - 0 4 ABS HYDRAULIC UNIT (F) 0 - 0 5 ABS HYDRAULIC UNIT (F) 0 - 0 6 ABS WHEEL SPEED SENSOR FRONT LH (F) 0 - 0 7 ABS WHEEL SPEED SENSOR FRONT RH (F)
.__□ ___ Q _ ___o . __
BR Y/G L G /B L G /B
L /B L /O L G /B L G /B
0 - 0 8 ABS WHEEL SPEED SENSOR 0 - 0 9 ABS WHEEL SPEED SENSOR
36U0PX-051
REAR LH (R) REAR RH (R)
Y/G Y/L
46U0PX-031
DIAGNOSTIC CHART
X . Cause Input Output

ABS Hydraulic
relay unit
ABS wheel speed sensor
Data link connector

ABS warning light
ABS control unit

Stoplight switch
Solenoid valve
Fail-safe relay
Motor relay
Alternator
Motor
Symptom
1 ABS warning light not illuminated when ignition switch turned ON O
2 ABS warning light remains ON 0 O O O O O 0 O 0
ABS warning light illuminates for 1.5 seconds and goes out before
3 O O 0
engine started
4 ABS warning light flashes O
46U0PX-032
DIAGNOSTIC INDEX
No. Troubleshooting Items Remarks Page
ABS warning light not illuminated when ignition switch turned

1 — P-42
ON
Warning light remains ON and ABS does

2 Warning light remains ON P-43
not operate
ABS warning light illuminates for 1.5 seconds and goes out P-44
3
before engine started
4 ABS warning light flashes P-44

46U0PX-033
P -41
WARNING LIGHT NOT ILLUMINATED WHEN IGNITION SWITCH TURNED ON
DETAILED DESCRIPTION
Possible cause:
• If other warning indicators do not illuminate, METER 15A fuse may be burnt.
• Failed warning light of open in related wiring harness.
Is METER 15A fuse OK? Yes Go to next step
c r page P -5 5
No Replace METER 15A fuse
Is harness of ABS warning light normal? Yes Inspect ABS warning light cr page P -5 2
cr page P -5 2
No • Inspect harness between ABS CU and ABS relay

• Inspect harness between instrument panel and ABS CU
• Inspect harness between instrument panel and ABS relay
• Inspect ABS warning light bulb
46U0PX-034
P—42
WARNING LIGHT REMAINS ON
DETAILED DESCRIPTION Warning light remains ON and ABS does not operate
Possible cause:
• If only ABS warning light illuminates, activate diagnostic mode and check for diagnostic trouble code
• Malfunction of alternator
• Malfunction of battery
• Malfunction of ABS warning light harness (fail-safe relay)
• Malfunction of ABS CU
With the SST (self diagnosis checker, system Yes Read diagnostic trouble code
selecter), verify that diagnostic trouble code is => Inspect as indicated cr page P -4 7
indicated. (Connect the SST to the data link
connector)
cr page P -4 5
49 H 0 1 8 9A1
No Go to next step
Are alternator and battery OK? Yes Go to next step

cr page P -51
No Inspect alternator, harness of alternator, and battery

voltage
Is ABS warning light harness normal? Yes Go to next step

cr page P -5 2
No Inspect harness between ABS CU and ABS relay

Inspect harness between instrument panel and ABS CU
Inspect harness between instrument panel and ABS
relay
Connect terminal 2J (B/L) of ABS CU connec Yes Go to next step

tor (18 pins) to a ground and check the follow
ing points (IG ON)
• Operation sound of relay is heard No Inspect ABS relay (fail-safe relay)
• ABS warning light is not illuminated Inspect harness between ABS relay (fail-safe relay) and
• 1D (BR) terminal of ABS CU connector indi ABS CU, battery
cates 12V Inspect harness between ABS relay (fail-safe relay) and
HU
P—43
P ANTI-LOCK BRAKE SYSTEM

5 Is voltage at terminals 1E (B), 1F (B) and 1H Yes Replace ABS CU
(BA/V) of ABS CU connector (12 pins) and
terminals 2B (G/R) and 2L (LA') of ABS CU
No • Inspect harness between ABS CU and ground
connector (18 pins) as specified?
• Inspect harness between ignition switch and ABS CU
cr page P -5 6
• Inspect harness between diagnosis connector and ABS
CU
• Inspect harness between ABS warning light and ABS
CU
46U0PX-035
3 ABS WARNING LIGHT ILLUMINATES FOR 1.5 SECONDS AND GOES OUT BEFORE ENGINE STARTED
DETAILED DESCRIPTION —
Possible cause:
• If other warning indicators do not illuminate, alternator or its harness may be faulty
• Disconnection of ABS CU connector (18 pins)
• Malfunction of ABS warning light harness
1 Check output voltage at L terminal of alterna
tor, and for disconnection of alternator con Yes Go to next step
nector
cr page P -51 No Inspect alternator
2 Is condition of ABS CU connector (18 pins) Yes Go to next step

OK?
No Inspect condition of connector
3 Is harness between alternator connector (termi Yes Go to next step

nal L) and ABS CU OK?
No Inspect harness between alternator connector (terminal L)
and ABS CU
4 Check if ABS warning light illuminates when Yes Replace ABS CU

terminal 2L of ABS CU connector is grounded
cr page P -5 7
No Inspect harness between ABS CU and ABS warning light
46U0PX-036
ABS WARNING LIGHT FLASHES
DETAILED DESCRIPTION
Possible cause:
• Data link connector terminal TBS grounded
Verify that there is no continuity between termi Yes Inspect ABS CU
nal TBS and GND
No Repair short between terminal TBS and ground
46UOPX-085
P -4 4
SELF-DIAGNOSIS FUNCTION
INSPECTION BY DIAGNOSIS TEST MODE
OUTLINE
The ABS control unit contains self-diagnostic and memory functions to watch for and indicate present and
past failures.
Read and note the diagnostic indications using the SST then take action according to the Diagnostic Trouble
Code Table. (Refer to page P-47.)
36U0PX-059
Inspection procedure
SELECT SW: A
SYSTEM SELECT: 3
1. Connect the SST to the data link connector and a ground.
TEST SW: 2. Set the select switch to position A.
TEST
49 B 0 19 9A 0
36U0PX-060
3. Set the System Selector to position 3 and SELF TEST as
SYSTEM SELECTOR
shown.
.T E S T SW
4 SELF '
TE9' ‘
‘- W -’ t ^ -S E L F
SYSTEM SELECT TEST
49 B 0 1 9 9A 0
16E0PX-106
5. Verify that 88 flashes on the digital display and the buzzer
sounds for 3 sec. after turning the ignition switch ON.
49 H 018 9A1
6. If 88 does not flash, check power supply circuit, and ground
wiring.
7. If 88 flashes and the buzzer continues for more than 20 sec.,
SaF-OtAGNOSIS CHECKER check for a short circuit between terminal TBS and ground.
SELECT S *
k Replace ABS control unit if necessary and perform Steps
3 and 4 again.
8. Note any code numbers and check for the causes by refer
ring to the check sequences shown on pages P-48 to
46U0PX-037 P-50. Repair as necessary.
9. After repairs, cancel the code numbers by performing
“ Memory Cancel” . (Refer to page P-47.)
P—45
36U0PX-062
1. Code cycle break

The time between diagnostic trouble code cycles is 4.0 seconds (the time the buzzer is oft).

1 CYCLE
CYCLE BREAK
ON
OFF
4.0 SEC.
36U0PX-063

The digit in the ones position of the diagnostic trouble code represents the number of times the buzzer
sounds 0.4 second during one cycle.
DIAGNOSTIC DIAGNOSTIC
1 CYCLE TROUBLE CODE TROUBLE CODE: 03
1 2 3 CYCLE BREAK
ON
OFF
0.4 0.4 4.0 SEC.

SEC. SEC.
36U0PX-064

The digit in the tens position of the diagnostic trouble code represents the number of times the buzzer
is on 1.2 seconds during one cycle.
It should also be noted that the light goes off for 1.6 seconds between the long and short pulses of the buzzer.
DIAGNOSTIC
1 CYCLE TROUBLE CODE DIAGNOSTIC TROUBLE CODE: 22
rr
1 2 1 2 CYCLE
BREAK
II, II
. .j !
S E C . S E C . 1.6 4.0 S E C .
h— : s n ;
F I R S T DIGIT SECOND
DIGIT
36U0PX-065
P—46
Memory Cancel
Diagnostic trouble codes memorized in the ABS control unit are canceled by performing the following steps.
1. Connect the TBS terminal to GND at the data link connector.
3. Output all memorized codes.
4. After verifying that the first code is repeated, depress the brake pedal 10 times at intervals of less than
one second (1 sec.).
Note
Diagnostic trouble codes will not be canceled if:
• Intervals of depressing the brake pedal exceed one second (1 sec.).
• Stoplight switch has failed.
• While performing the memory cancel operation, the ABS warning light will not illuminate.
• When the memory cancel operation is completed, the ABS warning light comes on for 2—3 seconds,
then goes off.
• After the memory is canceled, the ABS control unit performs self-diagnosis.
Diagnostic Trouble Code Table
Note
• Diagnostic trouble code “ 15” will be replaced by a code from 11 through 14 inclusive after vehicle
speed exceeds 10 km/h {6.2 MPH}.
Code Pattern of output signal Diagnosis

Possible cause
No. (Self-Diagnosis Checker) chart No.
Right front wheel speed sensor

11
Right front sensor rotor
12
Left front wheel speed sensor
Left front sensor rotor
Right rear wheel speed sensor

n ABS-1
13
Right rear sensor rotor
14
Left rear wheel speed sensor
Left rear sensor rotor ITL
15 Wheel speed sensor ABS-2
22
Hydraulic unit
Harness
rrm_ ABS-3
51 Fail-safe relay
nnnnnn. ABS-4
53
Motor
Motor relay
nnmnnm ABS-5
61 ABS control unit ABS-6
46U0PX-038
P—47
p ANTI-LOCK BRAKE SYSTEM
Diagnosis Chart
ABS-1 Diagnostic trouble code: 11—14

Possible failure: Wheel speed sensor, harness, sensor rotor, hydraulic pressure
11: Right front 12: Left front 13: Right rear 14: Left rear
Step Check item Remark Refer to

1 Check control unit connector Check for poor connection —
Check wiring harness between control unit and Check for open or short to ground
2 —
wheel speed sensor
3 Check wheel speed sensor — P-60
4 Check sensor rotor — P-60
5 Check stoplight switch — P-53
6 If a problem is found, replace hydraulic unit or

Check hydraulic system P-61
repair hydraulic system piping as necessary
If all above are OK after diagnostic trouble If code of 11—14 is obtained, replace ABS control
code(s) is erased, recheck for service code after unit
7 P-64
driving from when vehicle is stopped to over 10
km/h (6 mph)
8 If all above are OK, there was temporarily poor contact in wiring and now ABS system is functioning
36U0PX-067
ABS-2 Diagnostic trouble code: 15

Possible failure: Wheel speed sensor, harness

1 If all the malfunctions are OK after diagnostic If code of 11—14 is obtained, go to ABS-1 Above
trouble code is erased, recheck for service code
If code 15 is obtained, replace ABS control unit P-64
after driving from when vehicle is stopped to
over 10 km/h (6 mph) If nothing is displayed, there was temporarily poor
—
contact in wiring and now ABS is OK
36U0PX-068
Possible failure: Solenoid valve, harness

1 Check control unit connector Check for poor connection —
2 Check wiring harness between hydraulic unit Check for open or short to ground
—
and control unit
3 Check hydraulic unit solenoid valve Check for open circuit P-55
4 Check ABS warning light operation If warning light illuminates constantly after turning
ignition switch ON, replace ABS control unit
If warning light does not illuminate after turning ig —
nition switch ON, there was temporarily poor con
tact in wiring and now ABS system is functioning
46U0PX-039

Possible failure: Fail-safe relay

1 Check pump fuse Check pump fuse condition P-55
Check short to ground —
2 Check ABS relay Check for open circuit P-65
3 Check wiring harness between ABS relay and Check for open or short to ground
—
hydraulic unit or control unit
If warning light does not illuminate after turning ig —
nition switch ON, there was temporarily poor con
tact in wiring and now ABS system is functioning
46UQPX-040
P—49

Possible failure: Motor, motor relay

1 Check motor relay If pump motor continues operating after turning ig
P-66
nition switch OFF, motor relay may be faulty
2 Check ABS pump fuse Check ABS pump fuse condition P-55
Check short to ground —
3 Check wiring harness between ABS relay and Check for open or short to ground
hydraulic unit and ABS control unit —
4 Check voltage at ABS control unit terminal Turn ignition switch ON and check motor relay
P-57
terminal voltage
5 Check motor Check for open circuit P-54
6 Check wiring harness between motor and Check for open circuit
ground —
7 Check wiring harness between motor and ABS Check for open or short to ground
—
control unit
If warning light does not illuminate after turning —
ignition switch ON, there was temporarily poor
contact in wiring and now ABS system is func
tioning
46U0PX-064

Possible failure: ABS control unit

1 — Replace ABS control unit P-64
36U0PX-072
Inspection of ABS system
Check alternator
The ABS control unit uses the output voltage at the alternator terminal L to judges if the engine is running.
The output voltage is not detected by the self-diagnosis system.
To determine a possible failure of the alternator, refer to the table below.
ABS warning light condition Possible cause
Light goes out before engine started • Open circuit between alternator and the ABS control unit
(terminal 2F)
• Disconnection or open at alternator connector (terminal L)
Light remains illuminated • Alternator problem

(low output voltage at terminal L)
46U0PX-041

2. Check the voltage at the alternator terminals with the en
gine idling.
Specifications
Terminal B: Battery positive voltage
Terminal L: Battery positive voltage
Terminal S: Battery positive voltage
36U0PX-074
Check battery
Note
• If the battery voltage is low, the ABS warning light may
illuminate.

2. Check the voltage at the battery and at the ABS control unit
terminal 1H.
Voltage: 10V min.
3. If the battery voltage is below the specification, charge or

replace the battery as necessary.
4. If the battery voltage is within the specification and termi
nal 1H voltage is below the specification, check the wiring
harness between the battery and the ABS control unit ter
minal 1H.
P—51
Check ABS warning light harness
1. Turn the ignition switch OFF, and disconnect the ABS con
trol unit connector (18 pins).
2. Turn the ignition switch ON. If the warning light is ON, go
to next step. If the warning light is OFF, check ABS relay
and the harness. (Warning light-ABS relay (h), ABS relay
(b)-Ground)
46U0PX-062
3. Disconnect the ABS relay connector.
4. If the warning light remains illuminated, check the warning
light harness for short to ground.
46U0PX-063
Check ABS warning light bulb
1. Remove the meter assembly.
2. Remove the warning light bulb from the rear of the cluster.
3. Check the condition of the bulb.
4. Replace the bulb if necessary.
46U0PX-043
Check stoplight switch
1. Depress the brake pedal.
2. Verify that the stoplights illuminate.
3. If not illuminated, check the following:
• Stoplight bulb
• Stoplight fuse
• Stoplight harness
4. Repair of replace parts as necessary.
16E0PX-124
Check stoplight switch harness at ABS control unit

2. Disconnect the ABS control unit connector (12 pins).
4. Check for voltage between terminal 1M at the vehicle side
harness and ground. (Refer to page P-56.)
5. If not as specified, check wiring harness between the stop
light switch and the ABS control unit.
P—53
Check motor harness at ABS control unit
1. Turn the ignition switch OFF, and disconnect the ABS con
trol unit connector (12 pin).
2. Measure the resistance between 1L (RAO terminal of the
control unit connector and a ground.
Resistance: 1Q max.
3. If not as specified, check the wiring harness between the

motor and the control unit and check the motor.
Check motor at hydraulic unit

2. Disconnect the hydraulic unit connector (2 pin).
3. Measure the resistance between the connector terminals.
/ ^
D -3b
Resistance: 1Q max.
V J
4. Verify that the motor operates when applying 12 V to con
nector (2 pin).
5. If not as specified, replace the hydraulic unit.
HYDRAULIC UNIT CONNECTOR (2-PIN)
16E0PX-127
Check solenoid valve harness of ABS control unit
2. Measure the resistance between a ground and the follow
ing terminals at the ABS control unit connector (12 pin).
Terminal: 1A (L/B), Right rear
1B (Y/G), Left front
1C (L/O), Right front
1D (BR), Left rear
Resistance: Approx. 3fi
3. If not as specified, check the wiring harness between the

hydraulic unit connector (8 pin) and the ABS control unit.
1M 1K 1E 1C 1A
W/G LG/B X I B L/O L/B
R/Y ’ B/W H B BR Y/G

1N 1L 1J 1H 1F 1D 1B
P—54
Check solenoid valve at hydraulic unit
1. Disconnect the hydraulic unit connector (8 pin).
H IE 2. Measure the resistance between the following terminals.
r 1
Terminal
B R Y G LG I B LCS/B __________ A (BR)—E (LG/B)___________
U
L/ 0 LG I B LG I B __________ B (L/B)—F (LG/B)________ __
V - B-| J __________ C (Y/G)—G (LG/B)__________
v r
__________ D (L/O)—H (LG/B)__________
E C - H
Resistance: approx. 3Q
36U0PX-078
3. If not as specified, check the hydraulic unit wiring harness
or replace the hydraulic unit if necessary.
Check fuse
Check the fuses according to the following table. If a fuse is burned, replace it.
Fuse name Rating (Amp) Location Failure condition Refer to
• ABS warning light illuminates
ABS 60 (Malfunction code 51 or 53) P-49, 50
Main fuse box • Motor and solenoid valves do not operate
MAIN 100 • Engine does not start —
• ABS warning light illuminates after engine started
ENGINE 15 —
Fuse panel • ABS control unit not activated
STOP 20 (at driver's side) • Stoplight does not illuminate —
METER 15 • No ABS warning lights in instrument cluster illuminate —
46U0PX-044
MAIN FUSE BLOCK No.1 FUSE BLOCK
ABS
P -5 5
Check ABS control unit
ABS CONTROL UNIT CONNECTOR
1M 1K 1E 1C 1A 2S 20 20 2M 2G 2E 2C 2A
W/G LG/B
IXI |
"J
B L/O UB 0 Y/G R G
EZ i G/B
1N
R/Y |"
1L 1J
B/W
1H
B
1F
BR
1D
Y/G
1B
Y
2T
Y/L
2R
W
2P 2N
LA'
2L
B/L
2J
r"J
v
2H
W/B
2F 2D
G/R
2B
12 PIN 18 PIN
46U0PX-045
Connector Terminal Wire color Connected to Condition Voltage Remark

1A L/B Right rear Solenoid ON* 0-2 ‘ Solenoid is ON only when
wheel solenoid Ignition switch ON B+ ABS system is functioning.
Voltage when solenoid is
1B Y/G Left front Solenoid ON* 0-2 ON can be measured fol
wheel solenoid Ignition switch ON B+ lowing "Hydraulic System
Test” (Refer to P-61.)
1C L/O Right front Solenoid ON* 0—2
wheel solenoid Ignition switch ON B+
1D BR Left rear wheel Solenoid ON* 0-2
solenoid Ignition switch ON B+
1E B Ground Constant 0
1F B Ground Constant 0
12 pins
1H B/W Battery Ignition switch ON B+
Ignition witch OFF 0
1J — Not used — —
1K LG/B Solenoid If malfunction present 0
monitor Ignition switch ON B+
1L R/Y Motor Motor running B+
Motor stopped 0-1
1M W/G Stoplight Brake pedal depressed B+
switch Brake pedal released 0-2
1N — Not used — —
Connector Terminal Wire color Connected to Condition Voltage Remark

2A G/B FBS check Ignition switch ON 0
terminal
2B G/R TBS check Normal mode B+
terminal Diagnostic test mode 0
2C — Not used — —
2D — Not used — —
2E — Not used — —
2F W/B Alternator Ignition switch ON 0.8-3
terminal (engine off)
Engine idling B+
2G — Ground Constant 0
2H Y Motor relay Motor relay ON 0-2
Motor relay OFF B+
2J B/L Fail-safe relay Normal
ro
1
0
18 pins If malfunction present B+
2L L/Y Warning light Illuminated 0—3
Not illuminated B+
2M G Right Vehicle stopped 0 • Turn wheel at specified
2N L front speed to prevent incor
Wheel turned 1 revolution 0.25-3.0
per second rect diagnosis
• Check following terminals
20 R Left Vehicle stopped 0 of wheel speed sensor in
2P W front Wheel turned 1 revolution AC range:
0.25-3.0
Wheel per second 2N-2M (right front)
speed 20-2P (left front)
2Q Y/G sensor Left Vehicle stopped 0 2R-2Q (left rear)
2R Y/L rear Wheel turned 1 revolution 0.25-3.0 2S-2T (right rear)
per second • In DC range, wheel
2S 0 Right Vehicle stopped 0 speed sensor voltage will
rear be approx. 1,0V
2T Y Wheel turned 1 revolution 0.25-3.0 (with ignition switch ON)
per second
46U0PX-046
Check ABS relay harness (fail-safe relay)
1. Turn the ignition switch OFF and disconnect the ABS con
3. Connect terminal 2J (B/L) of the control unit connector (18
pin) to a ground.
4. Check the following points.
Condition Action
Fail-safe relay in ABS relay does • Check fail-safe relay
not click when 2J terminal • Check harness between fail
grounded safe relay and ABS control
unit
Warning light illuminates after • Check fail-safe relay
grounding 2J terminal
1D (BR) terminal of ABS control • Check fail-safe relay
unit connector does not indicate • Check harness between fail
12V safe relay and hydraulic unit
ABS RELAY
Check ABS relay (fail-safe relay)
1. Measure resistance between terminals c (B/L) and d (B/W)
of ABS relay connector.
2. Check for continuity between terminals a (B) and e(LG/B)

and between b (L/R) and e (LG/B).
Terminal Continuity
a—e Yes
b—-e No
3. Apply 12 V between terminals d (B/W) and c (B/L). Check

for continuity between terminals b (L/R) and e (LG/B) and
between b (L/R) and e (LG/B).
f b
Terminal Continuity
R/Y 1 1 L/R b—e Yes
Y L/Y LG/B B/W B/L B

a—e No
h g e d c a
46U0PX-079
Check ABS relay harness (motor relay)
1. Inspect the fail-safe relay.
2. Turn the ignition switch OFF and disconnect the ABS con
4. Connect terminal 2J (B/L) to a ground.
5. Connect terminal 2H (Y) to a ground.
6. Check the following points:
46U0PX-080
Caution
• Allowing the motor to operate for more than two
seconds will damage the motor.
2S 2Q 20 2M 2G 2E 2C 2A Condition Action
0 JY/G I R | G | I G/B
Motor relay in ABS relay does • Check harness between mo
Y | Y /U W rf L L/Y I B/L Y MW/BI G/R not click when terminals tor relay and ABS control unit
2T 2R 2P 2N 2L 2J 2H 2F 2D 2B grounded • Check motor relay
Motor does not operate • Check motor relay
• Check harness between mo
tor relay and motor
• Check fuse
46U0PX-081
7. If not as specified, replace the ABS relay.
Check ABS relay (motor relay)

1. Measure the resistance between terminals e (LG/B) and h
(Y), or between a (B) and h (Y) of ABS relay connector.
Resistance: 50—90Q
2. Check for continuity between terminals b (L/R) and f(R/Y).

Terminal Continuity
b-f No
3. Apply 12 V to terminals g (L/Y) (+) and h (Y) (-). Check

for continuity between terminals b (L/R) and f (R/Y).
Terminal Continuity
b-f Yes
46U0PX-047
P—59
Check ABS wheel speed sensor
on safety stands.
2. Remove the wheel and tire assembly.
3. Check for looseness and damage.
46U0PX-082
4. Check the clearance between the wheel speed sensor and
the sensor rotor.
Clearance: 0.3—1.1 mm (0.012—0.043 in}
5. If not as specified, replace the ABS wheel speed sensor or

sensor rotor as necessary.
16E0PX-139
Check resistance of ABS wheel speed sensor
1. Disconnect the ABS wheel speed sensor connector.
2. Check resistance at the ABS wheel speed sensor.
Resistance: 1.6—2.0 kfl
Check voltage of ABS wheel speed sensor

on safety stands.
2. Disconnect the wheel speed sensor connector.
3. Check each wheel by rotating it at one revolution per
second.
Voltage: 0.25—3.0V (AC)
4. If not as specified, replace the ABS wheel speed sensor or

sensor rotor as necessary.
5. Cancel the ABS control unit memory.
Check ABS sensor rotor

on safety stands.
3. Inspect for missing and damaged teeth.
4. Replace the ABS sensor rotor as necessary.
46U0PX-083
P -6 0
HYDRAULIC UNIT
The ABS control unit contains a self-diagnostic function to check the hydraulic system operation. During
the diagnostic test mode, the ABS control unit activates the hydraulic unit to reduce the hydraulic pressure
of the right front, left front, right rear, left rear in sequence for 0.5 second each at intervals of 1.5 seconds.
46UQPX-049
Inspection
Verify that the ABS warning light goes out after the engine
is started.
2. If the light stays ON after the engine has started, the ABS
control unit detects a failure and will not activate the hydraulic
unit.
3. Turn off the engine.
on safety stands. Shift the transaxle to neutral or N range.
46U0PX-050 6. Rotate the wheels by hand, and inspect for brake drag.
7. Using a jumper wire, connect the TBS and GND terminals

of the data link connector.
8. Depress the brake pedal, and have an assistant verify that
the right front wheel will not turn.
46U0PX-051
9. With the brake pedal still depressed, turn the ignition switch
ON and verify that the brake is released momentarily (ap
prox. 0.5 sec.) and that the wheel turns when pressure-
reduction operates.
10. Check operation of the remaining wheels in order: left front,
right rear, left rear.
11. If Steps 9 and 10 show correct operation, the following sys
tems are OK:
• Brake piping to hydraulic unit
• Braking system, including hydraulic unit
• Electrical system in hydraulic unit (solenoid, motor, etc.)
46U0PX-052 • ABS control unit, its output system (solenoid, relay, etc.)
and harness
IGNITION SWITCH The following are not checked with the above steps.
0.5 1.5 • Input system and harness of ABS control unit
OFF __ I sec. sec. • Intermittent failure
LJ_ _L.L -L-L -L.L • Fluid leakage
PRESSURE
LOW
_ n _ n _ n _ n 12. Replace the hydraulic unit if necessary.
RF LF RR L R | i
MOTOR 10851
sec.
ON
I 1
46U0PX-053
P—61
1. Remove the nuts mounting the fuel filter and igniter to the bracket, and move them toward the engine.
2. Remove the hydraulic unit in the order shown in the figure, referring to Removal Note.
3. The hydraulic unit is not serviceable. If there is a malfunction, replace the hydraulic unit assembly. Install
in the reverse order of removal, referring to Installation Note.
4. Add brake fluid, bleed the air, and check for fluid leakage.
5. Verify whether the diagnostic trouble code is canceled. (Refer to page P-47.)
46U0PX-054
1. Charcoal canister 6. Hydraulic unit

2. Cruise control actuator 7. Casing
3. Brake pipe 8. Mount rubber
Removal Note........ below 9. Hex stud
Installation Note...... P-63 10. Connector bolt
4. Connector 11. Connector
5. Nut and washer 12. Spacer
Removal Note
Brake pipes
Caution
mediately.
Loosen the brake pipes by using the SST.
46U0PX-055
P—62
Installation Note
Brake pipe
Tighten the brake pipe by using the SST.
Tightening torque:
12.9—21.5 N-m {130—220 kgf-cm, 113—190 in-lbf}
49 0259 77 0B
36UQPX-103
ABS CONTROL UNIT
4. Connect the negative battery cable, verify whether the diagnostic trouble code is cancelled.
1. Connector 3. ABS control unit

2. Nut
P -6 4
ABS RELAY
4. Connect the negative battery cable, verify whether the diagnostic trouble code is cancelled.
6 .9 — 9 .8 ( 7 0 — 1 0 0 , 6 1 — 8 7 )
6 .9 — 9 .8 170 — 10 0 , 6 1 — 8 7 )
6 .9 — 9 .8 ( 7 0 — 1 0 0 , 6 1 — 8 7 )
N-m { k g f-c m , In-lb f)
46U0PX-056
1. Fuse box cover 4. ABS relay

2. Data link connector Inspection..........................................below
3. Fuse box 5. Connector
Inspection
ABS relay (Fail-safe relay)
1. Measure resistance between terminals e (LG/B) and d (B/W)
of the ABS relay box connector.
2. Check for continuity between terminals a (B) and e (LG/B)
and between b (L/R) and e (LG/B).
Terminal Continuity
a—e Yes
b—e No
3. Apply 12 V between terminals d (B/W) and c (B/L). Check

for continuity between terminals b (L/R) and e (LG/B) and
between a (B) and e (LG/B).
Terminal Continuity
b—e Yes
a—e No
46U0PX-084
P—65
16E0PX-155
ABS relay (Motor relay)

1. Measure the resistance between terminals e (LG/B) and h
(Y) or between a (B) and h (Y) of the ABS relay connector.
2. Check for continuity between terminals b (L/R) and f (R/Y).

Terminal Continuity
b-f No
3. Apply 12 V to terminals g (L/Y) ( + ) and h (Y) (-). Check

for continuity between terminals b (L/R) and f (R/Y).
Terminal Continuity
b-f Yes
46U0PX-057
ABS WHEEL SPEED SENSOR (FRONT)
1. Jack up the vehicle and support it on safety stands.
4. Install in the reverse order of the removal.
5. Install the wheel and tire assembly.
6. Verify whether diagnostic trouble code is cancelled. (Refer to page P-47.)
N-m | kgf-m, ft-lbfj

36U0PX-092
1. Connector 4. Bolt
2. Nut 5. ABS wheel speed sensor
3. Bolt Inspection..........................................below
Inspection
1. Check resistance at the ABS wheel speed sensor terminals.
Resistance: 1.6—2.0 kQ
2. If not as specified, replace the ABS wheel speed sensor.
16E0PX-158
P—67
ABS SENSOR ROTOR (FRONT)
Removal / Inspection
1. Inspect the ABS sensor rotor for missing and damaged teeth.
2. Remove the drive shaft assembly from the vehicle. (Refer to Section M.)
36U0PX-104
1. ABS sensor rotor 3. Drive shaft

Removal Note................................... below Removal.....................................Section M
2. Boot band and boot
Removal Note
ABS Sensor rotor
Tap the ABS sensor rotor off the drive shaft with a chisel.
46U0PX-058
P—68
Installation
2. Install the drive shaft assembly to the vehicle. (Refer to Section M.)
16E0PX-161
1. ABS sensor rotor 3. Drive shaft

Installation Note ..., below Installation. Section M
2. Boot and boot band
Installation Note
ABS sensor rotor
tion shown and press it onto the shaft assembly the SST.
P—69
ABS WHEEL SPEED SENSOR (REAR)
5. Install the wheel and tire assembly.
6. Verify whether the diagnostic trouble code is cancelled. (Refer to page P-47.)
7 .9 -1 0 .7 N-m 180-110 kgfcm,

1 6 — 2 3 ( 1 .6 — 2 .3 , 1 2 — 1 7 )
1 8 — 2 5 ( 1 .8 — 2 .6 , 1 3 — 1 9 )
N-m fkgf-m, ft-lbf)

36U0PX-O93
1. Connector 4. Bolt
2. Bolt 5. ABS wheel speed sensor
3. Bolt Inspection..........................................below
Inspection
1. Check resistance at the ABS wheel speed sensor terminals.
Resistance: 1.6—2.0Q
2. If not as specified, replace the ABS wheel speed sensor.
16E0PX-164
P—70
ABS SENSOR ROTOR (REAR)
1. Remove the rear wheel hub assembly from the vehicle. (Refer to Section M.)
4. Install the rear wheel hub assembly to the vehicle. (Refer to Section M.)
36U0PX-105
1. ABS sensor rotor 2. Wheel hub

Removal Note.., below
Installation Note below
Removal Note
ABS sensor rotor
Tap the ABS sensor rotor off the wheel hub with a chisel.
46U0PX-060
Installation Note
ABS sensor rotor
1. Install a new rear ABS sensor rotor on to the wheel hub.
2. Using a steel plate and the SST, press the rotor until it is
flush with the wheel hub.
Note
• The ABS sensor rotor can be installed in either direction.
46U0PX-061
P—71
WHEELS AND TIRES
OUTLINE........................................................... Q - 2
SPECIFICATIONS........................................ Q - 2
TROUBLESHOOTING GUIDE.........................Q - 3
WHEELS AND TIRES...................................... Q - 4
SPECIAL NOTES ABOUT WHEELS
AND TIRES................................................ Q - 4
NOTES REGARDING TIRE
REPLACEMENT......................................... Q - 4
INSPECTION / ADJUSTMENT..................... Q - 4
REMOVAL/INSTALLATION........................Q - 6
TIRE ROTATION.......................................... Q - 6
WHEEL BALANCE ADJUSTMENT.............. Q - 6
16E0QX-001
Q OUTLINE
OUTLINE
SPECIFICATIONS
Standard Tires
___ ______ Engine KL
FS
Item
Size 14x5 1/2-JJ 14x6-JJ 15x6 1/2-JJ
Offset mm {in} 45 (1.77)
Wheels
Pitch circle diameter mm {in) 114:3 [4.50)
Material Steel Aluminum Alloy
Size P195/65R14 88S P205/55R15 87V
Tires Air pressure Front 220 (2.2, 32)
kPa (kgf/cm2, psi) Rear 180 (1.8, 26)
36U0QX-001
Temporary spare tire

Item Specifications
Size 15 x 4T
Offset mm (in) 45 (1.77)
Wheel Pitch circle diameter mm (in) 114.3 (4.50)
Material Steel
Size T125/70D15
Tire Air pressure kPa (kgf/cm2, psi) 415 (4.2, 60)
36U0QX-002
Q—2
TROUBLESHOOTING GUIDE Q
Excessive or
irregular tire wear Refer to page Q-5 for details.
Premature tire wear Incorrect tire pressure Adjust Q-2
Tire Squeal Incorrect tire pressure Adjust Q-2

Tire deterioration Replace —
Road noise or body Insufficient tire pressure Adjust Q-2

vibration Unbalanced wheel Adjust Q-6
Deformed wheel or tire Repair or replace —
Irregular tire wear — Q-5

“ Shake” occurs Excessive tire and wheel runout Replace -
(steering wheel vi Loose lug nuts Tighten Q-5
brates up/down) Unbalanced wheel Adjust Q-6
Cracked or worn engine mount rubber Replace Section B
Cracked or worn transaxle mount rubber Replace Sections J, K
“ Shimmy” occurs Excessive tire and wheel runout Replace —
(steering wheel Loose lug nuts Tighten Q-5
vibrates Unbalanced wheel Adjust Q-6
circumferentially) Irregular tire wear — Q-5
Insufficient tire pressure Adjust Q-2
Damaged or worn front wheel bearing Replace Section M
Malfunction of steering system — Section N
Malfunction of suspension — Section R
Steering wheel pulls Incorrect tire pressure Adjust Q-2
to one side Excessive or irregular tire wear — Q-5
Malfunction of braking system — Section P
General driving In Unequal tire air pressures Adjust Q-2
stability Deformed wheel or tire Repair or replace —
Loose lug nuts Tighten Q-5
Uneven (one-sided) Unequal tire air pressures Adjust Q-2
braking Malfunction of braking system — Section P
Heavy handling Insufficient tire pressure Adjust Q-2
Steering wheel Insufficient tire pressure Adjust Q-2
doesn’t return prop Malfunction of steering system — Section N
erly Malfunction of suspension — Section R
16E0QX-003
Q WHEELS AND TIRES
WHEELS AND TIRES
SPECIAL NOTES ABOUT WHEELS AND TIRES
1. Do not use wheels or tires other than the specified types.
2. Aluminum wheels are easily scratched. When washing them, use a soft cloth, never a wire brush.
If the vehicle is steam cleaned, do not allow boiling water to contact the wheels.
3. If alkaline compounds (such as salt-water or road salts) get on aluminum wheels, wash them as soon as
possible to prevent damage. Use only a neutral detergent.
16E0QX-004
NOTES REGARDING TIRE REPLACEMENT

Note the following points when tires are to be removed from or mounted onto the wheels.
1. Be careful not to damage the tire bead, the rim bead, or the edge of the rim.
2. Use a wire brush, sandpaper, or cloth to clean and remove all rust and dirt from the rim edge and the rim
bead.
3. When cleaning aluminum wheels, use a soft cloth, never a wire brush or sandpaper.
4. Remove pebbles, glass, nails, and other foreign items embedded in the tire tread.
5. Be sure the air valve is installed correctly.
6. Apply a soapy solution to the tire bead and the edge of the rim before mounting.
7. After mounting a tire onto a wheel, inflate the tire to 250—300 kPa {2.55—3.06 kgf/cm2, 36—42 psi).
Verify that the bead is seated correctly onto the rim and that there are no air leaks. Then reduce the
pressure to the specified level.
8. If a tire iron is used to change a tire on an aluminum wheel, be sure to use a piece of rubber between the
iron lever and the wheel to avoid damage to the wheel. Work should be done on a rubber mat, not on a
hard or rough surface.
16E0QX-005
INSPECTION / ADJUSTMENT
Visual Inspection
Inspection (Tire and Wheel)
A wheel or tire should be replaced if any cracks, dam
ages, deformation and other problem is found.
16E0QX-006
Tire Wear
1. Check the remaining tread.
Remaining tread
Standard tires: 1.6mm {0.063 in} min.
Snow tires: 50% of tread
2. A tire should be replaced if the wear indicators are expos

WEAR INDICATOR
ed.
wcrtn INDICATOR
16E0QX-007
Q—4
WHEELS AND TIRES Q
Abnormal tire wear
Abnormal tire wear patterns shown in the illustration can
occur. Refer to the chart for the possible causes and ac
tions.
Possible cause Action
(a) •Underinflation • Measure and adjust

(both sides worn) pressure
• Incorrect camber • Repair or replace suspen
SHOULDER WEAR CENTER WEAR
(one side worn) sion parts
•Hard cornering • Reduce speed
• Lack of rotation • Rotate tires
(b) • Overinflation • Measure and adjust
(c) (d)
pressure
FEATHERED EDGE • Lack of rotation • Rotate tires
(c) •Incorrect toe-in • Adjust toe-in
(d) • Incorrect camber or caster • Repair or replace axle and
suspension parts
• Malfunctioning suspension • Repair or replace
• Unbalanced wheel • Balance or replace
•Out-of-round brake drum • Correct or replace
or disc
TOE-IN OR UNEVEN WEAR
• Other mechanical problem • Correct or replace
TOE-OUT WEAR
• Lack of rotation • Rotate tires
16E0QX-008
Air Pressure
Check the air pressure of all tires, including the spare tire,
with an air pressure gauge. If necessary, adjust the air
pressure.
Air pressure: Refer to page Q -2
Q
Air Leakage
Verify that there is no air leakage from the air valve.
AIR VALVE
16E0QX-010
Loose Lug Nuts
Verify that the lug nuts are tightened to the specified tor
que.
Tightening torque:
88—118 Nm (9—12 kgf-m, 65—87 ftlbf)
Q -5
Q WHEELS AND TIRES
Wheel and Tire Runout
2. Set the probe of a dial indicator against the wheel, and meas
ure the runout through one full revolution.
Runout limit
mm (in)
Radial direction 1.5 (0.06)
2.5 (0.10) Steel
Lateral direction
2.0 (0.08) Aluminum
3. Replace the wheel if necessary.

Installation
1. The wheel-to-hub contact surfaces must be clean.
2. Tighten the lug nuts to the specified torque.
Tightening torque:
8 8 -1 1 8 N m { 9 -1 2 kgf m, 6 5 - 8 7 ft Ibf}
3. Retighten the lug nuts to the specified torque after about

1000 km {620 miles) of driving.
TIRE ROTATION
To prolong tire life and assure uniform tire wear, rotate the
tires as specified below. After rotating the tires, adjust each
tire to the specified air pressure. (Refer to page Q-2.)
U.S.A. : Every 6000 km {3750 miles)

Canada: Every 24000 km (15000 miles) or 15
monthes (whichever comes first)
46U0QX-002
WHEEL BALANCE ADJUSTMENT
If a wheel becomes unbalanced or if a tire is replaced or
repaired, the wheel must be rebalanced to within the specifi
cation.
Maximum unbalance (at rim edge)

14—inch wheel: 10g {0.35 oz)
15—inch wheel: 9g {0.32 oz)
Caution
• Do not use more than two balance weights on the
36U0QX-004 inner or outer side of the wheel.
• One balance weight; max. 60g (2.1 oz).
• If the total weight exceeds 100g (3.5 oz) on one
side, rebalance after moving the tire around on the
rim.
• Attach the balance weights tightly to the wheel.
• Select suitable balance weights for steel or alumi
num alloy wheels.
• Do not use an on-car balancer on automatic trans
axle models; it may cause transaxle damage.
Q—6
Before beginning any service procedure, refer to section S of the 1994
626/MX-6 Body Electrical Troubleshooting Manual for air bag system service
warnings.___________________________________
SUSPENSION
INDEX................................................................. R - 2
OUTLINE............................................................ R - 4
SPECIFICATIONS......................................... R - 4
TROUBLESHOOTING GUIDE..........................R - 5
WHEEL ALIGNMENT....................................... R - 6
PREINSPECTION......................................... R - 6
FRONT WHEEL ALIGNMENT...................... R - 6
REAR WHEEL ALIGNMENT........................ R - 8
FRONT SUSPENSION (STRUT)...................... R-11
PREPARATION............................................ R-11
FRONT SHOCK ABSORBER AND SPRING.. R-12
LOWER ARM................................................ R-17
FRONT STABILIZER.................................... R-20
STABILIZER CONTROL LINK...................... R-22
TRANSVERSE MEMBER.............................. R-23
FRONT CROSSMEMBER............................. R-24
REAR SUSPENSION (STRUT).........................R-26
PREPARATION............................................ R-26
REAR SHOCK ABSORBER AND SPRING.... R-27
REAR STABILIZER...................................... R-31
STABILIZER CONTROL LINK...................... R-32
LATERAL LINK AND TRAILING LINK......... R-33
REAR CROSSMEMBER............................... R-35
36U0RX-001
R INDEX
INDEX
FRONT SUSPENSION
FRONT WHEEL ALIGNMENT

MAXIMUM STEERING ANGLE
INNER: 3 7 ° ± 2°
OUTER: 32° ± 2°
CAMBER ANGLE: 626 - 0 ° 3 6 ’ ± 45’
MX-6 —0 °4 2 ’ ± 45’
CASTER ANGLE: 626 2 °3 7 ’ ± 4 5 ’
MX-6 3 °0 1 ’ ± 45 ’
TOTAL TOE-IN: 3 ± 3mm {0.12 ± 0.12 in)
0 °1 7 ’ ± 0°17'
TOE-IN (PER SIDE)*: 0 ° 0 8 ’30 ” ± 0 °0 8 ’30”
KINGPIN ANGLE: 626 1 5 °0 4 ’
MX-6 1 5 °2 5 ’
’ Indicates measurements made by using the 4-wheel alignment tester
36U0RX-002
1. Front shock absorber and spring 4. Stabilizer control link

Removal / Inspection.................page R-12 Removal / Inspection /
Disassembly / Inspection...........page R-14 Installation.............................. page R-22
Assembly..................................page R-15 5. Transverse member
2. Lower arm Removal / Inspection /
Removal / Inspection / Installation.............................. page R-23
Installation.............................. page R-17 6. Front crossmember
3. Front stabilizer Removal / Inspection /
Installation.............................. page R-20
R—2
INDEX R
REAR SUSPENSION
DISC BRAKE TYPE
DRUM BRAKE TYPE
REAR WHEEL ALIGNMENT

TOTAL TOE-IN: 3 ± 3mm (0.12 ± 0.12 in)
0 °1 7 ’ ± 0 °1 7 ’*
TOE-IN (PER SIDE)*: 0 °0 8 ’30 ” ± 0 ° 0 8 ’30”
CAMBER ANGLE: 626 - 0 ° 0 9 ’ ± 45 ’
MX-6 - 0 ° 2 2 ’ ± 45’
THRUST ANGLE: 0 ° ± 0 .1 °*
'Indicates measurements made by using 4-wheel alignment tester
36U0RX-003
1. Rear shock absorber and spring 4. Lateral link and trailing link
Removal / Installation................page R-27 Removal / Inspection I
Disassembly / Inspection...........page R-28 Installation.............................. page R-33
Assembly................................. page R-29 5. Rear crossmember
2. Rear stabilizer Removal / Inspection I
Installation...............................page R-31
Installation...............................page R-32
R—3
R OUTLINE
OUTLINE
SPECIFICATIONS
--------------------------- - Model MX-6
Item ----------------------------- 626
Suspension type St■ut
Shock absorber type Cylindrical, double-acting (oil-filled)
Front Straight wound
Type
Coil spring Rear Taper wound
Dimension See coil spring specification
Type Torsion bar
Stabilizer Diameter Front 25.4 (1.00) 22.2 (0.87)
mm (in) Rear 12 (0.47)
Maximum Inner 37° ± 2°
steering angle Outer 32° ± 2°
mm (in) 3 ±3 (0.12 ± 0.12)
Total toe-in
Degree 0°17’ ± 0°17’*2
Front
Toe-in (per side) 0°08'30” ± 0°08’30" *2
Wheel Camber angle -0°42' ± 45’ -0°36' ± 45’
alignment Caster angle 3°01’ ± 45’ 2°37' ± 45’
(*HJnladen) King pin angle 15°25' 15°04’
mm (in) 3 ± 3 (0.12 ± 0.12)
Total toe-in
Degree 0°17' ± 0°17' *2
Rear Toe-in (per side) 0°08’30" ± 0°08’30” *2
Camber angle -0°22' ± 45' -0°09’ ± 45'
Thrust angle 0° ±0.1°*2
36UORX-004
Fuel tank full; radiator coolant and engine oil at specified level, and spare tire, jack and tools in designated position
*2 Indicates measurements made by using the 4-wheel alignment tester
Coll Spring Specifications

Identification mark color Wire diameter Coil outer Free length
Item Coil number
! A»;' mm (in) diameter mm (in) mm (in)
A Purple — 13 (0.51) 293 (11.5) 2.78
B Light blue — 13 (0.51) 301 (11.8) 2.94
C Orange — 13 (0.51) 309 (12.2) 3.11
Front D White White 13 (0.51) 175 (6.9) 337 (13.3) 3.24
E White Purple 13 (0.51) 345 (13.6) 3.46
F White Green 13 (0.51) 353 (13.9) 3.57
G White Yellow 14 (0.55) 349 (13.7) 3.63
H Yellow — 11 (0.43) 275 (10.8) 3.94
I Pink — 11 (0.43) 122—152 279 (11.0) 4.08
Rear (4.8—6.0)
J Blue — 11 (0.43) 332 (13.1) 4.92
K Red — 11 (0.43) 338 (13.3) 5.24
46U0RX-001
*‘ Main identification mark color on second coil from bottom
*2 Auxiliary identification mark color on third coil from bottom
Coil Spring Applications

Model Engine Transaxle Front Rear right Rear left
FS MTX D J K
FS ATX E J K
626
KL MTX F J K
KL ATX G J K
FS MTX A H I
FS ATX A H I
MX-6
KL MTX B H I
KL ATX C H I
36U0RX-006
R -4
TROUBLESHOOTING GUIDE R
Body "rolls” Weak stabillizer Replace R-20, 21
Damaged or worn stabilizer bushing or control link Replace R-20,22,31,32
Worn or deteriorated lower arm bushing Replace R-17
Malfunction of shock absorber Replace R-12, 27
Poor riding comfort Weakened coil spring Replace R-16, 28
Body leans Weakened coil spring Replace R-14, 28
Worn or deteriorated lower arm bushing Replace
Abnormal noise from Poor lubrication or wear of thrust bearing Replace R-12
suspension system Poor lubrication or wear of lower arm ball joint Lubricate or replace R-18
Looseness of peripheral connections Tighten
Damaged or worn stabilizer, control link or stabilizer
bracket Replace R-20,22,31,32
General driving Weakened coil spring Replace R-14, 30
instability Malfunction of shock absorber Replace R-12, 27
Inproperly adjusted wheel alignment Adjust R- 6
Damaged lower arm ball joint Replace R-18
Malfunction of steering system Section N
Damaged or unbalanced wheel(s) Section Q
Heavy steering Poor lubrication or wear of lower arm ball joint Lubricate or replace R-18
Improperly adjusted wheel alignment Adjust R- 6
Malfunction fo steering system Section N
Steering wheel pulls Weakend coil spring Replace R-14, 30
to one side Damaged or worn stabilizer bushing or control link Replace R-20,22,31,32
Damaged lower arm ball joint Replace R-18
Malfunction of braking system Section P
“ Shimmy” occurs Damaged lower arm ball joint Replace R-18
(steering wheel vi Malfunction of shock absorber Replace R-12, 27
brates circumferen- Loose shock absorber mounting Tighten R-12, 27 R
tially) Worn or deteriorated lower arm bushing Replace R-17
Damaged or leaking lower arm bushing (rear) Replace R-18
Damaged or worn wheel bearing Replace Section M
Steering wheel Stuck or damaged lower arm ball joint Replace R-18
doesn’t return prop Improperly adjusted wheel alignment Adjust R- 6
erly Malfunction of steering system Section N
36U0RX-007
R WHEEL ALIGNMENT
WHEEL ALIGNMENT
PREINSPECTION
1. Check the tire inflations and set to the recommended pres
sure if necessary.
2. Inspect the front wheel bearing play. Replace the bearing
if necessary.
3. Inspect the wheel and tire runout.
4. Inspect the ball joints and steering linkage for excessive
looseness.
5. Position the vehicle on level ground and with no luggage
or passenger load.
6. The difference in height between the left and right sides from
the center of the wheel to the fender brim must not exceed
10mm (0.39 in).
7. Shake the vehicle to check operation of the shock absorbers.
16E0RX-011
FRONT WHEEL ALIGNMENT

Specifications (* Unladen)
Model MX-6 626

Item
Inner 37° ± 2°
Maximum steering angle
Outer 32° ± 2°
mm (in) 3 ±3 (0.12 ± 0.12)
Total toe-in
Degree 0°17' ± 0°17'*2
Toe-in (per side) 0°08'30” ± 0°08’30” *2
Camber angle -0°42' ± 45' -0°36’ ± 45'
Caster angle 3°01' ± 45’ 2°37’ ± 45'
King pin angle 15°25' 15°04’
36U0RX-039
*' Fuel tank full; radiator coolant and engine oil at specified level, and spare tire, jack and tools in designated position
Adjustment
Total toe-in
1. Remove the steering gear boot clamps.
2. Loosen the left and right tie rod locknuts, and turn the tie
rods equally. Both tie rods are right threaded, so turning
the right tie rod toward the front of the vehicle and the left
toward the rear increases toe-in.
Note
• Turning both tie rods one complete turn changes toe-in
by about 6mm (0.24 in ) .
R—6
WHEEL ALIGNMENT R
3. Tighten the tie rod locknuts.
Tightening torque:
69—98 N m (7.0—10.0 kgf-m, 51—72.3 ft lbf}
4. Verify that the boots are not twisted and install the boot
clamps.
16A0RX-035
Maximum steering angle
1. Remove the steering gear boot clamps.
2. Loosen the left and right tie rod locknuts, and turn the tie
rods equally to provide the correct maximum steering angle.
Maximum left/right difference: 3mm (0.12 in)
36U0RX-041
3. Tighten the tie rod locknuts.
Tightening torque:
69—98 N m (7.0—10.0 kgf m, 51—72.3 ft lbf}
4. Verify that the boots are not twisted and install the boot
clamps.
5. Inspect and adjust the toe-in after adjusting the turning angle.
Camber and caster

1. Jack up the front of the vehicle and support it on safety
stands.
2. Remove the mounting block nuts.
3. Push the mounting block downward, and turn it to the
desired position.
36U0RX-042
Difference from standard position

Mark
Camber angle Caster angle
A + 30’ 0°
B + 30’ -30’
C 0° -30’
46U0RX-003
R -7
R WHEEL ALIGNMENT
4. Install and tighten the mounting nuts to the specified torque.
Tightening torque:
47—62 N m {4.7—6.4 kgf m, 33—46 ft Ibf}
REAR WHEEL ALIGNMENT

Specifications ( * ‘Unladen)
______ Model MX-6 626
Item ______
mm (in) 3 ± 3 {0.1 2 ± 0.12)
Total toe-in _
Degree 0°17’ ± 0°17’ *2
Toe-in (per side) 0°08'30” ± 0°08'30” *2
Camber angle -0°22' ± 45’ -0°09' ± 45’
Thrust angle 0° ± 0.1°*2
36U0RX-043
*' Fuel tank full; radiator coolant and engine oil at specified level, and spare tire, jack and tools in designated position
Adjustment
Total toe-in
The thrust angle can only be measured with 4-wheel align
ment tester. If the thrust angle is not within specification,
check the body dimensions.
(Refer to the 626/MX-6 Bodyshop Manual [form
NO.3212-10-92A])
Thrust angle: 0° ± 0.1°
46U0RX-004
1. Remove the access hole caps.
36U0RX-011
R—8
WHEEL ALIGNMENT R
2. Loosen the cam nut on the lateral link.
3. Turn the adjusting cam bolt as indicated to adjust the toe-in.
Lett wheel Right wheel
Toe-out direction Counterclockwise Clockwise
Toe-in direction Clockwise Counterclockwise
Note
• Turning the adjusting cam bolt one graduation changes
the toe-in about 3.2mm {0.13 in} (0°18’).
4. Tighten the cam nut.
Tightening torque:
79—116 N m (8.0—11.9 kgf-m, 58—86.0 ft lbf)
5. Install the caps.
16A0RX-040
WHEEL ALIGNMENT
MEMO
R—10
FRONT SUSPENSION (STRUT) R
FRONT SUSPENSION (STRUT)
PREPARATION
SST
49 B034 2A0A For 49 B034 202 For

removal / removal of lower
Replacer, rubber installation of Support block arm bushing
bushing lower arm (Part of
bushing 49 B034 2A0A)
49 B034 203 For 49 B034 204A For

Guide lower arm Attachment installation of
(Part of bushing (Part of lower arm
49 B034 2A0A) 49 B034 2A0A) bushing
49 B034 205A For 49 B034 206 For

Replacer lower arm Shaft installation of
(Part of bushing (Part of lower arm
49 B034 2A0A) 49 B034 2A0A) bushing
49 G034 205 For 49 W038 002 For

removal I removal /
Bearing installation of Nut installation of
(Part of lower arm (Part of lower arm
49 B034 2A0A) 49 B034 2A0A)
49G034 1A0 For 49 0180510B For

removal / measurement of
Coil spring installation of coil Attachment, ball joint preload
compressor spring steering worm
bearing preload
measuring
49 G034101 For 49 G034 103 For

removal / removal /
Body installation of coil Arm installation of coil
(Part of spring (Part of spring
49G034 1A0) 49 G0341A0)
49 G034 102 For 49 8038 785 For

removal / installation of ball
Screw installation of coil Installer, boot joint dust boot
(Part of spring
49 G034 1A0)
49G017 5A0 For 49 G017 502 For

Support, engine engine Support engine
(Part of
49G017 5A0)
R -1 1
R FRONT SUSPENSION (STRUT)
49 G017 501 For 49 G017 503 For

engine engine
Bar
(Part of (Part of
49 G017 5A0) 49 G017 5A0) ^
49 0118 850C For

removal of
Puller, ball joint \ tie rod end — -
'
16U0RX-Q34
FRONT SHOCK ABSORBER AND SPRING

1. Jack up the front of the vehicle and support it on safety stands.
6. Tighten all nuts and bolts to the specified torques, referring to the figure.
Tightening torque: 89—117 Nm {9.0—12.0 kgf m, 66—86.7 ft lbf}
8. Adjust the front wheel alignment. (Refer to page R-6.)
( 1 .6 — 2 .3 , 12 — 1 6 )
Mm (kgf-m, ft-lbf)
46UQRX-005
R—12
1. Hose clip and flexible hose 5. Sheet
2. Wheel speed sensor harness (ABS) 6. Front shock absorber and spring
Installation Note.......................... below Installation Note.................................below
3. Shock absorber bolt Disassembly / Inspection...........page R-14
4. Nut Assembly................................. page R-15
36U0RX-014
Installation Note
Front shock absorber and spring
Face the mounting block direction indicator toward the
rear-outboard position, and install the shock absorber.
Wheel speed sensor harness (ABS)

Install the sensor harness bracket in the direction shown.
<D
_ ( g ) 9 0 — 1 1 6 ( 9 .1 — 1 1 . 9 , 6 6 — 8 6 .0 ]
N-m (kgf-m, ft-lbf)
36U0RX-016
1. Cap 7. Dust cover

2. Piston rod nut Inspect for damage and deterioration
Disassembly Note............................. below 8. Bound stopper
3. Mounting rubber Inspect for damage and cracks
Inspect for damage, deterioration, 9. Coil spring
and weakness Inspect for damage, deterioration,
4. Thrust bearing and weakness
Inspect for damage, wear, and poor 10. Lower rubber spring seat
lubrication Inspect for damage and cracks
5. Upper spring seat 11. Shock absorber
Inspect for damage and cracks Inspection.................................page R-15
6. Upper rubber spring seat
Inspect for damage and deterioration
Disassembly Note
Piston rod nut
Warning
• Removing the piston rod nut is dangerous. The
shock absorber and spring could fly off under
tremendous pressure and cause serious injury or
death.
Secure the shock absorber in the SST before remov
ing the piston rod nut.
Caution
• Do not remove the nut.
• To prevent damage to the mounting rubber, use pro
tective plates in the vise jaws.
1. Secure the mounting rubber in a vise.
2. Loosen the nut several turns, but do not remove it.
R—14
4. Secure the shock absorber in the SST.
5. Compress the coil spring by using the SST and remove
the nut.
Inspection
Shock absorber
Check the following and replace if necessary.
1. Inspect for damage and oil leakage.
2. Secure a handle to the piston rod, and compress and ex
pand the shock piston at least three times. Verify that the
operational force does not change and that there is no un
usual noise.
Assembly
1. Assemble the SST, and secure the SST in a vise.
2. Install the lower rubber spring seat.
3. Install the coil spring, fitting the end of the coil into the step
of the lower seat.
4. Compress the coil spring by using the SST.

49 G 03 4 102
5. Install the spring so that the lower coil is seated on the step
49 G 03 4 103 of the lower seat.
49 G 03 4 101
16E0RX-092
R—15
6. Install the bound stopper.
7. Install the dust cover.
8. Install the upper rubber spring seat.
9. Install the upper spring seat, facing the direction indicator
as shown.
16E0RX-042
10. Install the thrust bearing.
11. Install the mounting rubber, facing the direction indicator
as shown.
12. Tighten the nut several turns.
13. Remove the SST.
14 Verify that the lower coil of the spring is seated on the step
of the lower seat.
Caution
tective plates in the jaws of the vise.

16. Tighten the nut.
Tightening torque:
90—116 Nm {9.1—11.9 kgf m, 66—86.0 ft lbf}
17. Install the cap.
R—16
LOWER ARM
5. Loosely tighten the lower arm bolts. Tighten all other nuts and bolts to the specified torque.
6. Lower the vehicle.
7. With the vehicle unloaded, tighten the lower arm bolts.
2 7 -3 9 )
N-m (kgf-m, ft-lbf)

46U0RX-Q10
1. Bolt (lower arm ball joint) 6 Lower arm bushing (front)

2. Nut (Stabilizer control link) Removal Note........................... page R-18
3. Bolt, and dynamic damper Installation Note........................ page R-18
4. Lower arm assembly 7 Stopper
Inspection...................... page R-18 Inspect for damage and deterioration
5. Dust boot 8 Lower arm bushing (rear)
Removal Note................ page R-18 Inspect for damage, oil leakage, and
Installation Note.............. page R-19 deterioration
Lower arm
R -1 7
Removal Note
Dust boot
Carefully remove the dust boot with a chisel.
46U0RX-011
Lower arm bushing (front)
1. Cut away the projecting rubber of the lower arm bushing.
2. Set the SST onto the lower arm, and remove the bushing.
36U0RX-020
Inspection
Lower arm assembly
Inspect all parts and repair or replace as necessary.
1. Lower arm for damage and cracks
2. Bushings for deterioration and wear
3. Dust boot for damage
4. Ball joint for looseness and damage
If the ball joint needs to be replaced, replace the lower arm.
46U0RX-012
5. Ball joint preload
Move the ball joint back and forth 5 or 6 times, then attach
the SST to the ball stud, and measure the preload with a
pull scale.
Ball joint preload:

1.0—4.9 N m {10—50 kgf-cm, 8.6—43 in lbf}
Pull scale reading:

9 .8 -4 9 N {1 .0 -5 .0 kgf, 2.2—11.0 Ibf}
Installation Note
Lower arm bushing (front)
Install the new bushing, and pull it into the lower arm by
T \
49 B 0 3 4 2 A 0 A BUSHING using the SST.
BUSHING
//]
16E0RX-050
R—18
Dust boot
1. Wipe the grease off the ball stud.
2. Fill the inside of the new dust boot with grease.
3. Press the boot onto the ball joint by using the SST.
4. Wipe away the excess grease.
16E0RX-051
FRONT STABILIZER
5. Loosely tighten the stabilizer bracket bolts. Tighten all other nuts and bolts to the specified torque.
7. With the vehicle unloaded, tighten the stabilizer bracket bolts.
9. Bleed the air from the power steering system. (Refer to Section N.)
N m I kgf-m , f t lb f |
FS ENGINE KL ENGINE 64-89,6.5-9.1.47-66,
REPLACE
3 8 — 51 [3 .8 — 5 . 3 , 2 8 — 3 8)
3 8 — 51
( 3 .8 — 5 .3, 2 8 — 38)
REPLACE
N-m | kgf-m , ft lb f | N-m | kgf-m , tt-lbf |
46U0RX-014
R -2 0
1. Transverse member 9. Bolt (lower arm ball joint)
Removal / Inspection / 10. Steering gear and linkage
Installation.................... ........... page R-23 11. Nut and bolt
2. Engine mount member 12. Crossmember and lower arm
Removal Note................. ...................below 13. Stabilizer control link
3. Front exhaust pipe 14. Stabilizer bracket
Removal / Installation...... .... Sections F1, F2 Installation Note..................................
4. Engine mount No.1 15. Stabilizer bushing
5. Tie rod end ball joint Inspect to damage and weakness
Removal / Installation...... ............. Section N Installation Note..................................
6. Pressure pipe 16. Front stabilizer bar
7. Return hose Inspect for damage and deformation
8. Bolt (intermediate shaft) Removal Note....................................
Removal Note 36U0RX-Q24
Engine mount member

36U0RX-025
Front stabilizer bar
1. Support the crossmember by using a jack, and remove
the bolts and nuts.
2. Remove the stabilizer bracket.
3. Lower the crossmember slowly and remove the stabilizer
bar from the crossmember.
36U0RX-026
Installation Note
Stabilizer bushing and bracket
1. Apply rubber grease to the inside surface of the stabilizer
bushing.
2. Align the bushing with the installation mark on the
stabilizer bar.
16E0RX-055
3. Install the stabilizer bracket in the direction shown.
16E0RX-056
R—21
STABILIZER CONTROL LINK
3. Remove in the order as shown in the figure.
Tightening torque: 89—117 Nm {9—12 kgf-m, 66—86.7 ftlbf)
FRONT
(kgf-m, ftlbf)
16A0RX-046
1. Nuts
Inspection......................................... below
Inspection
Check the following and replace if necessary.

1. Inspect for bending and damage.
2. Measure the ball joint starting torque.
(a) Rock the ball joint stud side to side 10 times.
(b) Rotate the ball joint stud 10 times.
(c) Measure the starting torque by using a suitable Allen
socket and a torque wrench.
Starting torque:
0.2—1.5 Nm (2.0—15.0 kgf-cm, 1.7—13 in-lbf)
R—22
TRANSVERSE MEMBER
2. Remove the undercover.
94—131 19.5—13.4, 69—96)
46U0RX-025
1. Bolt 2. Transverse member

Inspect for cracks and damage
R—23
FRONT CROSSMEMBER
5. Loosely tighten the lower arm and the stabilizer bracket bolts. Tighten all other nuts and bolts to the speci
fied torque.
7. With the vehicle unloaded, tighten the lower arm and stabilizer bracket bolts.
9. Bleed the air from the power steering system. (Refer to Section N.)
N-m (kgf-m, ft-lbf)
FS ENGINE KLENGINE
38— S1 ( 3 .8 — 5 . 3 ,2 8 — 381
N-m (kgf-m, ft-lbf) N-m (kgf-m, ft-lbf)
46U0RX-015
R—24
1. Transverse member 10. Steering gear and linkage
2. Engine mount member 11. Nut and bolt
Removal Note............. below 12. Lower arm
3. Front exhaust pipe 13. Front crossmember and stabilizer
Removal I Installation... Sections F1, F2 Removal Note...................................... below
4. Engine mount No.1 14. Stabilizer bracket
5. Tie rod end ball joint Installation Note................................... below
Removal I Installation... Section N 15. Stabilizer bushing
6. Pressure pipe Installation Note................................... below
7. Return hose 16. Front stabilizer
8. Bolts (intermediate shaft) 17. Front crossmember
9. Bolt (lower arm ball joint) Inspect for damage and deformation
36U0RX-028
Removal Note
Engine mount member
2. Remove the engine mount member nuts.
16E0RX-061
Front crossmember and stabilizer
1. Support the crossmember by using a jack and remove the
bolts and nuts.
2. Remove the crossmember and steering assembly.
Installation Note
bushing.
2. Align the bushing with the installation mark on the stabiliz
er bar.
16E0RX-063
3. Install the stabilizer bracket in the direction shown.
16E0RX-056
R—25
R REAR SUSPENSION (STRUT)
REAR SUSPENSION (STRUT)
PREPARATION
SST
49G034 1AO For 49 G034 102 For

removal / removal /
Compressor, coil installation of coil Screw installation of coil
spring spring (Part of spring
49G0341A0)
49 G034 101 For 49G34 103 For

removal / removal /
Body installation of coil Arm installation of coil
(Part of spring (Part of spring
49G0341A0) 49G034 1A0)
36U0RX-030
REAR SUSPENSION (STRUT) R
REAR SHOCK ABSORBER AND SPRING
1. Jack up the rear of the vehicle and support it on safety stands.
3. Remove the trunk side trim. (Refer to Section S.)
4. Remove in the order as shown in the figure.
6. Install the trunk side trim. (Refer to Section S.)
Tightening torque: 89— 117 N-m {9— 12 kgf-m, 66—86.7 ftlb f)
8. After installation, measure the rear wheel alignment and adjust it if necessary. (Refer to page R-8.)
N-m (kgf-m, ftlb f)
36U0RX-031
1. Hose clip and flexible hose 5. Sheet

2. Wheel-speed sensor harness (ABS) 6. Rear shock absorber and spring
Installation Note........................... below Disassembly / Inspection........... page R-28
3. Shock absorber bolt Assembly................................... page R-29
4. Nut
Installation Note
Wheel speed sensor harness (ABS)
Install the sensor harness bracket in the direction shown.
R -2 7
- 0 90—116 (9.1—11.9, 66—66.0)
-<§)
N m (kgf m, ft lbf)
36U0RX-033
1. Nut 5. Bound stopper

Disassembly Note.............................. below Inspect for damage and cracks
2. Mounting rubber 6. Coil spring
Inspect for damage and weakness Inspect for damage and weakness
3. Upper spring seat 7. Lower spring seat
Inspect for damage and cracks Inspect for damage and cracks
4. Dust cover 8. Shock absorber
Inspect for damage and deterioration Inspection.................................. page R-29
Disassembly Note
Nut
Warning
• Removing the piston rod nut is dangerous. The
shock absorber and spring could fly off under
tremendous pressure and cause serious injury or
death. Secure the shock absorber in the SST before
removing the piston rod nut.
Caution
tective plates in the vise jaws.
1. .Secure the mounting rubber in a vise.
2. Loosen the nut several turns, but do not remove it.
R—28
49 G 034 102
4. Secure the shock absorber in the SST.
5. Compress the coil spring by using the S S T and remove
49 G 034 103 the nut.
49 G 03 4 101
46U0RX-018
In sp ectio n
S h o ck ab so rb er
Check for the following and replace the shock absorber, if
necessary.
1. Inspect for damage and oil leakage.
2. Secure a handle to the piston rod, and compress and ex
pand the shock piston at least three times. Verify that the
operational force does not change and that there is no un
usual noise.
16E0RX-094
A ssem b ly
1. Assemble the SST, and secure the S S T in a vise.
16A0RX-047
2. Install the lower rubber spring seat.
3. Install the coil spring, fitting the end of the coil into the step
of the lower seat.
4. Compress the coil spring by using the SST.
49 G 034 103
49 G 034 102
36U0RX-044
R—29
5. Install the stopper.
6. Install the dust cover.
8. Install the mounting rubber, facing the direction indicator
9. Tighten the nut several turns.
10. Remove the SST.
11. Verify that the lower coil of the spring is properly seated on
the step of the lower seat.
Caution
• Use protective plates in the jaws of the vise.

13. Tighten the nut.
Tightening torque:
90— 116 N m {9.1— 11.9 kgf m, 66—86.0 ft-lbf}
46U0RX-020
REAR STABILIZER
5. Loosely tighten the stabilizer bracket bolts. Tighten all other nuts to the specified torque.
7. With the vehicle unloaded, tighten the stabilizer bracket bolts.
37—53 (3.7—5.5, 2 7 -3 9 )
3 7 -5 3 13.7—5 .5 ,2 7 -3 9 ) ( § )
37—53 (3.7—5.5, 27—39)
46U0RX-021
1. Nut 7. Stabilizer bushing

2. Set washer Inspect for damage and weakness
3. Protector Installation Note................................. below
4. Bolt 8. Stabilizer bar
5. Nut Inspect for damage and deformation
6. Stabilizer bracket
Installation Note below
Installation Note
bushing.
2. Align the bushing with the installation mark on the stabiliz
er bar.
16E0RX-074
R-31
R REAR SUSPENSION (STRUT)
STABILIZER CONTROL LINK
Tightening torque: 89— 117 Nm {9— 12 kgf-m, 66—86.7 ftlb f)
N-m {kgf-m, ft lbf |

16A0RX-050
1. Nuts 4. Stabilizer control link

2. Set washer Inspection............................................below
3. Protector
Inspection
Check the following and replace if necessary

1. Inspect for bending and damage.
2. Measure the ball joint starting torque.
(a) Rock the ball joint stud side to side 10 times.
(b) Rotate the ball joint stud 10 times.
(c) Measure the starting torque by using a suitable Allen
socket and a torque wrench.
Starting torque:
0.2—1.5 N-m {2.0—15.0 kgf-cm, 1.7—13 in-lbf)
16EORX-076
R -3 2
LATERAL LINK AND TRAILING LINK
2. Remove in the order as shown in the figure, referring to Removal Note.
5. Loosely tighten the lateral link and trailing link mounting bolts and nuts. Tighten brake cable nuts to the
specified torque.
7. With the vehicle unloaded, tighten the lateral link and the trailing link mounting bolts.
N m {kgf m, ft lbf)
46U0RX-022
1. Cap 6. Bolt (Crossmember)

2. Stabilizer control link Removal Note....................... page R-34
3. Bolt, washers and nut 7. Bolt, washer, and nut
4. Nut, cam plate, and adjusting cam bolt 8. Lateral link (front)
Removal Note.............................page R-34 Inspect for deformation
Installation Note..........................page R-34 Inspect bushing for damage
5. Lateral link (rear) 9. Brake cable bracket
Inspect for deformation 10. Trailing link
Inspect bushing for damage Inspect for deformation
Inspect bushing for damage
R—33
Removal Note
Nut, cam plate, and adjusting cam bolt
Before loosening the nut, make a mark on the cam plate
and the crossmember for reference during installation.
16E0RX-078
Bolt (Crossmember)
Support the crossmember by using a jack and remove the
bolts.
46U0RX-023
Installation Note
Nut, cam plate, and adjusting cam bolt
1. Install the cam plate so that the notch faces the same direc
tion as the adjusting cam bolt.
2. Align to the mark made before removing the adjusting cam
bolt. Tighten the nut.
Tightening torque:
79— 116 N m (8.0— 11.9 kgf m, 58—86.0 ft Ibf}
16A0RX-051
REAR CROSSMEMBER
5. Loosely tighten the stabilizer bracket, lateral link and trailing link mounting bolts. Tighten all other bolts
and nuts to the specified torque.
7. With the vehicle unladen, tighte the stabilizer bracket lateral link and trailing link mounting bolts.
1. Rear stabilizer 4. Rear crossmember and lateral link

Removal / Inspection / 5. Lateral link (front)
Installation.................................page R-31 Removal I Inspection I
2. Lateral link (rear) Installation................................ page R-33
Removal / Inspection / 6. Rear crossmember
Installation.................................page R-33 Inspect for damage and cracks
3. Bolts
R—35
BODY
IN D E X ......................................................S - 2 M OLDING...............................................S - 44
HOOD....................................................... S - 5 PREPARATION................................... S - 44
COMPONENTS .................................. S - 5 COMPONENTS..................................S - 44
FRONT D O O R ....................................... S - 7 COWL GRILLE.......................................S - 52
PREPARATION................................... S - 7 COMPONENTS..................................S - 52
COMPONENTS .................................. S - 8 OUTSIDE MIRROR............................... S - 53
FRONT WINDOW REGULATOR, COMPONENTS..................................S - 53
GLASS AND G U ID E .......................... S - 10 REARVIEW M IRROR........................... S - 56
COMPONENTS .................................. S - 10 COMPONENTS..................................S - 56
FRONT DOOR GLASS...................... S - 17 WINDSHIELD WIPER AND
FRONT DOOR LOCK AND WASHER...............................................S - 57
O P E N E R ............................................... S - 18 COMPONENTS..................................S - 57
COMPONENTS.................................. S - 18 WIPER MOTOR ..................................S - 59
REAR D O O R .......................................... S - 20 WINDSHIELD......................................... S - 60
COMPONENTS.................................. S - 20 PREPARATION................................... S - 60
REAR WINDOW REGULATOR, COMPONENTS..................................S - 60
GLASS AND G U ID E .......................... S - 22 REAR WINDOW GLASS...................... S - 65
COMPONENTS .................................. S - 22 PREPARATION................................... S - 65
REAR DOOR LOCK AND OPENER... S - 24 COMPONENTS..................................S - 65
COMPONENTS.................................. S - 24 QUARTER WINDOW GLASS............. S - 70
WINDOW FRAME WEATHERSTRIP.. S - 25 PREPARATION................................... S - 70
COMPONENTS.................................. S - 25 COMPONENTS..................................S - 70
TRUNK L ID .............................................S - 26 INNER SLIDING SUNROOF................S - 73
COMPONENTS.................................. S - 26 PREPARATION................................... S - 73
TRUNK LID LOCK AND OPENER .... S - 29 COMPONENTS..................................S - 73
COMPONENTS.................................. S - 29 OUTER SLIDING SUNROOF.............. S - 78
FUEL-FILLER LID AND OPENER..... S - 31 COMPONENTS..................................S - 78
COMPONENTS .................................. S - 31 SUNROOF DRIVE UNIT
FRONT BUM PER.................................. S - 32 ASSEMBLY....................................... S - 82
COMPONENTS .................................. S - 32 DASHBOARD AND CONSOLE.......... S - 84
REAR BU M PER.....................................S - 36 COMPONENTS..................................S - 84
COMPONENTS .................................. S - 36 T R IM ........................................................S - 91
RADIATOR GRILLE.............................. S - 40 COMPONENTS..................................S - 91
COMPONENTS .................................. S - 40 FLOOR COVERING..............................S - 99
REAR FINISHER................................... S - 41 COMPONENTS..................................S - 99
COMPONENTS .................................. S - 41 HEADLINER...........................................S -100
REAR SPOILER.....................................S - 42 COMPONENTS..................................S -100
COMPONENTS.................................. S - 42 SEAT BELT............................................ S -103
EXTRACTOR CHAMBER..................... S - 43 COMPONENTS..................................S -103
COMPONENTS .................................. S - 43 SEAT........................................................S—106
COMPONENTS..................................S -1 0 6
46U0SX-001
INDEX
INDEX
46U0SX-002
1. Hood 8. Radiator grille

Removal / Installation................. page S- 5 Removal / Installation................. page S-40
Adjustment..................................page S- 6 9. Molding
2. Front door Removal / Installation................. page S-44
Removal / Installation................. page S- 8 10. Cowl grille
Adjustment..................................page S- 9 Removal / Installation................. page S-52
3. Front window regulator, glass and guide 11 . Outside mirror
Removal / Installation................. page S-10 Removal / Installation................. page S-53
Adjustment..................................page S-13 Replacement of mirror glass..... page S-55
Disassembly / Assembly............ page S -17 12. Rearview mirror
4. Front door lock and opener Removal / Installation................. page S-56
Removal / Installation................. page S -18 13. Windshield wiper and washer
5. Window frame weatherstrip Removal / Installation................. page S-57
Removal / Installation................. page S-25 Adjustment................................. page S-58
6. Fuel-filler lid and opener Disassembly / Assembly............ page S-59
Removal / Installation................. page S-31 14. Windshield
7. Fro/it bumper Removal / Installation................. page S-60
Removal / Installation................. page S-32
Disassembly / Assembly............ page S-34
INDEX S
46U0SX-003
1. Rear door 8. Rear spoiler

Removal / Installation................. page S-20 Removal / Installation................. page S-42
Adjustment..................................page S-21 9. Extractor chamber
2. Rear window regulator, glass and guide Removal / Installation................. page S-43
Removal / Installation................. page S-22 10. Molding
3. Rear door lock and opener Removal / Installation................. page S-44
Removal / Installation................. page S-24 11. Rear window glass
4. Trunk lid Removal / Installation................. page S-65
Removal / Installation................. page S-26 12. Quarter window glass
Adjustment..................................page S-28 Removal / Installation................. page S-70
5. Trunk lid lock and opener 13. Inner sliding sunroof
Removal / Installation................. page S-29 Removal / Inspection................. page S-73
Adjustment..................................page S-30 Adjustment................................. page S-77
6. Rear bumper Inspection.................................. page S-77
Removal / Installation................. page S-36 14. Outer sliding sunroof
Disassembly / Assembly............ page S-38 Removal / Installation................. page S-78
7. Rear finisher Disassembly / Assembly............ page S-82
Removal / Installation................. page S-41 Adjustment................................. page S-83
Inspection.................................. page S-83
S -3
s INDEX
46U0SX-004
1. Trunk lid lock and opener 5. Floor covering

Removal / Installation............... page S - 29 Removal / Installation............... page S - 99
Adjustment................................page S - 30 6. Headliner
2. Fuel-filler lid and opener Removal / Installation............... page S-100
Removal / Installation............... page S - 31 7. Seat belt
3. Dashboard and console Removal / Installation............... page S-103
Removal / Installation............... page S- 84 Inspection................................ page S-105
4. Trim 8. Seat
Removal / Installation............... page S - 91 Removal / Installation............... page S-106
Disassembly / Assembly.......... page S-109
S—4
HOOD S
HOOD
COMPONENTS
N-m (kgf-m, ft-lbf)

36U0SX-005
1. Washer pipe 6. Hinge

2. Hood insulator 7. Lock assembly
3. Parting seal weatherstrip Adjustment..., page S-6
4. Surround seal weatherstrip 8. Release cable
5. Hood
Adjustment..................... page S-6
S—5
s HOOD
Adjustment
Hood
1. Verify that the hood can be closed easily and that there is
no looseness.
Clearance (1): 4.0 ± 1.0 mm (0.16 ± 0.04 in]
2. If not as specified, loosen the hood-to-hinge mounting nuts

and reposition the hood.
Tightening torque:
19—25 Nm {1.9—2.6 kgf-m, 14— 18 ftlbf}
36U0SX-006
Lock assembly
1. Adjust the lock assembly after the hood has been aligned.
2. Loosen the lock assembly mounting bolts and nut and align
the lock with the striker on the hood.
Tightening torque
Bolts:
7.9— 10.7 N-m {80— 110 kgf cm, 70—95.4 in-lbf)
Nut:
7.9— 10.7 N-m {80— 110 kgf-cm, 70—95.4 in-lbf)
46U0SX-005
S -6
FRONT DOOR
FRONT DOOR
PREPARATION
For
TORX tool (T40) installation / removal of door
lock striker
16E0SX-018
TORX TOOL (T40)
1. ILLUSTRATION
6.6mm
<
2. USAGE
TORX SCREW
S
DOOR LOCK STRIKER TORX TOOL (T40)
16E0SX-019
S—7
FRONT DOOR
COMPONENTS
2. Remove in the order shown in the figure. To remove the checker, remove the door trim and door screen.
(Refer to page S-10 or S-12.)

46U0SX-006
1. Harness connector 5. Checker

2. Checker pin 6. Door lock striker
3. Door hinge Adjustment....................................page S-9
4. Front door
Adjustment....................................page S-9
S—8
FRONT DOOR S
Adjustment
Front door
1. Verify that the front door can be closed easily and that there
is no looseness or excessive clearance.
Clearance (1): 4.0 ± 1.0 mm {0.16 ± 0.04 in)

(2): 4.0 +
_ i» mm {0.16 :°0£ in)
(3): 4.0 ± 1 . 0 mm {0.16 ± 0.04 in}
2. If not as specified, loosen the door-hinge-to-body mount

ing nuts and reposition the front door.
Tightening torque:
2 2 -3 1 Nm {2.2— 3.1 kgf-m, 16—22 ftlbf)
36UQSX-009
Door lock striker
1. Verify that the door can be closed easily and that there is
no looseness.
2. If not correct, loosen the striker mounting screws and move
the striker horizontally or vertically.
3. Verify that the rear offset of the door to the body is not ex
cessive.
4. If the offset is excessive, move the door lock striker vertically.
Tightening torque:
18—26 N-m {1.8—2.7 kgf-m, 14— 19 ftlb f)
36U0SX-010
S
s FRONT WINDOW REGULATOR, GLASS AND GUIDE
FRONT WINDOW REGULATOR, GLASS AND GUIDE

COMPONENTS
1. Raise the rear edge of front door glass about 80 mm {3.2 in} from the fully lowered position.
Note
• Remove the door screen carefully so that it may be reused.

2.0—2.9 N-m
(20—30 kgfcm,
1 8 -2 6 in-lbf ]
POWER
8.9—12.7 N-m (90—130 kgfcm,
Caution:
Damage to door trim can occur if
center clip is not disengaged. (Drivers
door excluded). To avoid damage, see
instructions on page S-93 and S-95.
MANUAL
6.9—9.8 N-m 170—100 kgfcm, 60—87 in-lbf)
46UCISX-007
1 Recess cover 5. Bracket

2. Regulator handle 6. Sealing pad
Removal Note.......................... page S -1 1 7. Door screen
Installation Note......................... page S -1 1 8. Front door glass
3. Inner handle 9. Manual window regulator
4. Front door trim 10. Power window regulator
Removal / Installation................. page S-91 11. Glass run channel
S—10 (1994 626/MX-6) Revised 7/94

FRONT WINDOW REGULATOR, GLASS AND GUIDE s
Removal Note
Regulator handle
Remove the regulator handle clip by using a rag as shown.
16E0SX-027
Installation Note
Regulator handle
1. Raise the door glass fully.
2. Install the clip in the handle and push the regulator handle
into position as shown.
16E0SX-028
1. Raise the rear edge of front door glass about 100 mm {3.9 in) from the fully lowered position.
Note
• Mark around the upper glass stopper mounting bolts with paint before removing them.

MX-6 Caution:
Damage to door trim can occur if center clip
is not disengaged. (Drivers door excluded).
To avoid damage, see instructions on pages
S-91 and S-93.
©
6.9—9.8 N-m
(70— 100 kgf-cm,
60—87 in-lbf)
N-m (kgf-m, ft-lbf)

46U0SX-008
1. Recess cover 6. Door screen

2. Inner handle cover 7. Upper glass stopper
3. Door trim 8. Door glass
Removal / Installation. page S-93 Adjustment................. page S-13
4. Bracket 9. Power window regulator
5. Sealing pad 10. Glass guide
S—12 (1994 626/MX-6) Revised 7/94

Adjustment
Door glass (MX-6)
Adjust the door glass on the MX-6 as follows.
46U0SX-009
Vertical adjustment of door glass (MX-6)
1. Loosen the upper glass stopper installation bolts.
2. Lower the door glass slightly.
3. Move the upper glass stoppers up or down so that the upper edge of the door glass is in the correct position.
4. Tighten the installation bolts.
Tightening torque: 6.9— 11.7 Nm {70— 120 kgf-cm, 61— 104 inlbf}
FRONT BRACKET
mm (in)
46U0SX-010
S -1 4
Inward/outward adjustment of door glass (MX-6)
Note
• The door glass moves outward about 1.5 mm {0.06 in) with one clockwise turn of the adjusting bolt.
1. Loosen front and rear brackets installation nuts.

2. Move the adjusting bolts inward or outward by using a screwdriver until the upper and side edges of the
door glass are in the correct positions.
3. Tighten the installation nuts while holding the adjusting bolt with a screwdriver.
Tightening torque: 5.9—8.8 Nm {60—90 kgf-cm, 53—78 in-lbf)
W INDOW REGULATOR
NUT
ADJUSTING BOLT
BOLT
® ( D R I P MOLDING MOUNTING HOLE No.3)
GLASS GUIDE (© (D R IP MOLDING MOUNTING HOLE No.9)
HOLE No.6)
15.63— 18.63 10.06— 13.06

( 0 .6 2 - 0 .7 4 ) (0.40—0.52)
GLASS
GLASS
SECTION ® SECTION ® SECTION ©
mm (in)
46U0SX-011
S—15
After completion of adjustment (MX-6)
1. Verify the following with the weatherstrip and drip molding removed:
(1) The door glass is in the correct position when fully closed.
(2) When the door glass is raised, the lower glass stoppers contact the upper glass stoppers at the same time.
2. Verify the following with the weatherstrip installed:
(1) The weatherstrip mounting is correct.
(2) The door glass raises and lowers smoothly with the door closed.
(J) (DRIP MOLDING MOUNTING HOLE No.3)
(§) (DRIP MOLDING MOUNTING HOLE No.6)
© (D R IP MOLDING MOUNTING HOLE No.9)
(WEATHERSTRIP MOUNTING HOLE No.3)
MOUNTING HOLE No.1)
15.63—18.63
{0.62-0.74)
10.26—13.26
(0.41—0.53)
12.15—15.15
(0.48—0.60)
8.23—11.23
(0.32—0.45)
(0.32—0.40)
SECTION SECTION SECTION SECTION ®
18.04—21.04
11.61—13.61
(0.46—0.54)
SECTION ©
mm (In)
46U0SX-012
S -1 6
FRONT WINDOW REGULATOR, GLASS AND GUIDE S
FRONT DOOR GLASS
1. Front bracket 3. Lower glass stopper

2. Rear bracket
S -1 7
s FRONT DOOR LOCK AND OPENER
FRONT DOOR LOCK AND OPENER
COMPONENTS
1. Raise the front door glass fully.
Note
• Remove the door screen carefully so that it may reused.

Caution:
S-91 and S-93.

2. Inner handle 7. Front door lock assembly
3. Front door trim 8. Outer handle
Removal / Installation................. page S-91 9. Lock cylinder retainer
4. Bracket 10. Lock cylinder
5. Sealing pad
S—18 (1994 626/MX-6) Revised 7/94

FRONT DOOR LOCK AND OPENER S
MX-6
Caution:
S-91 and S-93.
46U0SX-014

2. Inner handle cover 7. Door lock assembly
3. Door trim 8. Outer handle
Removal / Installation page S-93 9. Lock cylinder retainer
4. Inner handle 10. Lock cylinder
5. Sealing pad
Revised 7/94 (1994 626/MX-6) S—19

s REAR DOOR
REAR DOOR
COMPONENTS
2. Remove in the order shown in the figure. To remove the checker, remove the door trim and door screen.
(Refer to page S-22 or S-24.)
626
Mm |kgf-m, ft-lbf)
46UQSX-015
1. Harness connector 5. Checker

2. Checker pin 6. Door lock striker
3. Door hinge Adjustment..... page S-21
4. Rear door
Adjustment......... page S-21
S—20
REAR DOOR S
Adjustment
Rear door
1. Verify that the rear door can be closed easily and that there
Clearance (1): 4.0 t 10-.s mm (0.16 1°0m >n )

(2): 4.0 ± 1.0 mm {0.16 ± 0.04 in)
2. If not as specified, loosen the door-hinge-to-body mount

ing nuts and reposition the door.
Tightening torque:
22—31 Nm (2.2—3.1 kgf-m, 16—22 ftlb f)
36U0SX-021
Door lock striker
1. Verify that the door can be closed easily and that there is
no looseness.
2. If not correct, loosen the striker mounting screws and move
the striker horizontally or vertically.
3. Verify that the rear offset of the door to the body is not ex
cessive.
4. If the offset is excessive, move the door lock striker vertically.
Tightening torque:
18—26 N-m (1 .8 —2.7 kgf-m, 14— 19 ftlb f)
36U0SX-Q22
S—21
s REAR WINDOW REGULATOR, GLASS AND GUIDE
REAR WINDOW REGULATOR, GLASS AND GUIDE
COMPONENTS
1. Raise the front edge of rear door glass about 50 mm {2.0 in} from the fully lowered position.
Note

8.9—12.7 ftm (90—130 kgf-cm, 79—112 In-lbf)
Caution:
POWER center clip is not disengaged. (Drivers
6.9—9.8 Nfll
(70—100 kgf-cm,
6 1 -8 6 in-lbf)
6 .9—9.8 N-m (70—100 kgf-cm, 61—86 in-lbf)
6.9—9.8 Mm
(70—100 kgf-cm,
61—86 In-lbf)
1. Regulator handle 6. Bracket

Removal Note.............................page S-23 7. Sealing pad
Installation Note..........................page S-23 8. Door screen
2. Inner handle 9. Rear door glass
3. Rear door trim 10. Manual window regulator
Removal / Installation.... :............page S-91 11. Power window regulator
4. Inner garnish 12. Glass run channel
5. Outer garnish 13. Glass guide
S—22 (1994 626/MX-6) Revised 7/94

REAR WINDOW REGULATOR, GLASS AND GUIDE S
Removal Note
Regulator handle
Remove the regulator handle clip by using a rag as shown.
16E0SX-042
Installation Note
Regulator handle
1. Raise the door glass fully.
2. Install the clip in the handle and push the regulator handle
into position as shown.
FRONT
16E0SX-043
s REAR DOOR LOCK AND OPENER
REAR DOOR LOCK AND OPENER

COMPONENTS
1. Raise the rear door glass fully.
Note

626
Caution:
S-91 and S-93.
46U0SX-017
1. Inner handle 4. Door screen

2. Rear door trim 5. Rear door lock assembly
Removal / Installation. page S-91 6. Outer handle
3. Sealing pad
S—24 (1994 626/M X-6) Revised 7/94

WINDOW FRAME WEATHERSTRIP S
WINDOW FRAME WEATHERSTRIP
COMPONENTS
MX-6
A -PILLA R , R O O F B-PILLAR
16E0SX-045
1. Window frame weatherstrip

s TRUNK LID
TRUNK LID
COMPONENTS
1. Remove the trunk lid trim. (Refer to page S-91.)
626
46U0SX-018
1. Harness 3. Balance spring
2. Trunk lid Removal Note............................ page S-28
Adjustment page S-28 Adjustment..................................page S-28
4. Trunk lid hinge
S—26
TRUNK LID
MX-6
N-m [kgf-m, ft-lbf |

36U0SX-026
1. Trunk lid 2. Stay damper

Adjustment..................................page S-28 3. Trunk lid hinge
S—27
s TRUNK LID
Removal Note
Balance spring
Warning
• Removing the balance spring without securing the
trunk lid can be dangerous. The trunk lid may fall
and injure you. Open the trunk lid fully and secure
it before removing the balance spring.
1. Lift the balance spring by using a protected screwdriver.

2. Remove the balance spring.
Adjustment
Trunk lid
1. Verify that the trunk lid can be closed easily and that there
Clearance (1): 4.0 ± 0.8 mm (0.16 ± 0.03 in]
2. If not as specified, loosen the trunk-lid-to-hinge mounting

nuts and reposition the trunk lid.
Tightening torque:
7.9—10.7 Nm (80—110 kgf-cm, 70—95 in-lbf)
\ \ SEC. A-A
a
— ^
^xo
36U0SX-027
Balance spring
1. Slide the balance spring to the desired position as described
below by using a protected screwdriver.
O: Position
TRUNK LID LOCK AND OPENER S
TRUNK LIP LOCK AND OPENER
COMPONENTS
1. Remove the trunk lid trim. (Refer to page S-91.)
46U0SX-021
1. Trunk lid lock 6. Trunk lid opener cover

2. Inboard combination light 7. Front scuff plate
3. Rear finisher Removal / Installation. page S-91
Removal / Installation.... page S-41 8. Trunk lid opener lever
4. Lock cylinder 9. Trunk lid opener cable
5. Trunk lid striker
Adjustment................... page S-30
S—29
s TRUNK LID LOCK AND OPENER
MX-6
46U0SX-022
1. Trunk lid lock 5. Trunk lid striker

2. Lock cylinder retainer Adjustment............... below
3. Lock cylinder 6. Trunk lid opener cover
4. Trunk end trim 7. Scuff plate
Removal / Installation. page S-93 8. Trunk lid opener lever
9. Trunk lid opener cable
Adjustment
Trunk lid striker
1. Adjust the trunk lid striker after the trunk lid has been aligned.
2. Loosen the trunk lid striker mounting bolts and align the strik
— a - —
-JLU.________ er with the lock assembly.
SfeSl
(•aes ; Tightening torque:
7.9—10.7 N m (80—110 kgf-cm, 70—95 in lbf J
36U0SX-030
S—30
FUEL-FILLER LID AND OPENER S
FUEL-FILLER LID AND OPENER
COMPONENTS
1. Remove in the order shown in the figure. To remove and install the filler lid opener, remove the trunk side
trim. (Refer to page S-91 or S-93.)
46U0SX-023
1. Filler lid 5. Front scuff plate

2. Lift spring Removal / Installation................. page S-91
3. Filler lid opener 6. Opener lever
4. Opener cover 7. Opener cable
S—31
s FRONT BUMPER
FRONT BUMPER
COMPONENTS
46U0SX-024
1. Radiator grille 4. Mud guard

Removal / Installation................. page S-40 5. Front bumper
2. Headlight Disassembly / Assembly............ page S-34
3. Front flap
S—32
FRONT BUMPER
MX-6
N-m {kgf-m, ftlbf I

46U0SX-025
1. Mud guard 4. Front bumper

2. Front combination light Disassembly / Assembly............ page S-35
3. Headlight
S—33
s FRONT BUMPER
626
36U0SX-034
1. Front bumper reinforcement 5. Front side bracket

2. Set plate 6. Side marker
3. Junction plate 7. Front air dam
4. Front bumper retainer 8. Front bumper fascia
S—34
FRONT BUMPER
1. Fog light 5. Front bumper reinforcement

2. Set plate 6. Front bumper retainer
3. Bracket 7. Front bumper fascia
4. Stay
S—35
M X -6
36U0SX-035
1. Fog light 5. Front bumper reinforcement

2. Set plate 6. Front bumper retainer
3. Bracket 7. Front bumper fascia
4. Stay
S—35
REAR BUMPER S
MX-6
N-m |kgf-m, ft-lbf)

46U0SX-027
1. Rear combination light 3. Rear bumper

2. License plate light Disassembly / Assembly.............page S-39
S—37
s REAR BUMPER
36U0SX-038
1. Set plate 4. Rear bumper retainer

2. Rear bumper reinforcement 5. Rear side marker
3. Energy-absorbing foam 6. Rear bumper fascia
S—38
REAR BUMPER
MX-6
36U0SX-039
1. Rear bumper reinforcement 4. Rear side marker

2. Energy-absorbing foam 5. Rear bumper fascia
3. Rear bumper retainer
S—39
s RADIATOR GRILLE
RADIATOR GRILLE
COMPONENTS
16E0SX-174
1. Radiator grille
S—40
REAR FINISHER
REAR FINISHER
COMPONENTS
36U0SX-04Q
1. Inboard combination light 2. Rear finisher
S—41
s REAR SPOILER
REAR SPOILER
COMPONENTS
MX-6
16E0SX-118
1. Rear spoiler
S—42
EXTRACTOR CHAMBER
EXTRACTOR CHAMBER
COMPONENTS
46U0SX-028
1. Rear bumper 2. Extractor chamber

Removal / Installation page S-36
S—43
s MOLDING
MOLDING
PREPARATION
SST
COMPONENTS
© ® ® ~
J) A
<D) ©
36U0SX-042
S—44
MOLDING S
1. Windshield molding 7. Lower molding No.2
Removal Note.................. ......... page S-45 Removal Note.................. ......... page S-46
Installation Note............... ......... page S-48 Installation Note............... ......... page S-51
2. Front beltline molding 8. Lower molding No.3
3. Rear beltline molding Installation Note............... ......... page S-51
Removal Note.................. ......... page S-45 9. Lower molding No.4
4. Front sash molding Installation Note............... ......... page S-47
Removal Note.................. ......... page S-46 10. Roof molding
Installation Note............... ......... page S—51 Removal Note.................. ......... page S-47
5. Rear sash molding Installation Note............... ......... page S-51
Removal Note.................. ......... page S-46 11. Drip molding (MX-6)
Installation Note............... ..... . page S-51 Removal Note.................. ......... page S-47
6. Lower molding No.1 12. Rear window molding ~\
Installation Note............... ......... page S-50
46U0SX-029
Removal Note
Windshield molding
1. Remove the cowl grille. (Refer to page S-52.)
2. Pull the molding from one end to separate it. Do not reuse
the windshield molding.
46U0SX-030
Front and rear beltline moldings

1. Open the door glass fully.
2. Remove the outside mirror. (Refer to pages S-53, 54.)
3. Remove the beltline molding mounting screw (626) or fastener (MX-6).
4. Pull the beltline molding upward to disengage the clips from the body.
46U0SX-031
S—45
s MOLDING
Front and rear sash moldings
1. Peel the top of the sash molding forward to disengage it from the sash.
2. Remove the sash molding from the door garnish.
36U0SX-046
Lower molding No.1

Pull the lower molding forward to disengage the clips from
the body.
46U0SX-032
Lower molding No.2
Pull the lower molding downward to disengage the clips
CLIP from the body.
46U0SX-033
Lower molding No.3
Pull the lower molding downward to disengage the clips
from the body.
46U0SX-034
S—46
s MOLDING
16E0SX-126
Installation Note
Windshield molding
1. Apply protective tape along the edge of the body to pro
2. Cut the sealant by using a razor knife as shown.
46U0SX-037
3. Cut the sealant near the body by using the SST as shown.
46U0SX-038
S—48
MOLDING S
4. Cut the sealant under the glass by using the SST as shown.
5. Cut the sealant near the glass by using the SST as shown.
6. Remove as much sealant as possible from between the
body and the glass.
7. Carefully clean around the edge of the glass and the adhe
sion surface on the body.
8. If the protector is damaged, replace it with a new one.
9. Apply primer onto the bonding area of the glass, body, and
new windshield molding by using a brush. Use only glass
primer on the glass and body primer on the body and mold
ing. Keep the area free of dirt and grease, and do not touch
the surface. Allow the primer to dry for approximately 30
minutes.
10. Apply a 3 mm {0.12 in) bead of repair sealant between

the glass and the body.
46U0SX-042
S—49
MOLDING
11. Reshape the repair sealant as shown if necessary.
46U0SX-043
12. Install the molding before the sealant has hardened.
(1) Align the marks on the molding with the roof inner line.
(2) Push on the upper portion of the molding.
(3) Push on the corner portion of the molding.
(4) Push on the side portion of the molding, starting from
the bottom and then toward the top.
Hardening time of repair sealant
Time required until car

Temperature Surface hardening time
can be put into service
5°C (41°F) Approx. 1.5 hr 12 hr
20°C (68°F) Approx. 1 hr 4 hr
35°C (95°F) Approx. 10 min 2 hr
13. Check for water leaks. If a leak is found, wipe the water off
well and repeat the installation procedure with a new wind
shield molding.
Rear window molding

1. If one of the protectors is damaged, replace it with a new
one.
46U0SX-045
2. Install the molding.
(1) Align the mark on the right molding with the roof outer
line.
(2) Push on the upper and side portions of the right molding.
(3) Insert the left molding into the joint.
(4) Align the upper portion of the left molding with the body
and push on the upper and side portions of the molding.
(5) Fasten the lower portion with the screws, working from
outside to inside.
36U0SX-054
S—50
MOLDING S
F ro n t an d re a r sash m o ld in g s
1. If the sash m olding will be reused,
a) Clean and degrease the bonding area of the sash corner and sash molding.
b) A pply primer by using a brush to the bonding area of the sash molding and allow it to dry for approxi
mately 3 0 m in u tes.
c) Attach double-sided adhesive tape to the sash molding.
2. Insert one end of the sash molding into the door garnish.
3. Remove the wax paper from the double-sided adhesive tape and fit the sash molding onto the door sash.
4. Press the adhesive tape firmly to fix the sash molding.
DOUBLE-SIDED ADHESIVE TAPE
46U0SX-O46
L o w e r m oldings N o .2 and N o .3
Apply plain or soapy water to the lower molding installa
tion part of the door. Then fit the lower molding onto the
door.
36U0SX-056
R oof m olding
1. If the clips are damaged, replace them.
2. Install the molding.
(1) Align the rear end of the molding with the body.
(2) Press the molding down firmly.
36U0SX-057
S—51
s COWL GRILLE
COWL GRILLE
COM PONENTS
46U0SX-047
1. Windshield wiper arm and blade 2. Cowl cap

Adjustm ent......................................page S -5 8 3. Cowl grille
S—52
OUTSIDE MIRROR S
OUTSIDE MIRROR
CO M PO NENTS
1. Disconnect the negative battery cable if a power outside mirror is installed.
2. Remove in the order shown in the figure. To remove the power outside mirror and rear window defroster
switches, remove the switch panel. (Refer to page S -8 4 or S -86.)
626
Caution:
center clip is not disengaged. (Drivers
46U0SX-048
1. Inner garnish 4. Front door trim

2. Remote control mirror Removal / Installation........... page S-91
Replacement of mirror g la s s......page S -5 5 5. Door screen
3. Power outside mirror 6. Power outside mirror harness
Replacement of mirror g la s s ......page S -5 5 7. Power outside mirror switch
8. Rear window defroster switch
Revised 7/94 (1994 626/MX-6) S—53

OUTSIDE MIRROR
MX-6
C au tio n :
D am age to d o o r trim can o ccur if ce n te r clip
is not disengaged. (Drivers d o o r excluded).
To avoid dam age, see instructions on pages
S-91 and S-93.
46U0SX-CI49
1. Inner garnish 4. Door trim

2. Power outside mirror Removal / Installation................... page S -9 3
Replacement of mirror g la s s ......page S -5 5 5. Power outside mirror switch
3. Inner handle cover 6. Rear window defroster switch
S—54 (1994 626/MX-6) Revised 7/94

OUTSIDE MIRROR
R e p la c e m e n t o f M irror Glass
(E x cep t heated outsid e m irror)
1. Warm the frame and the mirror glass by using a heat gun.
2. Insert a scraper between the mirror glass and the frame,

and pry the glass loose.
3. Remove the remaining adhesive.
4. Warm the adhesive surface of the frame and the mirror by

using a heat gun.
5. Install the glass in the mirror frame and gently press it in

to secure it.
S -5 5
s REARVIEW MIRROR
REARVIEW MIRROR
COM PONENTS
________________________________________________________________________________________________________________________________________________________________________ N E W ___ N E W
Com press spring plate with
sm all screw d river and slide
m irror up from base plate.
NEW
36U0SX-O61
1. Rearview m irror 2. S pring Plate 3. M irror Base
S -56 (1994 626/MX-6) Revised 7/94

WINDSHIELD WIPER AND WASHER
WINDSHIELD WIPER AND WASHER
COM PONENTS
R em o val / In sta llatio n
1. Wiper arm cover 5. Wiper link

2. Wiper arm and blade 6. Washer tank
Installation N o te ............................ page S -5 8 7. Washer motor
Adjustm ent......................................page S -5 8 8. Washer pipe
3. Cowl grille 9. Washer nozzle
4. Wiper motor Adjustment... page S -5 8
Assembly / D isassem bly..............page S -5 9
S—57
s WINDSHIELD WIPER AND WASHER
W ip e r arm and blade
Clean the wiper arm connector shafts with a wire brush be
fore installing the wiper arms.
CONNECTOR
SHAFT
46U0SX-051
A d ju stm en t
W ip e r arm and blade
1. Operate the wipers once to set them in the park position.
2. Set the height of the wiper arms as shown.
T ig h ten in g torque:
9 .8 1 — 1 3 .7 N-m {1 0 0 — 140 kgf-cm, 8 6 — 121 in Ib f)
36U0SX-063
W a s h e r n ozzle
Insert a needle or similar object into the nozzle hole and
move the nozzle to adjust the spray direction.
16E0SX-209
WINDSHIELD WIPER AND WASHER S
W IP E R M O T O R
D isasse m b ly / A s se m b ly
36U0SX-064
1. Wiper motor 3. Motor gear assembly

2. Brush plate holder
S—59
s WINDSHIELD
WINDSHIELD
SST
16E0SX-253
CO M PO NENTS
R em oval / In stallatio n
46U0SX-052
1. Overhead console 6. Wiper arm and blade

Removal / Installation......pages S -100, 101 Adjustment..................................... page S -5 8
2. Sunvisor and adaptor 7. Cowl grille
3. A-pillar trim Removal / Installation................... page S -5 2
Removal / Installation......pages S -91, 93 8. Windshield
4. Rearview mirror Removal Note................................page S-61
Removal / Installation......page S -5 6 Installation N o te ............................ page S -6 2
5. Windshield molding 9. Dam
Removal / Installation......page S -4 4 10. Spacer
11. Protector
S—60
k
WINDSHIELD S
R em oval N ote
W indshield
If th e glass w ill not be reused,

1. Use a tool like that shown in the figure and insert the blade
into the sealant.
2. Pull through the sealant around the edge of the glass.
3. If the protector is damaged, remove it.
4. Remove the glass.
36U0SX-066
If th e glass w ill be reused,
1. Apply protective tape along the front edge of the headliner
to protect it from damage.
36U0SX-C167
3. Make a hole through the sealant from the inside of the ve
hicle by using an awl.
4. Pass piano wire through the hole.
36U0SX-068
5. Wind each end of the wire around a bar.
6. Working with another person, saw through the sealant
around the edge of the glass. Use a long sawing action to
spread the work over the whole length of wire to prevent
it from breaking. Make sure the wire does not rub on the
body or the dashboard.
46U0SX-053
\
j-l.-vrrr -.'.r-!—
\
W ind shield
/ * 1/ vi*
1. Cut away the old sealant by using a razor knife so that 1
to 2 m m (0 .0 4 to 0 .0 8 in ) of sealant remains around the
IgES circumference of the frame. If all the sealant has come off
in any one place, apply some primer after degreasing, and
allow it 30 m in u tes to dry. Then apply new sealant to cre
ate a 2 m m (0 .0 8 in ) layer.
•
2. Carefully clean an area 5 cm (1 .9 7 in ) wide around the
circumference of the glass and clean the bonding area on
the body.
36U0SX-070
S—61
S WINDSHIELD
MARK
3. Mark the outer edge of the glass with a marking pen to en
sure proper reinstallation.
mm (in)
36U0SX-071
4. Securely bond a new dam along the top and sides 8 mm
{0.31 in} from the edge of the glass as shown. Allow it to
dry completely.
MARKER
mm (in )
46U0SX-054
5. Align and bond the spacer with the marker under the ce
CENTER
ramic edging as shown.
11
)
16E0SX-264
MOLDING 6. Apply primer to the bonding area of the glass, new wind
shield molding, and body by using a brush. Keep the area
(UPPER)
free of dirt and grease, and do not touch the surface. Allow
it to dry for approximately 30 minutes.
MOLDING
(SIDE)
BODY
46U0SX-055
7. Install the spacers onto the body as shown. If a spacer is
CENTER damaged, replace it.
8. Set the glass onto the body and adjust the clearance be
tween the top of the glass and the body to 8 mm {0.31
SPACER in) by moving the spacers up or down.
9. Remove the glass from the body.
mm (in)
46U0SX-056
S—62
WINDSHIELD S
10. After the primer has dried, apply an 11 mm {0.43 in} high
bead of repair sealant around the entire circumference of
the glass as shown. Keep the bead of sealant smooth and
even, reshaping it with a spatula where necessary. If the
windshield is being reused, apply new repair sealant over
the original.
46U0SX-057
11. If the protector was removed, securely bond a new protec
tor onto the body as shown. Allow it to dry completely.
46U0SX-058
12. Align the glass marks with the notches in the spacers and
CENTER install the glass onto the body.
13. Press firmly on the glass to compress the sealant. Verify that
the clearance between the top and sides of the glass and
NOTCH
the body is 8 mm {0.31 in).
460 460
m m | in )
46U0SX-059
14. Use a scraper to smooth away any sealant that oozes out.
GLASS Add more sealant to any points of poor contact. Adjust the
upper and side sealants as shown, if necessary.
//
-/4/
DAM /
hT
REPAIR ADJUST SEALANT
SEAL*N T IN THIS AREA
46U0SX-060
S—63
s WINDSHIELD
15. Align the marks on the molding with the roof inner line (1).
16. Install the upper part of the molding (2).
17. Install the corner part of the molding (3).
18. Install the side parts of the molding, starting from the bot
tom and then toward the top (4).
19. To prevent the glass from being pushed out by air pres
sure if a door is closed, open all of the windows until the
repair sealant has hardened.
T im e re q u ire d until c a r
T e m p e ra tu re S u rfa ce h a rd e n in g tim e
c a n be p u t into se rvice
5 ° C { 4 1 °F J A p p ro x . 1.5 hr 12 hr
2 0 °C (6 8 °F ) A p p ro x . 1 hr 4 hr
3 5 °C (9 5 °F ) A p p ro x . 10 m in. 2 hr
20. Eliminate wrinkles in the repair sealant by using white

gasoline.
21. If a leak is found, wipe the water off well and remove the
molding. Install a new molding.
REAR WINDOW GLASS
REAR WINDOW GLASS

PREPARATION
SST
49 0305 870A For

re m o va l /
T oo l set, w in d o w in sta lla tio n o f rea r
w in d o w g la ss
16E0SX-271
COMPONENTS
46U0SX-062
1. C-pillar trim 4. Rear window glass

Removal / Installation.................. page S-91 Removal Note..............................page S-67
2. Rear package trim Installation Note...........................page S-68
Removal / Installation.................. page S-91 5. Dam
3. Rear window molding 6. Spacer
Removal / Installation.................. page S-44 7. Protector
S—65
s_ REAR WINDOW GLASS
MX-6
46U0SX-063
1. Rear window molding 3. Dam

Removal / Installation.................. page S-44 4. Spacer
2. Rear window glass 5. Protector
Removal Note.............................. page S-67
Installation N ote...........................page S-68
S—66
REAR WINDOW GLASS S
Removal Note
Rear window glass
If the glass will not be reused
1. Use a tool like that shown in the figure and insert the blade
into the sealant.
2. Pull through the sealant around the edge of the glass.
3. If a protector is damaged, remove it.
If the glass will be reused

1. Apply protective tape along the rear edge of the headliner
to protect it from damage.
36U0SX-082
3. Make a hole through the sealant from the inside of the ve
hicle by using an awl.
36U0SX-083
body.
46U0SX-064
REAR WINDOW GLASS
Installation Note
Rear window glass
to 2 mm {0.04 to 0.08 in } of sealant remains around the
circumference of the frame. If all the sealant has come off
allow it 30 minutes to dry. Then put on new sealant to cre
ate a 2 mm {0.08 in ] layer.
2. Carefully clean an area 5 cm {1.97 in) wide around the
the body.
3. Mark the outer edge of the glass with a marking pen to en
sure proper reinstallation.
36U0SX-086
4. Securely bond a new dam along the circumference of the
glass 8 mm {0.31 in} from the edge. Allow it to dry com
pletely.
...... tin )
46U0SX-065
5. Apply primer to the bonding area of the glass and body
by using a brush. Use only glass primer on the glass and
body primer on the body. Keep the area free of dirt and
grease, and do not touch the surface. Allow it to dry for ap
proximately 30 minutes.
46U0SX-066
6. Install the spacers onto the body.
SPACER
2 i_ T
J V.
®®
1
It-— 11 1
mm (in)
16E0SX-282
REAR WINDOW GLASS S
7. If the protectors are removed, securely bond new protec
te d onto the body as shown. Allow them to dry completely.
8. Prepare the nozzle of the sealant tube so that it has a flange

that can run along the edge of the glass and a V from which
the sealant can flow. Once the primer is dry, apply repair
sealant around the entire circumference to fill the gap be
tween the dam and the edge of the glass with a ridge of
sealant 11 mm [0.43 in) high. Keep the bead of sealant
smooth and even, reshaping it with a spatula where
necessary.
36U0SX-165
9. Align the glass marks with the V notches in the spacers and
install the glass to the body.
10. Press firmly on the glass to compress the sealant.
NOTCH 11. To prevent the glass from being pushed out by air pres
ca n be p u t into se rvice
46U0SX-068 5 °C [4 1 °F ) A p p ro x . 1.5 hr 12 hr
2 0 ° C |6 8 ° F ) A p p ro x . 1 hr 4 hr
3 5 °C (9 5 °F ) A p p ro x . 10 m in 2 hr
12. Check for water leaks. If a leak is found, wipe the water off
well and add sealant where needed.
46U0SX-069
13. Install the rear window molding.
(1) Align the mark on the right molding with the roof outer
line.
(2) Push on the upper and side portions of the right molding.
(3) Insert the left molding into the joint molding.
(4) Align the upper portion of the left molding with the body
and push on the upper and side portions of the molding.
(5) Fasten the lower portion with screws, working from out
side to inside.
46U0SX-070
S—69
s QUARTER WINDOW GLASS
QUARTER WINDOW GLASS
PREPARATION
SST
49 0305 870A I I F or
I I re m o va l /
T oo l set, w in d o w r fj* r r i- n l in sta lla tio n of
l/\ ■■ q u a rte r w in d o w
gla ss
16E0SX-513
COMPONENTS
MX-6
46U0SX-071
1. C-pillar trim 2. Quarter window glass

Removal / Installation................... page S -9 3 Removal N ote................................page S-71
Installation N o te ............................ page S -7 2
S—70
QUARTER WINDOW GLASS S
Removal Note
Quarter window glass
1. Cut the quarter window molding by using a razor knife as
shown.
46U0SX-072
3. Using an awl, make a hole through the sealant from the in
side of the vehicle.
16E0SX-517
body.
46U0SX-073
Note
• The quarter window glass has locating clips as shown.
If it is difficult to cut the sealant with the piano wire, use
a razor knife.
36U0SX-092
s QUARTER WINDOW GLASS
I
Installation Note
Quarter window glass
to 2 mm {0.04 to 0.08 in } of sealant remains around the
circumference of the frame. If all the sealant has come off
allow it 30 minutes to dry. Then put on new sealant to cre
ate a 2 mm {0.08 in } layer.
2. Carefully clean an area 5 cm {1.97 in) wide around the
the body.
3. Apply primer to the bonding area of the glass and body

by using a brush. Use only glass primer on the glass and
body primer on the body. Keep the area free of dirt and
grease. Do not touch the surface. Allow it to dry for approx
imately 30 minutes.
46U0SX-074
4. Prepare the nozzle of the sealant tube so that it has a flange
that can run along the edge of the glass and a V from which
the sealant can flow. Once the primer is dry, apply repair
sealant around the entire circumference to fill the gap be
tween the dam and the edge of the glass with a ridge of
sealant 11 mm {0.43 in) high. Keep the bead of sealant
smooth and even, reshaping it where necessary with a
spatula.
36U0SX-095
5. Align the glass via the stud pins and install it onto the body.
6. Press firmly on the glass to compress the sealant.
7. To prevent the glass from being pushed out by air pres
ca n be p u t in to se rv ic e
5 °C (4 1 °F ) A p p ro x . 1.5 h r 12 hr
2 0 °C (6 8 °F ) A p p ro x . 1 hr 4 hr
3 5 °C (9 5 °F ) A p p ro x . 10 m in 2 hr
8. Check for water leaks.

9. If a leak is found, wipe the water off well and remove the
quarter window glass. Install a new quarter window glass.
S—72
INNER SLIDING SUNROOF S
INNER SLIDING SUNROOF
For
T O R X to o l (T25) 1
in sta lla tio n re m o va l of
g la ss pa n el
36U0SX-097
CO M PO NENTS
1. Remove in the order shown in the figure, referring to R em oval Note. Disconnect the negative battery
cable before removing the headliner.
2. Install in the reverse order of removal, referring to In stallatio n Note.____________________________
N m (kgf-cm, In-lbf,
46U0SX-076
S—73
INNER SLIDING SUNROOF
1. Deflector 11. Drip rail
Removal N o te ......................................... below Removal N ote................................page S -7 5
2. Glass panel 12. Sunshade
Removal N o te ......................................... below Removal N ote................................page S -7 5
Adjustm ent................................... page S - 77 13. Sunroof motor
3. Weatherstrip Installation N o te ............................ page S -7 7
Removal N ote..............................page S - 76 Inspection...................................... page S -7 7
Installation N o te .......................... page S - 77 14. Guide rail cover
4. Headliner 15. Front guide
Removal N ote..............................page S -1 02 Removal N ote................................page S -7 5
5. Sunroof relay Installation N o te ............................ page S -7 6
6. Motor bracket 16. Rear guide
7. Drain hose Removal N ote................................page S -7 5
8. Frame Installation N o te ............................ page S -7 6
9. Set bracket 17. Position plate
10. Relay bracket Removal Note................................page S -7 5
Installation N o te ............................ page S -7 6
46U0SX-077
R em oval N ote
D eflecto r
1. Operate the switch to fully open the panel.
2. Remove the link from the link connector by using a screw
driver.
3. Remove the mounting screws and remove the deflector from
the frame.
G lass panel
1. Firmly push the sunshade to slide it to the rear.
2. Remove the link cover.
3. Tilt the glass panel up by using the tilt switch.

4. Remove the panel mounting screws by using a TORX tool
(T25) and remove the glass panel from the position plate.
S—74
INNER SLIDING SUNROOF S
W eath erstrip
Peel the weatherstrip from the top to remove it.
D rip rail
1. Remove the drip rail mounting screws.
2. Pull the drip rail to remove it from the position plate.
S un shade
Free the guides from the frame groove by using a screw
driver, and remove the sunshade.
16E0SX-316
Front and rear g u id es, position plate
1. Remove the motor bracket mounting bolts and remove the
bracket from the frame.
2. Remove the motor mounting screws and remove the mo
tor from the frame.
3. Remove the guide rail cover from the rear end of the frame.
36U0SX-101
4. Push the front of the retaining hook to disengage it from
the frame. Pull the position plate to remove the front guide,
rear guide, and position plate from the guide rail.
46U0SX-079
S—75
s INNER SLIDING SUNROOF
Fro n t and re a r guides, position p late
1. Grease the contact surfaces of the cable and rear guide
position plate.
2. Insert the rear guide cable into the channel of the guide rail.
46UQSX-080
3. Insert the front guide, rear guide, and position plate into the
guide rail.
4. Tilt the position plate upward. Verify that the spring hooks
onto the retaining hook when the position plate is inserted
into the guide rail.
46U0SX-081
5. Push the rear guide forward until the retaining hook engages
with the notch of the guide rail.
46U0SX-083
S -7 6
INNER SLIDING SUNROOF s
S u n ro o f m otor
1. Install the motor to the frame. Close the panel by turning
the mechanism with a screwdriver.
2. Install the frame to the body.
36U0SX-106
3. Remove the motor from the frame and install the harness
connector to the overhead console.
4. Set the limit switches.
(1) Press the back of either the TILT switch or SLIDE switch
and operate the motor until it stops.
(2) Press the front of the same switch until the motor stops.
5. Install the motor to the frame.
6. After installing the motor, use the sliding sunroof switches
to verify that the panel operates normally.
A d ju stm en t
G lass panel
G ap
1. Slide the sunshade to the rear.
2. Remove the link cover.
3. Loosen the panel mounting screws by using a TORX tool
(T25) to adjust the gap vertically, horizontally, inward, or
outward.
m m ( in )
G lass panel
S tra ig h t C o rn e r
© 6 .9 2 ± 0 .2 2 (0 .2 7 2 ± 0 .0 9 ) 6 .9 2 ± 0 .2 5 (0 .2 7 2 ± 0 .1 )
n
U -+0-5
1.5 f n -006
+002 j1 o . +; j ( 0 1 8 8 )
(D
4. Tighten the panel mounting screws.
2 .5 — 3 .5 N m {2 5 — 36 kgf-cm, 2 2 — 31 in-lbf)
In spection
S u n ro o f m otor
1. Measure the operation time of the slide panel from fully
opened to fully closed and vice versa.
S p e c ifie d tim e: 4 — 7 sec.
2. If not as specified, replace the sunroof motor.
36U0SX-109
S -7 7
s OUTER SLIDING SUNROOF
OUTER SLIDING SUNROOF
COM PONENTS
1. Open the slide panel 100 m m {3 .9 in ) from the fully closed position.
Nm (kgf cm, Inlbf)

46U0SX-085
1. Sunroof trim 5. Sunroof motor

Removal N ote................ ............ page S - 79 Removal Note.......................... .... page S -7 9
Installation N o te ............ ............ page S - 81 Installation N o te ....................... .... page S -8 0
2. Slide panel 6. Drain hose
Removal N ote................ ............ page S - 79 Installation N o te ....................... .... page S—81
Adjustm ent...................... ............ page S - 83 7. Sunroof drive unit assembly
3. Sunroof shim Removal Note.......................... .... page S -7 9
4. Headliner Installation N o te ...................... .... page S -7 9
Removal N ote ................ ............ page S - 102 Disassembly / A ssem bly........ .... page S -8 2
S—78
OUTER SLIDING SUNROOF S
R em oval N ote
S u n ro o f trim
1. Tilt up the sliding panel.
2. Remove the fasteners on the front side of the sunroof trim.
3. Pull down the trim and remove it from the sunroof panel.
4. Pull out the sunroof trim from between the slide panel and
the roof.
36U0SX-111
S lid e panel
1. Fully close the slide panel by using the emergency handle
(provided in vehicle).
2. Remove the slide panel mounting nuts.
3. Push up the slide panel from inside and remove it from the
lower panel.
36U0SX-112
S u n ro o f m otor
1. Tilt up the lower panel 80 m m {3.1 in j from the fully closed
position by using the emergency handle (provided in
vehicle).
2. Remove the screws and remove the sliding sunroof motor
from the sunroof frame.
3. Disconnect the motor harness connector.
46U0SX-086
S u n ro o f d rive u nit assem bly
1. Remove bolts C.
2. Loosen nuts B.
3. Loosen height adjusting nuts A and remove the sunroof
drive unit from the body.
16E0SX-352
S u n ro o f d rive unit assem bly
1. Set the sunroof drive unit into the roof panel and align the
locator pins.
16E0SX-353
S -7 9
s OUTER SLIDING SUNROOF
2. Loosely install the sunroof drive unit to the roof panel by
using the height adjusting nuts.
16E0SX-354
3. Loosen the set bracket attaching nuts. Position the set brack
SET BRACKET
et so that it touches the roof panel fixing bracket. Tighten
FIXING BRACKET the bolts, and then tighten the nuts.
T ig h te n in g to rque:
SEC. C-C 7 . 9 - 1 0 . 7 N m [ 8 0 - 1 1 0 kgf-cm, 6 9 - 9 5 in-lbf}
BOLT
46U0SX-087
4. Affix the rear of the sunroof frame to the roof panel.
7 .9 — 1 0 .7 N-m {8 0 — 110 kgf-cm, 6 9 — 9 5 in-lbf}
46U0SX-088
5. Install the slide panel to the lower panel.
7 .9 — 1 0 .7 N m [8 0 — 110 kgf-cm, 6 9 — 95 in-lbf}
6. If the height difference between the slide panel and the roof
panel is greater than 2 .0 m m [0 .0 8 in }, loosen the slide
panel attaching nuts and insert shim(s) between the panels.
46U0SX-089
S u n ro o f m o to r
1. Move the lower panel fully forward by hand.
SWITCH 2. Turn the limit switch off by using the emergency handle.
3. Turn the limit switch on by using the emergency handle.
4. Set gear B inside the guide plate.
5. Install the motor to the sunroof frame with screws.
6. Connect the motor harness connector.
GEAR B GUIDE PLATE

46U0SX-090
S—80
OUTER SLIDING SUNROOF S
D rain hose
N ote
• Apply soapy water to the drain hoses and insert them
fully into the sunroof frame.
(fro n t)
Insert one end of the hose into the sunroof frame, affix the
hose along the A-pillar, and insert the other end into the
cowl side panel.
(rear)
Insert one end of hoses into the sunroof frame, affix the hose
along the B-pillar and insert the other end into the rear fender
panel hole via hole in the upper part of the B-pillar.
46U0SX-091
S u n ro o f trim
1. Tilt up the slide panel. Insert the sunroof trim between the
slide panel and the roof panel from the rear of the vehicle.
36U0SX-117
2. Match the sunroof trim guide pin with the notch in the slide
panel trim bracket to locate the trim.
3. Install the sunroof trim fasteners to the slide panel.
46U0SX-092
S OUTER SLIDING SUNROOF
S U N R O O F D R IV E U N IT A S S E M B L Y
D isasse m b ly / A s s em b ly
46U0SX-093
1. Sunroof motor 6. Position plate

Inspection.......................................page S -8 3 7. Guide assembly
2. Sunroof relay 8. Wind deflector
3. Closing guide plate 9. Guide rail
4. Closing assembly 10. Sunroof frame
5. Drive unit
S—82
OUTER SLIDING SUNROOF s
A d ju stm en t
S lid e panel
H eight
1. Remove the headliner. (Refer to page S -1 01.)
2. Loosen the set bracket mounting nuts.
3. Turn the height adjusting nuts to adjust the sunroof frame
height.
C learan ce (1): 0 -°.o mm {0 S.os in )
4. After adjustment, securely install the sunroof to the roof

panel.
Gap
1. Loosen the slide panel mounting nuts and move the panel
to adjust the clearance between the slide panel and roof
panel.
C learan ce (2): 7 .0 5 ± 0 .3 5 mm (0 .2 8 ± 0 .0 1 4 in )
2. If the above adjustment is not enough, loosen the attach

ing screws and bolts of the sunroof frame and set bracket
and adjust again. (Refer to Installation Note for the sunroof
36U0SX-120
drive unit assembly, page S-79.)
In sp ectio n
S u n ro o f m otor
1. Measure the operation time of the slide panel from fully open
to fully closed and vice versa.
S p ecified tim e: 4 — 6 sec.
46U0SX-095
2. If not as specified, adjust it by increasing or decreasing the
sliding sunroof motor driving torque.
(1) Remove the housing cover attaching screws, E-ring, and
gear. Remove the housing cover from the motor.
(2) Unfold the locking washers.
(3) Hold the motor shaft with the emergency handle (provid
ed in vehicle) and turn the locknut to adjust the torque.
(4) Fold the locking washer against the locknut.
46U0SX-096
S—83
s DASHBOARD AND CONSOLE
DASHBOARD AND CONSOLE
COM PONENTS
626
N-m (k g f-m , ft-)bf|
46UQSX-097
S—84
DASHBOARD AND CONSOLE S
1. Air bag m odule (driver-side) 9. Front console
1994 626/MX-6 Body Electrical Removal N ote.................. ............ page S -8 8
Troubleshooting Manual 10. Rear console
2. Steering wheel Removal N ote.................. ............ page S -8 9
Removal / Installation.......................section N 11. Side wall
3. Column cover Removal N ote.................. ............ page S -8 9
Removal N ote................................ page S -8 7 12. Undercover
4. Combination switch Removal N ote.................. ............ page S -8 9
5. Side panel 13. Glove compartment
Removal N ote................................ page S -8 7 Removal Note.................. ............ page S -9 0
6. Hood release knob 14. Heater control unit assembly
7. Lower panel 15. Meter hood
Removal N ote................................ page S -8 8 Removal Note................................page S -9 0
8. Switch panel 16. Instrument cluster
Removal N o te................................ page S -8 8 17. Dashboard
46U0SX-098
S—86
1. Air bag module (driver-side) 9. Glove comparment
1994 626/MX-6 Body Electrical Removal Note.......................... .... page S -9 0
Troubleshooting Manual 10. Meter hood
2. Steering wheel Removal Note.......................... .... page S -9 0
Removal I Installation.......................section N 11. Front console
3. Column cover Removal Note.......................... page S -8 8
Removal N o te ......................................... below 12. Rear console
4. Combination switch Removal Note............................... page S -8 9
5. Side panel 13. Side wall
Removal N o te ......................................... below Removal N ote............................... page S -8 9
6. Hood release knob 14. Heater control unit assembly
7. Lower panel 15. Instrument cluster
Removal N ote................................page S -8 8 16. Upper garnish
8. Undercover Removal Note........................... .... page S -9 0
Removal N ote................................ page S -8 9 17. Dashboard
46U0SX-099
R em oval N ote
C olum n co ver
Remove the column cover mounting screws.
36U0SX-127
S id e panel
Pull the side panel forward to disengage the clips.
sxsssss)
MX-6
36U0SX-128
S -8 7
DASHBOARD AND CONSOLE
L o w e r panel
1. Pull the lap duct from the rear of the lower panel.
2. Remove the mounting screws from the lower panel.
3. Pull the lower panel to disengage the clips.
s * ...
S w itc h panel
1. Remove the switch panel mounting screws.
2. Pull the switch panel forward to disengage the clips.
Fro n t co n so le
Pull the front console forward to disengage the clips.
S—88
R ear co n so le
Remove the rear console mounting screws.
36U0SX-130
S id e w all
HOOK
Remove the side wall mounting screws and fasteners.
■ ^S T
<S>
LEFT SIDE
RIGHT SIDE
16E0SX-383
U n d e rc o v e r
Remove the undercover mounting fasteners.
16E0SX-384
G lo ve co m p a rtm e n t
Remove the glove compartm ent mounting screws.
M e te r h ood (6 2 6 )
Remove the meter hood mounting screws.
36U0SX-131
M e te r hood (M X -6)
1. Remove the meter hood mounting screws.
2. Pull the meter hood forward to disengage the clips.
36U0SX-132
U p p er g arnish (M X -6)
1. Remove the upper garnish mounting screw.
2. Pull the upper garnish upward to disengage the clips.
36U0SX-133
S -9 0
TRIM S
TRIM
CO M PO NENTS
Caution:
NEW
16E0SX-389
Revised 7/94 (1994 626/MX-6) S—91
s TRIM
1. A-pillar trim 8. Rear package trim
Removal N ote ................................ page S -94 Removal N ote................................ page S -9 5
2. Front scuff plate 9. C-pillar trim
Removal N ote................................ page S -94 Removal N ote................................ page S -9 6
3. Front side trim 10. Trunk end trim
4. Rear scuff plate Removal N ote................................ page S -9 6
Removal N ote ................................ page S -9 4 11. Trunk side trim
5. B-pillar lower trim 12. Front door trim
Removal N o te ................................ page S -9 5 Removal N ote................................ page S -9 7
6. B-pillar upper trim 13. Rear door trim
Removal N ote ................................ page S -9 5 Removal N ote................................ page S -9 7
7. Tire house trim 14. Trunk lid trim
Removal N ote................................page S -95 46U0SX-100
S—92
TRIM
Caution:
A fte r rem oving all o ute r retaining screw s
and clips, g en tly slide d o o r trim upw ard
about 1 inch. Do not pull outward until
center internal clip is disengaged.
Note: (Applies only to p asse n ge r d o o r on MX-6).
46U0SX-101
1. A-pillar trim 6. Rear package trim

Removal N ote................................page S -9 4 Removal N ote................................page S -9 5
2. Scuff plate 7. Trunk end trim
Removal N ote................................page S -9 4 Removal N ote................................page S -9 6
3. Front side trim 8. Trunk side trim
4. Quarter trim 9. Door trim
Removal N ote................................page S -9 5 Removal Note................................page S -9 7
5. C-pillar trim
Removal N ote................................page S -9 6
Revised 7/94 (1994 626/MX-6) S -9 3

s TRIM
R em o val N o te
A -p illa r trim
1. Pull the A-pillar trim forward to disengage the clips from the
body.
2. Pull the A-pillar trim upward to disengage the hook from
the body.
36U0SX-136
F ro n t s c u ff p la te (6 2 6 )
Pull the front scuff plate upward to disengage the clips from
the body.
36U0SX-137
S c u ff p la te (M X -6)
Pull the scuff plate upward to disengage the clips from the
body.
36U0SX-138
R ear s c u ff p late (6 2 6 )
Pull the rear scuff plate upward to disengage the clips from
the body.
36U0SX-139
S—94
TRIM
B -pillar lo w e r trim (626)
1. Remove the front and rear scuff plates.
(Refer to page S-94.)
2. Pull the rear of the B-pillar lower trim to disengage the clips
from the body.
B -pillar u p p er trim (626)

1. Remove the front seat belt shoulder anchor.
2. Pull the B-pillar upper trim to disengage the clips from the
body.
Q u a rte r trim (M X -6)

1. Remove the rear seat cushion and rear seat back.
(Refer to page S -1 08.)
2. Remove the scuff plate. (Refer to page S -94.)
3. Remove the quarter trim mounting fasteners.
4. Pull the quarter trim forward to disengage the clips from the
body.
T ire house trim (626)

1. Remove the rear seat cushion, rear seat sides, and rear seat
back. (Refer to page S -1 07.)
2. Remove the rear scuff plate. (Refer to page S -94.)
3. Remove the tire house trim mounting fasteners and screws.
4. Pull the tire house trim forward to disengage the clips from
the body.
R ear package trim

(6 2 6 )
1. Remove the rear seat cushion, rear seat sides, and rear seat
back. (Refer to page S -1 07.)
2. Remove the tire house trim. (Refer above.)
3. Remove the rear package trim mounting fasteners.
4. Pull the rear package trim upward to disengage the clips
from the body.
46U0SX-105
S -9 5
s TRIM
(M X -6)
1. Remove the rear seat cushion and rear seat back.
(Refer to page S -1 08.)
2. Remove the C-pillar trim. (Refer below.)
3. Remove the rear package trim mounting screws.
4. Pull the rear package trim upward to disengage the clips
from the body.
46U0SX-106
C -p illar trim
(626)
1. Remove the tire house trim. (Refer to page S -95.)
2. Remove the rear package trim. (Refer to page S -95.)
3. Pull the C-pillar trim forward to disengage the clips from the
body.
46U0SX-107
(M X -6)
1. Remove the quarter trim. (Refer to page S -95.)
2. Remove the C-pillar trim mounting screws.
3. Pull the C-pillar trim forward to disengage the clips from the
body.
46U0SX-108
T ru n k end trim
1. Remove the trunk end trim mounting fasteners.
2. Pull the trunk end trim upward to disengage the clips from
the body.
FASTENER
MX-6
16E0SX-4O7
S—96
TRIM S
F ro n t d o o r trim (6 2 6 )
1. Remove the recess cover and the mounting screw.
2. Remove the inner handle mounting screw and remove the
inner handle.
3. Remove the door trim mounting screws.
36U0SX-148
4. Pull the front door trim to disengage the clips from the body.
5. Lift the front door trim to remove it.
6. Disconnect the harness connectors.
16E0SX-412
D o o r trim (M X -6)
1. Remove the recess cover and the mounting screw.
inner handle.
3. Remove the door trim mounting screws and fastener.
16E0SX-413
4. Pull the door trim to disengage the clips from the body.
5. Lift the door trim to remove it.
16E0SX-414
R ear d o o r trim (626)
inner handle.
36U0SX-149
S -9 7
TRIM
2. Pull the rear door trim to disengage the clips from the body.
3. Lift the rear door trim to remove it.
16E0SX-416
S—98
FLOOR COVERING S
FLOOR COVERING
COM PONENTS
R e m o va l / In s ta lla tio n
2. Remove the following:
a. Front seats (Refer to page S -1 06.)
b. Rear seat cushion (Refer to pages S -1 07, 108.)
c. Dashboard and rear console (Refer to pages S -8 4, 86.)
d. Front side trim, scuff plates, B-pillar lower trim, and tire house trim (Refer to pages S -9 1 , 93.)
e. Front seat belt lower anchor (page S -1 03) or slide bar (page S -1 04).
3. Remove the remaining parts in the order shown in the figure.
46U0SX-110
1. Cabin carpet
S—99
HEADLINER
HEADLINER
COM PONENTS
R e m o v a l / In s ta lla tio n
2. Remove in the order shown in the figure, referring to R em o val Note.
2. Sunvisor and adapter 6. Headliner

3. Assist handle Removal N ote..............................page S -1 02
4. Interior lamp
S -1 0 0
HEADLINER S
MX-6
&
46U0SX-112
1. Sunvisor and adapter 4. Seaming welt (with sunroof)

2. Overhead console 5. Headliner
3. Assist handle Removal Note..............................page S -1 02
S - 1 01
s HEADLINER
R em oval N o te
H ead lin er
1. Remove the A-pillar trim, C-pillar trim, and either the B-pillar
trim (626) or the quarter trim (MX-6).
(Refer to page S-91 or S -93.)
2. Remove the mounting clips.
3. Remove the sides of the headliner from the weatherstrip.
4. Slide the headliner forward to remove it.
46U0SX-113
SEAT BELT
SEAT BELT
COM PONENTS
C au tio n
• T h e E LR (e m e rg e n c y lo ckin g re tra c to r) has a spring th a t w ill u n w ind if th e re tra c to r’s c o v e r
is rem o ved . T h e spring can n o t be rew ound by hand. If this occurs, th e ELR w ill not w ork proper
ly. T h e re fo re , d o n o t d isa ss em ble th e bu ckle o r re tra c to r assem bly.
1. Remove in the order shown in the figure. To remove the front seat belt on the 626, remove the B-pillar
lower trim. (Refer to page S -9 1 .) To remove the rear seat belts, remove the C-pillar trim (page S-91 or
S -9 3 ) and the rear seat cushion (page S -1 07 or S -1 08.)
3 9 — 7 8 { 3 .9 — 8 .0 , 2 9 — 5 7 )
Nm {kgf m, ftlbf)
46U0SX-114
1. Front seat belt 3. Front buckle

Inspection.......... page S -1 05 Inspection................................ page S -1 05
a) U pper anchor 4. Rear seat belt
b) Lower anchor Inspection.................................... page S -1 05
2. Anchor adjuster 5. Rear buckle
S - 1 03
SEAT BELT
MX-6
N-m (kgf-m, ft-lbf)

46U0SX-115
1. Front seat belt 4. Rear seat belt

Inspection.................................... page S -1 05 Inspection................................... page S -105
2. Slide bar 5. Rear buckle
3. Front buckle
Inspection.....................................page S -1 05
S—104
SEAT BELT s
FRONT
In sp ectio n
Fro n t and rear se a t b elts
W eb b in g and fittin g s
1. Inspect the webbing for scars, tears, and wear.
2. Inspect the fittings for deformation and damage.
3. If any problem is found, replace the seat belt assembly.
E m erg en cy locking re tra c to r (ELR)

1. Verify that the belt can be pulled out smoothly, and that it
moves smoothly when worn.
2. Verify that the retractor locks when the belt is quickly pulled.
36U0SX-156
3. Remove the retractor.

4. Hold the retractor as it would be installed.
5. Slowly incline the retractor while pulling out the belt.
6. Verify that the retractor locks at approximately 30 degrees
inclination.
7. If not as specified, replace the seat belt assembly.
46U0SX-116
Front buckle
1. Disconnect the buckle switch connector and check for con
tinuity between the connector terminals.
Terminal Driver
Seat belt A B
B u c k le d
U n b u c k le d 0 -------------- --------------O
O ------- O : C o n tin u ity
2. If not as specified, replace the buckle assembly.
S -1 05
O ______________________________SEAT
SEAT
COM PONENTS
FRONT SEAT
Nm (kgf-m, ft-lbf)
46U0SX-117
1. Cover 2. Front seat

Disassembly / A ssem bly........... page S -1 09
S -1 0 6
SEAT s
REAR SEAT (626)
N-m {kgf-m, ft-lbf)

46U0SX-118
1. Rear seat cushion 5. Trunk carpet

2. Rear seat side 6. Rear package trim
3. Rear seat back hinge Removal / Installation................... page S-91
4. Rear seat back 7. Seat back striker
S—107
SEAT
REAR SEAT (MX-6)
46U0SX-121
1. Rear seat cushion 3. Rear seat back

2. Rear seat back hinge 4. Trunk carpet
S - 1 08
SEAT
D is as se m b ly / A s s e m b ly
MANUAL SEAT (DRIVER SIDE)
36U0SX-167
1. Headrest 7. Seat back

2. Recliner lever 8. Pole guide
3. Cap 9. Seat cushion
4. Side cover 10. Slide adjuster
5. Tilt knob 11. Buckle
6. Seat back cover 12. Cover
S—109
s SEAT
36U0SX-161
1. Headrest 7. Pole guide

2. Recliner lever 8. Seat cushion
3. Cap 9. Slide adjuster
4. Side cover 10. Buckle
5. Seat back cover 11. Cover
6. Seat back
S - 1 10
SEAT s
1. Headrest 10. Seat cushion

2. Power seat switch knob 11. Slide adjuster
3. Recliner lever 12. Buckle
4. Cap 13. Cover
5. Knuckle cover 14. Front-lift motor
6. Front cover 15. Rear-lift motor
7. Seat back cover 16. Slide motor
8. Seat back 17. Power seat switch
9. Pole guide
S-111
s SEAT
REAR SEAT (626)
36U0SX-163
1. Rear seat catch knob
S—112
SPECIAL TOOLS
GENERAL INFORM ATION..............................S T - 2

ENGINE................................................................S T - 3
CLUTCH AND MANUAL TRANSAXLE......... S T - 4
AUTOMATIC TRANSAXLE..............................S T - 5
FRONT AND REAR AXLES............................ S T - 7
STEERING.......................................................... S T - 7
BRAKE................................................................. S T - 8
FRONT AND REAR SUSPENSIONS............. S T - 9
CHECKER AND OTHER EQUIPMENT.......... S T - 9
46USTX-002
ST SPECIAL TOOLS
GENERAL INFORMATION
The letters A and B in the priority column indicate the degree of importance of each tool.
A: Necessary for performing operation. All service shops should have these tools.
B: Selective.
Not as necessary as tools ranked A, but these tools will help to perform repairs more easily and efficiently.
When ordering tool sets, check the List in the Parts Catalogue to make sure that some tools in the set are
duplicated in other sets you may already have. If they are, instead of ordering the set, order only the tools
that are needed.
46USTX-001
SPECIAL TOOLS ST
ENGINE
Note SST ® , (§), © a n d © a r e used in the following combinations. (KL DOHC engine only)
• ® + (D
•® + © + ©
Either combination can be used.
S T -3
ST SPECIAL TOOLS
ENGINE (Cont’d)
TOOL NUMBER
PRIORITY ILLUSTRATION
& DESCRIPTION
4 9 G 011 103 3G
B olt B
(FS D O H C )
8
4 9 S 1 2 0 7 10
H o ld e r, A
c o u p lin g
fla n g e
4 9 E011 1A 0
B ra k e set, rin g A
gear
YV
4 9 E301 144
R e m o v in g p la te A
CLUTCH AND MANUAL TRANSAXLE
TOOL NUMBER
& DESCRIPTION
4 9 F401 3 3 0 B
Installer set, A
b e a rin g
4 9 G 0 3 0 338
A tta c h m e n t E
4 9 1285 071
A
©
Puller, n e e dle
b e a rin g A
ST—4
SPECIAL TOOLS ST
CLUTCH AND MANUAL TRANSAXLE (Cont’d)
TOOL NUMBER TOOL NUMBER

PRIORITY ILLUSTRATION PRIORITY ILLUSTRATION
& DESCRIPTION & DESCRIPTION
49 0839 425C 49 G 030 380C
P u lle r set, A S him se le cto r set

b e a rin g
4 9 G 0 1 7 1AO 4 9 FT01 361
R e m o v e r set,
b e a rin g
A
j SjC i R e m ove r, b e a rin g
49 G 030 370 49 G 030 440
R e m o v in g p la te A H o ld e r, p rim a ry
shaft
4 9 0 6 3 6 145 4 9 B 0 1 7 102
P uller, fa n p u lle y A P re lo a d a d a p te r
b o ss
49 G 030 455 4 9 G 0 1 7 2 02
H o ld e r, A P re lo a d a d a p te r
d iffe re n tia l sid e
gear
AUTOMATIC TRANSAXLE
0
4 9 G 0 19 0 A 5 A 4 9 G 0 1 9 017
I
S him s e le c to r set A Installer, oil seal A
(G F 4 A -E L ) (G F4A -E L)
im i
4
49 G 019 0A7A 4 9 FT01 4 39
C o m p re s s o r set,
re tu rn s p rin g
(G F 4 A -E L )
A H o ld e r, id le g e a r
shaft
(G F4A -E L)
A
IJ b
S T -5
ST SPECIAL TOOLS
AUTOMATIC TRANSAXLE (Cont’d)

4 9 G 0 1 9 011
Installer, b e a rin g
(G F 4 A -E L )
49 G 019 013
A
%
49 G 019 022
A tta c h m e n t K
(G F4A-EL)
4 9 G 0 1 9 012
A
©
R e m o v e r, b e a rin g A Leak checker A
(G F 4 A -E L ) (G F4A -E L)
■©
4 9 G 0 1 9 031
W re n c h
(G F 4 A -E L )
A
49 0378 400A
G a u g e set, oil
p re ssu re
A
&
49 G 019 0A2
H o ld e r, tu rb in e
shaft
(G F 4 A -E L )
A
® s ia 0 g
"
~~Z-_______
4 9 B 0 1 9 901
O il p re ssu re
gauge
A
n,
SPECIAL TOOLS ST
FRONT AND REAR AXLES
TOOL NUMBER
& DESCRIPTION
%
49 G 030 795
Installer, oil seal A
CD
49 W 027 003
Installer, b e a rin g A
(
(9
4 9 H 0 3 4 201
S u p p o rt b lo c k A
4 9 F 02 6 102
P u lle r & installer, A

b e a rin g
4 9 F 0 2 6 103
Puller, w h e e l h u b A
"L r— U
4 9 G 0 3 3 102
H a n d le A
< 0 )
STEERING

49 G 032 3A4 4 9 F 03 2 301
A d a p te r, p o w e r A © © (§ ) H a n g e r, B
s te e rin g g a u g e p o w e r ste e rin g
f t ® pum p
« ^ X 9 *
S T -7
ST SPECIAL TOOLS
STEERING (Cont’d)
BRAKE
TOOL NUMBER
& DESCRIPTION
49 E 0 4 3 0 0 3
cT
L o c k to o l, tu rn in g A
In / /
4 9 B 0 4 3 004
S o cke t w re n c h A
//
4 9 H 0 1 7 101
Hook A
4 9 B 0 4 3 001
A d ju s t g a u g e A
49 H 028 204
A tta c h m e n t A
S T -8
SPECIAL TOOLS ST
BRAKE (Cont’d)

49 U 043 0A0
G a u g e set, A —
oil p re s s u re
v ~4 4 » .
FRONT AND REAR SUSPENSIONS

49 B034 2A0A 4 9 8 0 3 8 785
R e p la c e r set, A Installer, d u s t . A
ru b b e r b u sh in g boot
4 9 G 0 3 4 1 AO
C o m p re s s o r set, A — —
co il s p rin g
CHECKER AND OTHER EQUIPMENT
TOOL NUMBER
& DESCRIPTION
49 0187 280
G a u g e , oil B
p re s s u re
49 0839 285 fs
U Ho
// 0 0 - 0 9 |J f
H.O o o . ■
C h e c k e r, fu e l & A //o o o m
II 0 o - o HI
H0 o -o Ii I
th e rm o m e te r tf .o 0 0 Al |
4 9 H 0 1 8 9A1
S e lf-D ia g n o sis A uHD

checker Y :- V
S T -9
ST SPECIAL TOOLS
CHECKER AND OTHER EQUIPMENT (Cont’d)
TOOL NUMBER
& DESCRIPTION
49 G 018 904
S3S 6iP1N ]35£.
—<.t ,—
STJL1-} ' ■<,—v ?~ ~
l! !-^)> >0*
Sheet A
H Z"' '-zEeK
-» ‘301* 901
49 G 018 903
A d a p te r h a rn e ss A \V7 jl \Vv| U
49 D 019 902
A d a p te r h a rn e s s A
///
4 9 9 2 0 0 020
A
T e n s io n g a u g e ,
V -rib b e d belt
TECHNICAL DATA
31. ENGINE (FS).............................................. T D - 2

32. ENGINE (KL).............................................. T D - 5
D1. LUBRICATION SYSTEM (FS).................T D - 8
D2. LUBRICATION SYSTEM (KL).................T D - 8
E1. COOLING SYSTEM (FS)..........................T D - 9
E2. COOLING SYSTEM (KL).......................... T D - 9
F1. FUEL AND EMISSION CONTROL
SYSTEMS (FS M T X )................................ T D -1 0
SYSTEMS (KL)...........................................TD -11
SYSTEMS (FS A T X )................................ T D -1 2
G. ENGINE ELECTRICAL SYSTEM ............T D -12
H. CLUTCH...................................................... T D -1 4
J. MANUAL TRANSAXLE............................ T D -1 4
K1. AUTOMATIC TRANSAXLE.....................T D -16
K2. AUTOMATIC TRANSAXLE.....................T D -20
M. FRONT AND REAR AXLES.....................TD -22
N. STEERING SYSTEM ................................ T D -22
P. BRAKING SYSTEM................................... T D -22
Q. WHEELS AND TIRES............................... T D -23
R. SUSPENSION............................................ T D -24
STANDARD BOLT AND
NUT TIGHTENING TO RQ UE....................... T D -25
46UTDX-001
TD TECHNICAL DATA
B1. ENGINE (FS)
Engine
Item FS
Type G a so lin e , 4 -c y c le
C y lin d e r a rra n g e m e n t a n d n u m b e r In-line 4 -c y lin d e r
C o m b u s tio n c h a m b e r P e n tro o f
V a lve syste m D O H C , b e lt-d rive n 16 va lve s
B o re x S tro ke m m ( in ) 8 3 .0 x 9 2 .0 (3 .2 7 x 3 .6 2 )
T ota l p isto n d is p la c e m e n t m l (c c , c u in ) 1,991 (1 ,9 9 1 , 1 2 1 .5 )
C o m p re s s io n ratio 9 .0
S ta n d a rd 1 ,1 77 (1 2 .0 , 171 )-3 0 0
C o m p re s s io n p re s s u re M in im u m 8 2 4 (8 .4 , 1 1 9 J-3 0 0
kP a (k g f/c m 2, p s i)-rp m M a x im u m d iffe re n c e b e tw e e n
196 (2 .0 , 2 8 )
c y lin d e rs
O p e n BT D C 8°
IN
C lo se A B D C 50°
V a lv e tim in g
O pen BBDC 54°
EX
C lo se A T D C 8°
IN 0: M a in te n a n ce -fre e
V a lv e c le a ra n c e m m ( in )
EX 0: M a in te n a n ce -fre e
Cylinder head
H e ig h t m m ( in ) 1 2 4 .4 5 - 1 2 4 .5 5 ( 4 . 8 9 9 6 - 4 . 9 0 3 5 )
D isto rtio n m m ( in ) 0 .1 0 ( 0 .0 0 4 ) m ax.
G rin d in g m m ( in ) 0 .1 5 ( 0 .0 0 6 ) m ax.
Valve and valve guide
IN 3 1 . 4 - 3 1 . 6 ( 1 .2 3 6 2 - 1 .2 4 4 1 )
V a lve h e a d d ia m e te r m m ( in )
EX 2 7 . 5 - 2 7 . 7 ( 1 .0 8 2 7 - 1 .0 9 0 5 )
IN 1.10 (0 .0 4 3 3 )
V a lv e h e a d th ic k n e s s (m a rg in e ) m m ( in )
EX 1.2 0 (0 .0 4 7 2 )
IN 45°
V a lv e fa c e a n g le
EX 45°
S ta n d a rd 8 9 .6 8 (3 .5 3 0 7 )
IN
M in im u m 8 9 .2 8 (3 .5 1 5 0 )
V a lve le n g th m m ( in )
S ta n d a rd 8 9 .7 8 (3 .5 3 4 6 )
EX
M in im u m 8 9 .3 8 (3 .5 1 8 9 )
S ta n d a rd 5 .9 7 0 — 5 .9 8 5 ( 0 . 2 3 5 1 - 0 . 2 3 5 6 )
IN
V a lv e stem d ia m e te r M in im u m 5 .9 4 0 (0 .2 3 3 9 )
m m ( in ) S ta n d a rd 5 .9 6 5 -5 .9 8 0 ( 0 .2 3 4 9 -0 .2 3 5 4 )
EX
M in im u m 5 .9 3 5 (0 .2 3 3 7 )
G u id e in n e r d ia m e te r m m ( in ) 6 .0 1 - 6 .0 3 (0 .2 3 6 7 -0 .2 3 7 4 )
IN 0 .0 2 5 -0 .0 6 0 (0 .0 0 1 0 -0 .0 0 2 3 )
V a lve s te m -to -g u id e c le a ra n c e m m ( in ) EX 0 .0 3 0 -0 .0 6 5 (0 .0 0 1 2 -0 .0 0 2 5 )
M a x im u m 0 .1 0 ( 0 .0 0 4 )
IN 1 3 .5 - 1 4 .1 (0 .5 3 2 -0 .5 5 5 )
G u id e p ro je c tio n (H e ig h t " A " ) m m ( in )
EX 1 3 .5 - 1 4 . 1 (0 .5 3 2 -0 .5 5 5 )
Valve seat
IN 45°
S e a t a n g le
EX 45°
IN 0 .9 - 1 .3 (0 .0 3 6 -0 .0 5 1 )
S eat c o n ta c t w id th m m ( in )
EX 0 .9 - 1 .3 (0 .0 3 6 -0 .0 5 1 )
S ta n d a rd 3 9 .0 (1 .5 3 5 )
IN
M a xim u m 4 0 .6 (1 .5 9 8 )
S ta n d a rd 3 9 .0 (1 .5 3 5 )
EX
M a x im u m 4 0 .6 ( 1 .5 9 8 )
TECHNICAL DATA TD
" -------- ------------------------ Engine FS
Item — ---------------
Valve spring
S ta n d a rd m m ( in ) 4 4 .0 ( 1 .7 3 2 )
IN
M inim um m m ( in )/N (kgf, Ibf) 3 6 .5 ( 1 . 4 3 7 ) /1 7 7 . 1 - 2 0 0 . 2 ( 1 8 .0 5 - 2 0 . 4 2 , 3 9 . 7 1 - 4 4 . 9 2 )
F re e le n g th
S ta n d a rd m m ( in ) 4 4 .0 ( 1 .7 3 2 )
EX
M inim um m m ( in )/N (kg f, Ibf) 3 6 .5 {1 .4 3 7 ) /1 7 7 . 1 - 2 0 0 . 2 ( 1 8 . 0 5 - 2 0 . 4 2 , 3 9 . 7 1 - 4 4 . 9 2 )
O u t-o f-s q u a re 1.54 ( 0 .0 6 1 ) m ax.
Camshaft
S ta n d a rd 4 2 .9 7 3 (1 .6 9 1 8 )
IN
W e a r lim it ' 4 2 .8 2 3 (1 .6 8 5 9 )
C a m h e ig h t m m ( in )
S ta n d a rd 4 3 .3 3 8 (1 .7 0 6 2 )
EX
W e a r lim it 4 3 .1 8 8 (1 .7 0 0 3 )
N o .1 — 5 2 5 .9 4 0 - 2 5 .9 6 5 ( 1 . 0 2 1 3 - 1 . 0 2 2 2 )
J o u rn a l d ia m e te r m m ( in )
O u t-o f-ro u n d 0 .0 3 (0 .0 0 1 2 ) m ax.
N o .1 — 5 0 .0 3 5 - 0 .0 8 1 (0 .0 0 1 4 -0 .0 0 3 1 )
C a m s h a ft b e a rin g oil c le a ra n c e m m ( in )
M a x im u m 0 .1 5 ( 0 .0 0 6 )
C a m s h a ft ru n o u t m m ( in ) 0 .0 3 ( 0 .0 0 1 2 ) m ax.
S ta n d a rd 0 . 0 8 - 0 . 2 0 ( 0 .0 0 3 2 - 0 .0 0 7 8 )
C a m s h a ft e n d p la y m m ( in )
M a x im u m 0.21 ( 0 .0 0 8 )
Cylinder block
H e ig h t m m ( in ) 2 7 1 .0 (1 0 .6 6 9 )
D isto rtio n m m ( in ) 0 .0 5 ( 0 .0 0 2 ) m ax.
S ta n d a rd size 8 3 .0 0 0 - 8 3 .0 1 9 ( 3 . 2 6 7 8 - 3 . 2 6 8 4 )
C y lin d e r b o re d ia m e te r
0 .2 5 ( 0 .0 1 ) o ve rsize 8 3 .2 5 0 - 8 3 .2 6 9 (3 .2 7 7 6 — 3 .2 7 8 3 )
m m ( in )
0 .5 0 ( 0 .0 2 ) o ve rsize 8 3 .5 0 0 - 8 3 .5 1 9 ( 3 . 2 8 7 4 - 3 . 2 8 8 1 )
C y lin d e r b o re ta p e r a n d o u t-o f-ro u n d m m ( in ) 0 .0 1 0 ( 0 .0 0 0 4 ) m ax.
Piston
P iston d ia m e te r S ta n d a rd 8 2 . 9 5 4 - 8 2 .9 7 4 ( 3 . 2 6 5 9 - 3 . 2 6 6 6 )
M e a s u re d at 9 0 ° to p in
b o re a xis a n d 1 6 .5 m m 0 .2 5 ( 0 .0 1 ) o ve rsize 8 3 . 2 0 4 - 8 3 .2 2 4 ( 3 .2 7 5 8 - 3 . 2 7 6 5 )
(0 .6 5 0 in ) b e lo w oil rin g
g ro o v e m m ( in ) 0 .5 0 ( 0 .0 2 ) o ve rsize 8 3 . 4 5 4 - 8 3 .4 7 4 ( 3 .2 8 5 6 - 3 . 2 8 6 3 )
S ta n d a rd 0 . 0 3 9 - 0 . 0 5 2 (0 .0 0 1 6 — 0 .0 0 2 0 )
P is to n -to -c y lin d e r c le a ra n c e m m ( in )
M a x im u m 0 .1 5 ( 0 .0 0 6 )
Piston ring
Top 1 . 1 7 0 - 1 .1 8 5 ( 0 . 0 4 6 1 - 0 . 0 4 6 7 )
T h ic k n e s s m m ( in )
Second 1 . 4 7 - 1 . 4 9 ( 0 .0 5 7 9 — 0 .0 5 8 7 )
Top 0 .1 5 -0 .3 0 (0 .0 0 6 -0 .0 1 1 )
Second 0 .1 5 -0 .3 0 (0 .0 0 6 -0 .0 1 1 )
End gap
O il (rail) 0 .2 0 - 0 .7 0 (0 .0 0 8 -0 .0 2 7 )
(M e a s u re d in c y lin d e r) m m ( in )
T op , S e c o n d 0 .5 ( 0 .0 2 0 )
M a x im u m
Oil (rail) 0 .9 ( 0 .0 3 5 )
Top 1 . 2 2 2 - 1 . 2 3 5 ( 0 .0 4 8 0 - 0 .0 4 8 6 )
R in g g ro o v e w id th in p is to n m m ( in ) Second 1 .5 2 0 -1 .5 3 5 (0 .0 5 9 8 -0 .0 6 0 4 )
Oil 3 . 0 2 0 - 3 . 0 4 0 ( 0 .1 1 8 9 — 0 .1 1 9 7 )
Top 0 . 0 3 5 - 0 . 0 6 5 (0 .0 0 1 4 — 0 .0 0 2 5 )
P iston rin g -to -rin g g ro o v e c le a ra n c e
Second 0 . 0 3 0 - 0 . 0 6 5 (0 .0 0 1 2 — 0 .0 0 2 5 )
m m ( in )
M a xim u m 0 .0 8 5 (0 .0 0 3 3 )
Piston pin
D ia m e te r m m ( in ) 1 8 . 9 7 4 - 1 8 .9 8 0 ( 0 . 7 4 7 0 - 0 . 7 4 7 2 )
In te rfe re n c e in c o n n e c tin g ro d m m ( in ) 0 .0 1 3 - 0 .0 3 7 (0 .0 0 0 5 -0 .0 0 1 5 )
In sta llin g p re s s u re N (k g f, Ib f) 4 ,9 0 3 -1 4 ,7 1 0 ( 5 0 0 - 1 ,5 0 0 , 1 ,1 0 0 - 3 ,3 0 0 )
TD TECHNICAL DATA
Engine
Item FS
Connecting rod and connecting rod bearing
L e n g th (C e n te r to ce n ter) m m ( in ) 1 3 5 .1 5 - 1 3 5 .2 5 ( 5 .3 2 0 9 - 5 .3 2 4 8 )
B e n d in g m m ( in ) 0 .0 5 ( 0 .0 0 2 ) m a x ./5 0 ( 1 .9 7 )
S m all e n d b o re m m ( in ) 1 8 .9 4 3 — 18.961 (0 .7 4 5 8 — 0 .7 4 6 5 )
B ig e n d b o re m m ( in ) 5 1 .0 0 0 - 5 1 .0 1 5 ( 2 .0 0 7 9 - 2 .0 0 8 5 )
B ig e n d w id th m m ( in ) 2 1 .8 3 8 — 2 1 .8 9 0 ( 0 .8 5 9 8 — 0 .8 6 1 8 )
S ta n d a rd 0 .1 1 0 -0 .2 6 2 ( 0 .0 0 4 3 -0 .0 1 0 3 )
C o n n e c tin g ro d s id e c le a ra n c e m m ( in )
M a x im u m 0 .3 0 (0 .0 1 2 )
Crankshaft
C ra n k s h a ft ru n o u t m m ( in ) 0 .0 3 (0 .0 0 1 2 ) m ax.
S ta n d a rd S ta n d a rd 5 5 .9 3 7 - 5 5 .9 5 5 ( 2 .2 0 2 2 - 2 .2 0 2 9 )
M a in jo u rn a l d ia m e te r size M a x im u m 5 5 .9 3 2 (2 .2 0 2 0 )
m m ( in ) 0.2 5 (0 .0 1 ) S ta n d a rd 5 5 .6 8 7 - 5 5 .7 0 5 ( 2 . 1 9 2 4 - 2 . 1 9 3 1 )
undersize M a xim u m 5 5 .6 8 2 (2 .1 9 2 2 )
M a in jo u rn a l ta p e r/o u t-o f-ro u n d m m ( in ) 0 .0 0 6 (0 .0 0 0 2 ) m a x ./0 .0 0 3 ( 0 .0 0 0 1 ) m ax.
S ta n d a rd S ta n d a rd 4 7 .9 4 0 - 4 7 .9 5 5 ( 1 . 8 8 7 4 - 1 . 8 8 8 0 )
size M in im u m 4 7 .9 3 5 (1 .8 8 7 2 )
C ra n k p in d ia m e te r 0.2 5 (0 .0 1 ) S ta n d a rd 4 7 .6 9 0 - 4 7 .7 0 5 [ 1 .8 7 7 6 — 1 .8 7 8 1 )
m m ( in ) undersize M in im u m 4 7 .6 8 5 (1 .8 7 7 4 )
0.50 (0 .0 2 ) S ta n d a rd 4 7 .4 4 0 - 4 7 .4 5 5 ( 1 .8 6 7 7 - 1 .8 6 8 3 )
undersize M in im u m 4 7 .4 3 5 (1 .8 6 7 5 )
C ra n k p in ta p e r/o u t-o f-ro u n d m m ( in ) 0 .0 0 6 ( 0 .0 0 0 2 ) m a x ./0 .0 0 3 ( 0 .0 0 0 1 ) m ax.
Main bearing
0 .0 2 4 — 0 .0 5 0 ( 0 . 0 0 0 9 - 0 . 0 0 2 0 ) ( # 1 , 2 , 4, 5),
M a in jo u rn a l b e a rin g oil c le a ra n c e S ta n d a rd
0 .0 3 0 -0 .0 5 6 (0 .0 0 1 2 -0 .0 0 2 2 ) ( # 3 )
M a x im u m 0 .0 6 7 (0 .0 0 2 6 )
A v a ila b le u n d e rs iz e d b e a rin g m m ( in ) 0 .2 5 ( 0 .0 1 )
Crankpin bearing
S ta n d a rd 0 .0 2 4 - 0 .0 6 1 (0 .0 0 0 9 -0 .0 0 2 4 )
M a xim u m 0 .0 6 7 (0 .0 0 2 6 )
A v a ila b le u n d e rs iz e d b e a rin g m m ( in ) 0 .2 5 ( 0 .0 1 ) , 0 .5 0 ( 0 .0 2 )
Thrust bearing
S ta n d a rd 0 .0 8 0 -0 .2 8 2 (0 .0 0 3 1 -0 .0 1 1 1 )
C ra n k s h a ft e n d p la y m m { in )
M a xim u m 0 .3 0 (0 .0 1 1 8 )
S ta n d a rd size 2 .5 0 0 -2 .5 5 0 (0 .0 9 8 4 -0 .1 0 0 4 )
0 .2 5 ( 0 .0 1 ) o ve rsize 2 .6 2 5 -2 .6 7 5 (0 .1 0 3 3 -0 .1 0 5 3 )
B e a rin g w id th m m ( in )
0 .5 0 ( 0 .0 2 ) o ve rsize 2 . 7 5 0 - 2 . 8 0 0 (0 .1 0 8 3 — 0 .1 1 0 2 )
0 .7 5 ( 0 .0 3 ) ove rsize 2 . 8 7 5 - 2 . 9 2 5 ( 0 . 1 1 3 2 - 0 .1 1 5 2 )
TECHNICAL DATA TD
B2. ENGINE (KL)
Engine KL
Item
T ype G a so lin e , 4 -c y c le
C y lin d e r a rra n g e m e n t a n d n u m b e r 6 0 ° V c o n fig u ra tio n 6 c y lin d e r
C o m b u s tio n c h a m b e r P e n troo f
V a lve syste m D O H C , b e lt-d rive n 2 4 va lve s
B o re x S tro ke m m ( in ) 8 4 .5 x 7 4 .2 ( 3 .3 3 x 2 .9 2 )
T ota l p is to n d is p la c e m e n t m l (c c , c u in ) 2 ,4 9 5 (2 ,4 9 5 , 1 5 2 .3 )
C o m p re s s io n ratio 9.2
S ta n d a rd 1 ,4 02 (1 4 .3 , 2 0 3 )-2 5 0
C o m p re s s io n p re s s u re M in im u m 981 (1 0 .0 , 1 4 2 )-2 5 0
kP a (k g f/c m 2, p s ij- rp m M a x im u m d iffe re n c e b e tw e e n
196 (2 .0 , 2 8 )
e a c h c y lin d e r
O pen BTDC 8°
IN
C lo se A B D C 47°
V a lve tim in g
Open BBDC 50°
EX
C lo se A T D C 5°
IN 0: M a in te n a n ce -fre e
V a lve c le a ra n c e m m ( in )
EX 0: M a in te n a n ce -fre e
Cylinder head
H e ig h t m m ( in ) 1 3 3 .4 - 1 3 3 .6 ( 5 . 2 5 2 - 5 . 2 5 9 )
D isto rtio n m m ( in ) 0 .1 0 (0 .0 0 3 9 ) m ax.
G rin d in g m m ( in ) 0 .1 5 (0 .0 0 5 9 ) m ax.
S ta n d a rd 0 . 0 2 5 - 0 . 0 6 6 ( 0 . 0 0 1 0 - 0 .0 0 2 5 )
M a x im u m 0 .1 8 (0 .0 0 7 0 )
Valve and valve guide
IN 3 1 .8 5 -3 2 .1 5
V a lve h e a d d ia m e te r m m ( in )
EX 2 7 . 4 5 - 2 7 .7 5
IN 0 .9 ( 0 .0 3 5 5 )
EX 1.0 (0 .0 3 9 4 )
IN 45°
V a lve fa c e a n g le
EX 45°
S ta n d a rd 93.91 ( 3 .6 9 7 )
IN
M in im u m 93.41 ( 3 .6 7 8 )
V a lve le n g th m m ( in )
S ta n d a rd 9 4 .9 9 ( 3 .7 4 0 )
EX
M in im u m 9 4 .4 9 ( 3 .7 2 0 )
IN 5 .9 7 0 -5 .9 8 5 (0 .2 3 5 1 -0 .2 3 5 6 )
V a lve stem d ia m e te r m m ( in )
EX 5 .9 6 5 -5 .9 8 0 ( 0 .2 3 4 9 -0 .2 3 5 4 )
G u id e in n e r d ia m e te r m m ( in ) 6 .0 1 - 6 .0 3 (0 .2 3 6 7 -0 .2 3 7 4 )
IN 0 . 0 2 5 - 0 . 0 6 0 ( 0 .0 0 1 0 - 0 . 0 0 2 3 )
V a lve s te m -to -g u id e c le a ra n c e m m { in ) EX 0 .0 3 0 — 0 .0 6 5 ( 0 .0 0 1 2 - 0 . 0 0 2 5 )
M a x im u m 0 .2 0 ( 0 .0 0 7 8 )
IN 1 4 . 7 - 1 5 . 3 (0 .5 7 9 — 0 .6 0 2 )
G u id e p ro je c tio n m m ( in )
EX 1 2 . 2 - 1 2 . 8 (0 .4 8 1 — 0 .5 0 3 )
Valve seat
IN 45°
S e a t a n g le
EX 45°
IN 0 . 8 - 1 . 4 ( 0 . 0 3 1 5 - 0 .0 5 5 1 )
Seat c o n ta c t w id th m m ( in )
EX 0 .8 - 1 .4 (0 .0 3 1 5 -0 .0 5 5 1 )
S ta n d a rd 4 1 .5 ( 1 .6 3 4 )
IN
M a x im u m 43.1 ( 1 .6 9 7 )
Seat s in k in g m m ( in )
S ta n d a rd 4 1 .5 ( 1 .6 3 4 )
EX
M a x im u m 43.1 ( 1 .6 9 7 )
Valve spring
S ta n d a rd m m ( in ) 4 6 .9 2 ( 1 .8 4 7 )
F re e le n g th
M inim um m m ( in )/N (kg f, Ibf) 3 8 .7 ( 1 . 5 2 J/2 3 3 .0 — 2 6 3 .6 ( 2 3 . 7 5 - 2 6 . 8 8 , 5 2 . 2 5 - 5 9 . 1 4 )
O u t-o f-s q u a re m m ( in ) 1 .6 3 ( 0 .0 6 4 2 )
TD TECHNICAL DATA
-------- —________ Engine

Item ' ---------------------------- KL
Camshaft
S ta n d a rd 4 3 .5 4 9 (1 .7 1 4 5 )
IN
W e a r lim it 4 3 .3 4 9 (1 .7 0 6 7 )
C a m h e ig h t m m ( in )
S ta n d a rd 4 3 .5 4 9 (1 .7 1 4 5 )
EX
W e a r lim it 4 3 .3 4 9 (1 .7 0 6 7 )
J o u rn a l n u m b e r No.1 N o .2 , 3, 4 N o .5
2 9 . 9 7 5 - 2 9 .9 9 5 2 5 . 9 1 0 - 2 5 .9 3 0 2 5 .9 4 0 - 2 5 .9 6 0
IN
RH c y lin d e r (1 .1 8 0 2 -1 .1 8 0 9 ) ( 1 .0 2 0 1 - 1 .0 2 0 8 ) ( 1 .0 2 1 3 — 1 .0 2 2 0 )
head 2 5 .9 4 0 - 2 5 .9 6 0
EX T T
( 1 .0 2 1 3 -1 .0 2 2 0 )
J o u rn a l d ia m e te r m m ( in )
2 5 . 9 4 0 - 2 5 .9 6 0
IN
(1 .0 2 1 3 -1 .0 2 2 0 )
t T
L H c y lin d e r
head 2 9 . 9 7 5 - 2 9 .9 9 5
EX t t
(1 .1 8 0 2 -1 .1 8 0 9 )
O u t-o f-ro u n d 0 .0 2 (0 .0 0 0 7 )
0 . 0 4 0 - 0 .0 8 1 0 . 0 7 0 - 0 .1 1 1 0 .0 4 0 - 0 .0 8 1
R H c y lin d e r IN
( 0 .0 0 1 6 - 0 .0 0 3 2 ) (0 .0 0 2 8 -0 .0 0 4 3 ) (0 .0 0 1 6 -0 .0 0 3 2 )
head
C a m s h a ft b e a rin g oil EX t t t
c le a n ra c e m m ( in ) LH c y lin d e r IN r t t
head EX t t t
M a x im u m 0 .1 2 (0 .0 0 4 7 ) 0 .1 5 (0 .0 0 5 9 ) 0 .1 2 (0 .0 0 4 7 )
C a m s h a ft ru n o u t m m ( in ) 0 .0 2 (0 .0 0 0 7 ) m ax.
S ta n d a rd 0 .0 5 - 0 .1 0 (0 .0 0 2 0 -0 .0 0 3 9 )
C a m s h a ft e n d p la y m m ( in )
M a x im u m 0 .1 4 (0 .0 0 5 6 )
Cylinder block
D isto rtio n m m ( in ) 0 .1 5 ( 0 .0 0 5 9 ) m ax.
S ta n d a rd size 8 4 .5 0 0 - 8 4 .5 2 2 ( 3 . 3 2 6 8 - 3 . 3 2 7 6 )
C y lin d e r b o re d ia m e te r
0 .2 5 ( 0 .0 1 ) o ve rsize 8 4 . 7 5 0 - 8 5 .7 7 2 ( 3 .3 3 6 7 - 3 .3 3 7 4 )
m m ( in )
0 .5 0 ( 0 .0 2 ) o ve rsize 8 5 .0 0 0 - 8 5 .0 2 2 ( 3 . 3 4 6 5 - 3 . 3 4 7 3 )
C y lin d e r b o re ta p e r a n d o u t-o f-ro u n d m m ( in ) 0 .0 2 2 (0 .0 0 0 8 ) m ax.
Piston
P isto n d ia m e te r S ta n d a rd size 8 4 . 4 5 3 - 8 4 .4 8 5 ( 3 .3 2 5 0 - 3 .3 2 6 1 )
M e a s u re d a t 9 0 ° to p in
b o re a x is a n d 1 6 .5 m m 0 .2 5 ( 0 .0 1 ) o ve rsize 8 4 .7 0 3 - 8 4 .7 3 5 ( 3 .3 3 4 8 - 3 .3 3 6 0 )
(0 .6 5 0 in ) b e lo w oil rin g
g ro o v e m m ( in ) 0 .5 0 ( 0 .0 2 ) o ve rsize 8 4 .9 5 3 — 8 4 .9 8 5 ( 3 .3 4 4 6 - 3 .3 4 5 8 )
S ta n d a rd 0 .0 2 8 -0 .0 5 6 (0 .0 0 1 2 -0 .0 0 2 2 )
P isto n to c y lin d e r c le a ra n c e m m ( in )
M a xim u m 0 .1 3 (0 .0 0 5 1 )
Piston ring
Top 1 .4 7 - 1 .4 9 (0 .0 5 7 9 -0 .0 5 8 7 )
T h ic k n e s s m m ( in )
S e co n d t
Top 0 . 1 5 - 0 . 3 0 ( 0 .0 0 6 0 - 0 .0 1 1 8 )
End gap S econd 0 .2 5 - 0 .4 0 (0 .0 1 0 -0 .0 1 5 )
(M e a s u re d in th e c y lin d e r) m m ( in ) Oil (rail) 0 .2 0 -0 .7 0 (0 .0 0 8 -0 .0 2 7 )
M a x im u m 1.0 (0 .0 3 9 3 )
Top 1 . 5 2 0 - 1 . 5 3 5 ( 0 .0 5 9 8 - 0 . 0 6 0 4 )
R in g g ro o v e w id th in p is to n m m ( in ) Second 1 .5 2 0 -1 .5 3 5 (0 .0 5 9 8 -0 .0 6 0 4 )
Oil 3 .0 2 - 3 .0 4 (0 .1 1 8 9 -0 .1 1 9 7 )
Top 0 . 0 2 0 - 0 . 0 6 5 ( 0 .0 0 0 8 — 0 .0 0 2 5 )
P isto n rin g -to -rin g g ro o v e c le a ra n c e S e co n d 0 .0 3 0 -0 .0 6 5 (0 .0 0 1 2 -0 .0 0 2 5 )
m m ( in ) Oil 0 .0 2 5 -0 .0 5 2 (0 .0 0 1 -0 .0 0 2 )
M a xim u m 0 .1 5 (0 .0 0 5 9 )
Piston pin
D ia m e te r m m ( in ) 1 9 .9 7 4 - 1 9 .9 8 0 ( 0 . 7 8 6 4 - 0 . 7 8 6 6 )
P is to n -to -p is to n p in c le a ra n c e m m ( in ) 0 . 0 0 8 - 0 . 0 2 6 ( 0 .0 0 0 4 - 0 . 0 0 1 0 )
TECHNICAL DATA TD
~ ---------- ----------------------- Engine KL
Item — ---------
Connecting rod and connection rod bearing
L e n g th (C e n te r to c e n te r) m m ( in ) 1 3 7 .8 0 - 1 3 7 .9 0 ( 5 . 4 2 6 - 5 . 4 2 9 )
B e n d in g m m ( in ) 0 .0 5 ( 0 .0 0 1 9 )/5 0 (1 .9 6 8 5 )
S m all e n d b o re (B u s h in n e r d ia m e te r) m m ( in ) 1 9 .9 4 3 - 1 9 .9 6 1 (0 .7 8 5 2 -0 .7 8 5 8 )
B ig e n d b o re m m ( in ) 5 6 .0 0 0 — 5 6 .0 1 5
B ig e n d w id th m m ( in ) 2 1 .2 7 0 - 2 1 .3 2 2
S ta n d a rd 0 . 1 7 8 - 0 . 3 3 0 ( 0 . 0 0 7 0 - 0 .0 1 3 0 )
iu u b iu c ^ ic a ia i ivê hum ( ui j
M a x im u m 0 .4 0 ( 0 .0 1 6 )
Crankshaft
C ra n k s h a ft ru n o u t m m ( in ) 0 .0 1 5 (0 .0 0 0 5 ) m ax.
M a in jo u rn a l d ia m e te r size M in im u m 61.931 (2 .4 3 8 2 )
m m ( in ) 0.2 5 (0 .0 1 )
S ta n d a rd 6 1 .6 8 8 - 6 1 .7 0 5 ( 2 . 4 2 8 7 - 2 . 4 2 9 3 )
undersize
M a in jo u rn a l ta p e r a n d o u t-o f-ro u n d m m ( in ) 0 .0 5 ( 0 .0 0 1 9 ) m ax.
C ra n k p in d ia m e te r size M in im u m 5 2 .9 3 5 (2 .0 8 4 1 )
m m ( in ) 0.2 5 (0 .0 1 )
S ta n d a rd 5 2 .6 9 0 - 5 2 .7 0 5 ( 2 . 0 7 4 5 - 2 . 0 7 4 9 )
undersize
C ra n k p in ta p e r a n d o u t-o f-ro u n d m m ( in ) 0 .0 5 ( 0 .0 0 1 9 ) m ax.
Main bearing
M a in jo u rn a l b e a rin g oil c le a ra n c e S ta n d a rd 0 . 0 3 7 - 0 . 0 5 7 ( 0 . 0 0 1 5 - 0 .0 0 2 2 )
m m ( in ) M a x im u m 0 .0 6 4 ( 0 .0 0 2 5 )
Crankpin bearing
S ta n d a rd 0 . 0 2 3 - 0 . 0 4 3 ( 0 . 0 0 0 9 - 0 .0 0 1 6 )
oraiift|JiM u c d in iy un u ic a ia n o c m in i ( iiij
M a x im u m 0 .0 8 ( 0 .0 0 3 2 )
Thrust bearing
S ta n d a rd 0 . 0 8 0 - 0 . 2 8 2 ( 0 . 0 0 3 2 - 0 .0 1 1 1 )
C ra n k s h a ft e n d p la y m m ( in )
M a x im u m 0 .3 2 (0 .0 1 2 5 )
S ta n d a rd size 2 . 0 0 0 - 2 . 0 5 0 ( 0 .0 7 8 8 - 0 .0 8 0 7 )
B e a rin g w id th m m ( in ) 0 .2 5 ( 0 .0 1 ) o ve rsize 2 .1 2 5 -2 .1 7 5 (0 .0 8 3 7 -0 .0 8 5 6 )
0 .5 0 ( 0 .0 2 ) o ve rsize 2 . 2 5 0 - 2 . 3 0 0 ( 0 .0 8 8 6 - 0 .0 9 0 5 )
TD TECHNICAL DATA
D1. LUBRICATION SYSTEM (FS)
_ Engine FS
Item — -------------- -
L u b ric a tin g m e th o d F orce -fe d
Oil pump
T ype T ro c h o id g e a r
R elief p re s s u re kP a ( k g f/c m 2, p s i) 4 4 2 - 5 4 0 ( 4 .5 — 5.5, 6 4 - 7 8 )
R e g u la te d p re s s u re kP a ( k g f/c m 2, p s i) 4 0 0 — 4 9 0 ( 4 .0 — 5.0, 5 7 - 7 1 )
In n e r ro to r to o th tip to o u te r ro to r S ta n d a rd 0 . 0 2 - 0 . 1 8 ( 0 .0 0 0 8 - 0 .0 0 7 1 )
c le a ra n c e m m ( in ) M a x im u m 0 .2 0 0 (0 .0 1 1 8 )
S ta n d a rd 0 . 1 1 3 - 0 . 1 8 6 ( 0 .0 0 4 4 - 0 . 0 0 7 3 )
O u te r ro to r to b o d y c le a ra n c e m m ( in )
M a xim u m 0 .2 1 0 (0 .0 0 8 3 )
S ta n d a rd 0 . 0 3 5 - 0 . 0 9 5 ( 0 .0 0 1 4 - 0 . 0 0 3 7 )
S id e c le a ra n c e m m ( in )
M a xim u m 0 .1 2 0 (0 .0 0 4 7 )
Oil filter
T ype Full-flow , p a p e r e le m e n t
R elief p re s s u re d iffe re n tia l kP a ( k g f/c m 2, p s i) 7 9 - 1 1 7 ( 0 .8 — 1.2, 1 2 - 1 7 )
Engine oil
T ota l (d ry e n g in e ) 3 .7 (3 .9 , 3 .3 )
C a p a c ity
Oil re p la c e m e n t 3 .3 (3 .5 , 3 .0 )
L (U S qt, Im p q t)
Oil re p la c e m e n t (w ith oil filter) 3 .5 (3 .7 , 3 .1 )
AP I S e rvice SG, SH (EC E)
G ra d e
ILSA C
A bove - 2 5 °C ( -1 3 ° F ) SAE 10 W -30
V is c o s ity n u m b e r
B e lo w 0 ° C ( 3 2 ° F ) SAE 5W -30
D2. LUBRICATION SYSTEM (KL)

Engine KL
Item
L u b ric a tin g m e th o d F orce -fe d
Oil pump
T ype T ro c h o ik g e a r
R elief p re s s u re kP a ( k g f/c m 2, p s i) 5 0 0 - 5 8 0 ( 5 .0 — 6 .0 , 7 2 - 8 5 )
2 0 0 (2 .0 , 2 8 )-1 ,0 0 0
R e g u la te d p re s s u re kP a ( k g f/c m 2, p s i)-rp m
3 4 0 - 4 9 0 ( 3 .4 — 5.0, 4 9 - 7 1 J-3000
In n e r ro to r to o th tip to o u te r roto r S ta n d a rd 0 . 0 2 - 0 . 1 8 ( 0 .0 0 0 8 - 0 .0 0 7 0 )
c le a ra n c e m m ( in ) M a x im u m 0 .2 0 (0 .0 0 7 9 )
S ta n d a rd 0 .1 1 3 -0 .1 8 6 (0 .0 0 4 5 -0 .0 0 7 3 )
O u te r ro to r to b o d y c le a ra n c e m m ( in )
M a xim u m 0 .2 2 (0 .0 0 8 7 )
S ta n d a rd 0 . 0 3 - 0 . 0 9 ( 0 . 0 0 1 2 - 0 .0 0 3 5 )
S id e c le a ra n c e m m ( in )
M a xim u m 0 .1 3 ( 0 .0 0 5 1 )
Oil filter
Type Full-flow , p a p e r e le m e n t
Relief p re s s u re d iffe re n tia l kP a (k g f/c m 2, p s i) 7 9 - 1 1 7 ( 0 . 8 - 1 . 2 , 12— 1 7 )
Engine oil
T ota l (d ry e n g in e ) 4 .9 (5 .2 , 4 .3 )
C a p a c ity
Oil re p la c e m e n t 3 .7 (3 .9 , 3 .3 )
Oil re p la c e m e n t (w ith oil filter) 4 .0 (4 .2 , 3 .5 )
AP I S e rvice SG, SH (ECD)
G ra d e
ILSA C
Above -2 5 ° C |- 1 3 ° F ) SA E 10 W -30
V is c o s ity n u m b e r
B e lo w 0 ° C ( 3 2 ° F ) SA E 5W -30
TECHNICAL DATA TD
E1. COOLING SYSTEM (FS)
--------------- Engine/T ransaxle FS
Item ~— — — MTX ATX
C o o l n g m e th o d W a te r-co o le d , fo rc e d c irc u la tio n
W ater pump
T ype C e n trifu g a l, V rib b e d -b e lt d rive n
Im p e lle r d ia m e te r m m ( in ) 6 3 .8 -6 5 .0 ( 2 .5 1 - 2 .5 6 )
N u m b e r o f im p e lle r b la d e s 6
S p e e d ratio 1 : 1.27
W a te r seal ty p e U n ifie d m e c h a n ic a l seal
Thermostat
Type W ax, b o tto m -b y p a s s
O p e n in g te m p e ra tu re °C ( ° F ) 8 0 -8 4 (1 7 6 -1 8 3 )
F u ll-o p e n te m p e ra tu re °C ( ° F ) 9 5 (2 0 3 )
F u ll-o p e n lift m m ( in ) 8 .5 ( 0 .3 3 ) m in.
Radiator
Type C o rru g a te d fin
C a p v a lv e o p e n in g p re s s u re kP a ( k g f/c m 2, p s i) 9 3 . 2 - 1 2 3 ( 0 . 9 5 - 1.25, 13.5 - 1 7 . 8 )
C o o lin g c irc u it c h e c k in g p re s s u re kP a { k g f/c m 2, p s i) 123 (1 .2 5 , 1 7 .8 )
Coolant fan
T ype E lectric
N u m b e r o f b la d e s 4 5
O u te r d ia m e te r m m ( in ) . 3 4 0 ( 1 3 .4 )
C a p a c ity w-v 8 0 -1 2 16 0 -1 2
8 . 0 - 1 4 . 0 (LO W )
C u rre n t A 5 .6 — 7.6
1 1 . 5 - 1 7 . 5 (H IG H )
Coolant
C a p a c ity L [U S qt, Im p q t) 7 .0 (7 .4 , 6 .2 )
V o lu m e p e rc e n ta g e °/o S p e c ific g ra v ity at
C o o la n t p ro te c tio n
W ater C o o la n t 2 0 °C (6 8 °F )
A n tifre e z e so lu tio n Above -1 6 ° C (3 °F ) 65 35 1 .0 54
Above -2 6 ° C (-1 5 °F ) 55 45 1 .0 66
Above -4 0 ° C (-4 0 °F ) 45 55 1 .0 78
E2. COOLING SYSTEM (KL)

Engine/Transaxle KL
Item MTX ATX
C o o lin g m e th o d W a te r-co o le d , fo rc e d c irc u la tio n
W ater pump
Type C e n trifu g a l, V rib b e d -b e lt d riv e n
Im p e lle r d ia m e te r m m [ in ) 6 0 ( 2 .3 6 )
N u m b e r o f im p e lle r b la d e s 6
S p e e d ratio 1 : 1.05
W a te r seal ty p e U n ifie d m e ch a n ica l seal
Thermostat
T ype W ax, b o tto m -b y p a s s
O p e n in g te m p e ra tu re °C ( °F ) 8 0 -8 4 (1 7 6 -1 8 3 )
F u ll-o p e n te m p e ra tu re °C [ °F ) 9 5 (2 0 3 )
F u ll-o p e n lift m m [ in ) 8 .5 ( 0 .3 3 ) m in.
Radiator
Type C o rru g a te d fin
C a p v a lv e o p e n in g p re s s u re kP a ( k g f/c m 2, p s i) 7 4 - 1 0 2 ( 0 .7 5 - 1 .0 5 , 1 0 .7 - 1 4 .9 )
C o o lin g c irc u it c h e c k in g p re s s u re kP a ( k g f/c m 2, p s i) 102 (1 .0 5 , 1 4 .9 )
TD OUTLINE
F1. FUEL AND EMISSION CONTROL SYSTEMS (FS MTX)
Engine
Item FS
Id le s p e e d * 1 rp m 6 5 0 -7 5 0 (700 ± 50)
Ig n itio n tim in g * 1 BTDC 1 1 - 1 3 (12 ± 1 °)
Throttle body
Type H o rizo nta l d ra ft
T h ro a t d ia m e te r m m ( in ) 55 ( 2 .2 )
Fuel pump
M a x im u m o u tp u t p re s s u re kP a (k g f/c m 2, p s i) 6 4 0 (6 .5 , 9 2 )
Fuel filter
L o w -p re s s u re sid e N ylo n e le m e n t (in fuel p u m p )
Type
H ig h -p re s s u re sid e P a p e r e le m e n t
Pressure regulator
R e g u la tin g p re s s u re kP a ( k g f/c m 2, p s i) 2 6 0 - 3 2 0 ( 2 .6 — 3 .3 , 3 7 - 4 6 )
Injector
T ype H ig h -o h m ic
T y p e o f d riv e V o lta g e
R e sista n ce fi [2 0 ° C ( 6 8 ° F ) ] 1 2 -1 6
V o lu m e m (c c , fl o z )/1 5 sec. 4 7 -6 8 (4 7 -6 8 , 1 .4 -2 .0 )
R e sista n ce fi [2 3 ° C ( 7 3 ° F ) ] 7 .7 — 9 .3
R e sista n ce fi [2 0 ° C ( 6 8 ° F ) ] 3 0 -3 4
R e sista n ce fi [2 0 ° C ( 6 8 ° F )] 3 6 -4 3
EGR function control solenoid valve (Except California)
R e sista n ce fi [2 0 ° C ( 6 8 ° F ) ] 3 3 -3 9
EGR solenoid valve (Vent and Vacuum) (California)
R e sista n ce fi [2 0 ° C ( 6 8 ° F ) ] 3 0 -4 5
T ype Hall se n so r
Mass airflow sensor
T ype H e a t resistor
Engine coolant tem perature sensor
-2 0 °C ( —4 ° F ) 1 3 .5 -1 6 .5
2 0 °C ( 6 8 °F ) 2 .2 0 -2 .7 0
8 0 °C ( 1 7 6 °F ) 0 .2 9 -0 .3 5
R e sista n ce k fi 9 1 °C (1 9 6 °F 0 .2 2 6 - 0 .2 4 1
9 7 °C (2 0 7 °F ) 0 .1 9 3 -0 .2 0 5
1 0 8 °C (2 2 6 °F ) 0 . 1 4 5 - 0 .1 5 3
1 1 0 °C ( 2 3 0 ° F ) 0 .1 3 7 -0 .1 4 6
Fuel tank
C a p a c ity L (U S gal, Im p g a l) 5 8 .5 (1 5 .5 , 1 2 .9 )
Air cleaner element
E le m e n t ty p e Oil p e rm e a te d
Fuel
S p e c ific a tio n U n le a d e d — (R + M )/2 m e th o d 8 7 o r h ig h e r
** T E N te rm in a l o f d a ta lin k c o n n e c to r g ro u n d e d
TECHNICAL DATA TD
F2. FUEL AND EMISSION CONTROL SYSTEMS (KL)
Item Specification
Id le s p e e d * rp m 6 0 0 -7 0 0 (650 ± 50)
Ig n itio n tim in g * BT D C 9 - 1 1 ° (10 ± 1 °)
Throttle body
T ype H o sizo n ta l d ra ft
T h ro a t d ia m e te r m m ( in ) 6 0 [2 .4 )
Fuel pump
T ype Im p e lle r (in-tank)
M a x im u m o u tp u t p re s s u re kPa { k g f/c m 2, p s i] 6 4 0 (6 .5 , 9 2 )
Fuel filter
T ype
H ig h -p re s s u re s id e P a p e r e le m e n t
Pressure regulator
R e g u la tin g p re s s u re kP a ( k g f/c m 2, p s i) 2 8 0 (2 .9 , 4 1 )
Injector
T ype H ig h -o h m ic , sid e -fe e d
T y p e o f d riv e V oltate
R e sista n ce fi 1 2 - 1 6 (at 2 0 ° C { 6 8 ° F })
S o le n o id re s is ta n c e fi 1 0 . 7 - 1 2 . 3 (at 2 0 ° C ( 6 8 ° F ) )
S o le n o id re s is ta n c e fi 3 0 - 3 4 (at 2 0 ° C ( 6 8 ° F ) )
Crankshaft position sensor 1 (Ne1, G signal)
T ype Hall e le m e n t p ic k -u p
Volume airflow sensor
T ype M e a su rin g c o re ty p e
F ully c lo s e d 2 0 -6 0 0
E2 » VS
F ully o p e n 2 0 -1 ,0 0 0
E2 « VC 2 0 0 -4 0 0
R e sista n ce fi 1 0 ,0 0 0 - 2 0 ,0 0 0
E2 « T H A -2 0 °C ( -4 °F )
(Inta ke air 2 0 °C [ 6 8 °F ) 2 ,0 0 0 -3 ,0 0 0
te m p e ra tu re sensor) 6 0 °C (1 4 0 °F ) 4 0 0 -7 0 0
-2 0 °C ( -4 °F ) 1 3 .5 -1 6 .5
2 0 °C { 6 8 °F ) 2 .2 0 -2 .7 0
8 0 °C ( 1 7 6 °F ) 0 .2 9 -0 .3 5
R e sista n ce k fi 91 ° C {1 9 6 0 F ) 0 .2 2 6 - 0 .2 4 1
9 7 °C (2 0 7 °F ) 0 .1 9 3 -0 .2 0 5
1 0 8 °C (2 2 6 °F ) 0 . 1 4 5 - 0 .1 5 3
1 1 0 °C (2 3 0 °F ) 0 . 1 3 7 - 0 .1 4 6
Fuel tank
C a p a c ity L { US gal, Im p gal J 5 8 .5 (1 5 .5 , 1 2 .9 )
Air cleaner element
Fuel
S p e c ific a tio n U n le a d e d — (R + M )/2 m e th o d 91 o r h ig h e r
* T E N te rm in a l o f d a ta lin k c o n n e c to r g ro u n d e d
TD TECHNICAL DATA
F3. FUEL AND EMISSION CONTROL SYSTEMS (FS ATX)
Engine
Item FS
Id le s p e e d * 1 rp m 6 5 0 - 7 5 0 (70 0 ± 50)
Ig n itio n tim in g * 1 BT D C 9 - 1 1 ° (10 ± 1 °)
Throttle body
T ype H o rizo n ta l d ra ft
T h ro a t d ia m e te r m m ( in ) 5 5 ( 2 .2 )
Fuel pump
M a x im u m o u tp u t p re s s u re kP a (k g f/c m 2, p s i) 6 4 0 (6 .5 , 9 2 )
Fuel filter
ly p e
H ig h -p re s s u re sid e P a p e r e le m e n t
Pressure regulator
R e g u la tin g p re s s u re kP a ( k g f/c m 2, p s i) 2 6 0 - 3 2 0 ( 2 .6 — 3.2, 3 7 - 4 6 )
Injector
T ype H ig h -o h m ic
T y p e o f d riv e V o lta g e
R e sista n ce ft [2 0 ° C ( 6 8 ° F ) ] 1 2 -1 6
ISC valve (solenoid valve [idle speed control])
R e sista n ce n [2 3 ° C ( 7 3 ° F ) ] 7 .7 — 9 .3
R e sista n ce 0 [2 0 ° C ( 6 8 ° F ) ] 3 0 -3 4
S o le n o id re s is ta n c e ft [2 0 ° C { 6 8 ° F } ] 3 6 .4 -4 2 .9
EGR solenoid valve (Vent and Vacuum)
S o le n o id re s is ta n c e 0 [2 0 ° C ( 6 8 ° F ) ] 3 0 -4 5
Type P h o to d io d e
Mass airflow sensor
Type H o t w ire
-2 0 °C ( -4 °F ) 2 6 3 .1 1 1 - 2 9 0 .8 0 7
2 0 °C ( 6 8 °F ) 3 5 . 4 7 3 - 3 9 .2 0 7
R e sista n ce k fi
6 0 °C (1 4 0 °F ) 7 .1 7 1 -7 .9 2 5
8 0 °C (1 7 6 °F ) 1 .1 3 1 - 1 .2 5 1
Fuel tank
C a p a c ity L {U S gal, Im p g a l) 5 8 .5 (1 5 .5 , 1 2 .9 )
Air cleaner element
Fuel
S p e c ific a tio n U n le a d e d — (R + M )/2 m e th o d 8 7 o r h ig h e r
R e m o v e th e s h o rtin g b a r fro m th e d o u b le w ire S P O U T c o n n e c to r
TECHNICAL DATA TD
G. ENGINE ELECTRICAL SYSTEM
D a rk c u rre n t* M ax. 20
T ype A .C .
O u tp u t V-A 12-80 12-90
R e g u la to r ty p e IC re g u la to r, in a lte rn a to r
R e g u la te d v o lta g e 1 4 .1 — 14.7
S ta n d a rd 2 1 .5 ( 0 .8 5 )
M in im u m 8 .0 (0 .3 1 ]
A lte rn a to r S ta n d a rd fo rc e 3 .1 4 - 4 .3 1 ( 3 2 0 -4 4 0 , 1 1 .3 -1 5 .5 )
B ru s h s p rin g N (g f, o z )
M in im u m 1 .5 7 -2 .3 5 (1 6 0 - 2 4 0 , 5 .6 5 -8 .4 7 )
5 .5 — 6 .5 ( 0 . 2 2 - 0 . 2 6 ) * 3
New 6 .5 — 7 .0 ( 0 . 2 6 - 0 . 2 8 )
6 .0 — 7 .0 (0 .2 4 — 0 .2 8 )
Drive belt deflection mm (in )
6 .5 — 7 .5 ( 0 .2 5 — 0 .2 9 )
/9 .8 N ( (10 kgf, 22 Ibf) U se d 7 .0 — 9 .0 ( 0 . 2 7 - 0 . 3 5 )
7 .0 — 8 .0 ( 0 . 2 7 - 0 . 3 1 )
L im it 10 ( 0 .3 9 ) 8 .0 (0.3 1 ) * 3, 9 .0 ( 0 .3 5 )
T ype C o a xia l re d u c tio n R e d u ctio n
O u tp u t V-kW 12-1.4 12-1.7 12- 1.6
S ta n d a rd 17.5 ( 0 .6 9 ) 17 .0 ( 0 .6 7 )
M in im u m 12 ( 0 .4 7 ) 11 .5 ( 0 .4 5 )
1 6 .7 -2 2 .5 1 6 .3 -2 1 .9
1 7 .6 -2 3 .6
S ta n d a rd (1 .7 0 - 2 .3 0 , ( 1 . 6 6 - 2 .2 4 ,
Brush balance N (kg f, Ibf) [ 1 . 7 9 - 2 . 4 1 , 3 .9 4 — 5 .3 0 )
S ta rte r 3 .7 4 -5 .0 6 ) 3 .6 6 -4 .9 2 )
M a x im u m 6 .9 (0 .7 , 1 .5 ) 9.32 (0.95, 2.09) 8 8 (0 .9 , 2 .0 )
run o u t Runout 0 .0 5 ( 0 .0 0 2 )
m m ( in ) M a x im u m 0.1 ( 0 .0 0 4 )
A rm a tu re M in im u m d ia m e c e r m m ( in ) 2 8 .8 ( 1 .1 3 ) 3 1 .4 ( 1 .2 4 )
Segment groove D e p rh 0 .4 — 0 .6 (0 .0 1 6 — 0 .0 2 3 )
depth mm (in) M in im u m 0 .2 ( 0 .0 0 8 )
S p a rk a d v a n c e ty p e E le ctro n ic s p a rk a d v a n c e (ESA)
D is trib u to r ---------------------------------------------- r?------
T ype H all effect, P h o to d io d e *
Ig n itio n tim in g BT D C
1 1 -1 3 ° 9 -1 1 °
(TE N te rm in a l o f d a ta lin k c o n n e c to r g ro u n d e d )
P rim a ry coil
w in d in g ( f l) 0 . 5 8 - 0 . 8 6 , 0 .7 *
R e sista n ce
Ignition coil
(2 0 °C (6 8 ° F )) S e c o n d a ry co il
1 1 . 5 - 1 8 . 5 , 8 .5 3 *
w in d in g |k 0 )
NGK B K R 5 E -1 1 * 2 B K R 6 E -1 1 Z F R 5 F -1 1 *2 Z F R 6 F -1 1
Type
S p a rk p lu g N IP P O N D E N S O K 1 6 P R -U 1 1 * 2 K 2 0 P R -U 1 1
P lu g g a p m m ( in ) 1 .0 -1 .1 (0 .0 3 9 -0 .0 4 3 )
F irin g o rd e r 1 -3 -4 -2 1— 2 — 3 — 4 — 5—6
D a rk c u rre n t is th e c o n s ta n t flo w o f c u rre n t w h ile th e ig n itio n is O FF (i.e., a u d io unit, c lo c k , etc.)
2 S ta n d a rd p lu g
* 3 A lte rn a to r + A /C
* 4 FS e n g in e [A T X ] o n ly
TD TECHNICAL DATA
H. CLUTCH
--------------------- - Engine/T ransaxle FS KL

Item -------- ------- G25 M-R
C lu tc h c o n tro l H y d i a u lic
Clutch pedal
Type S u sp e n d e d
P e d a l ra tio m m ( in ) 6 .5 5
Full s tro k e m m ( in ) 135 ( 5 .3 1 )
H e ig h t m m ( in ) 1 8 6 -2 1 1 ( 7 . 3 2 - 8 . 3 1 ) (with ca rp e t)
F re e p la y m m [in } 5 -1 4 ( 0 .2 -0 .5 5 )
D o s ta n c e to c a rp e t w h e n c lu tc h fu lly . . . .____
6 7 ( 2 .6 4 )
d is e n g a g e d m m ( in ) M in im u m
Flywheel
R u n o u t lim it m m ( in ) 0 .2 0 0 (0 .0 0 7 9 )
Clutch disc
T ype S in g le d ry plate
R u n o u t lim it m m ( in ) 0 .7 0 0 (0 .0 2 7 6 )
W e a r lim it m m ( in ] 0 .3 ( 0 .0 1 2 ) fro m rive t h ead
O u te r d ia m e te r m m ( in ) 2 2 5 ( 8 .8 6 )
In n e r d ia m e te r m m ( in ) 150 ( 5 .9 1 )
F lyw h e e l sid e 3 .5 ( 0 .1 4 )
F a c in g th ic k n e s s m m ( in )
P re ssu re p la te sid e 3 .8 ( 0 .1 5 )
Clutch cover
Type D ia p h ra g m s p rin g
S e t lo a d N (k g f, Ib f) 4 ,6 1 0 (4 7 0 , 1 ,0 3 0 ) 5 ,2 0 0 (5 3 0 , 1 ,1 7 0 )
Clutch fluid
Type F M V S S 116 D O T-3
J. MANUAL TRANSAXLE
------------------ Engine
Item FS KL
Specification
T ra n s a x le ty p e G 2 5 M -R
T ra n s a x le sh ift c o n tro l Rod
F o rw a rd : S yn ch ro m e sh
S y n c ro m e s h syste m
R e ve rse : S e le ctive s lid in g a n d s y n c h ro m e s h
1st 3 .3 0 7
2nd 1.833
3 rd 1 .2 33 1 .3 10
G e a r ratio
4 th 0 .9 1 4 1 .0 30
5th 0 .7 1 7 0 .7 9 5
R everse 3 .1 6 6
Final g e a r ratio 4 .1 0 5
S p e e d o m e te r g e a r ratio (D rive n g e a r/d riv e ge a r) 0 .8 4 0 (21/25)
G ra d e API se rvice G L -4 o r G L -5
All-season: SAE 75 W -9 0
Oil V is c o c ity
A b o v e 1 0 °C ( 5 0 ° F ) : SAE 8 0 W -9 0
C a p a c ity L (U S qt, Im p q t) 2 .7 (2 .9 , 2 .4 )
Runout
P rim a ry s h a ft g e a r ru n o u t m m ( in ) 0 .0 5 0 (0 .0 0 2 0 )
S e c o n d a ry sh a ft g e a r ru n o u t m m ( in ) 0 .0 1 5 (0 .0 0 0 6 )
TECHNICAL DATA TD
Engine FS KL
Clearance
1 st (G e a r in n e r d ia . -sha ft o u te r d ia) m m ( in ) 0 . 0 3 0 - 0 . 0 8 0 ( 0 .0 0 1 2 - 0 . 0 0 3 1 )
2 n d (G e a r in n e r d ia . -shaft o u te r d ia) m m ( in ) 0 .0 3 0 -0 .0 8 0 (0 .0 0 1 2 -0 .0 0 3 1 )
3 rd (G e a r in n e r d ia . -sha ft o u te r dia) m m ( in ) 0 .0 3 0 -0 .0 8 0 (0 .0 0 1 2 -0 .0 0 3 1 )
4 th (G e a r in n e r dia. -sha ft o u te r dia) m m ( in ) 0 .0 3 0 -0 .0 8 0 (0 .0 0 1 2 -0 .0 0 3 1 )
5 th (G e a r in n e r d ia . -sha ft o u te r dia) m m ( in ) 0 .0 3 0 -0 .0 8 0 (0 .0 0 1 2 -0 .0 0 3 1 )
1 -2 sh ift fo rk a n d re ve rse g e a r S ta n d a rd 0 .1 0 -0 .4 5 (0 .0 0 4 -0 .0 1 8 )
m m ( in ) W e a r lim it 0 .9 5 ( 0 .0 3 7 )
3-4 sh ift fo rk a n d c lu tc h h u b sle e ve S ta n d a rd 0 . 1 0 - 0 . 4 0 (0 .0 0 4 — 0 .0 1 6 )
m m ( in ) W e a r lim it 0 .9 0 ( 0 .0 3 5 )
5 th sh ift fo rk a n d c lu tc h h u b sleeve S ta n d a rd 0 .1 0 -0 .3 6 (0 .0 0 4 -0 .0 1 4 )
m m ( in ) W e a r lim it 0 .8 6 ( 0 .0 3 4 )
S ta n d a rd 1.50 ( 0 .0 5 9 )
S y n c ro n iz e r rin g a n d g e a r m m ( in )
W e a r lim it 0 .8 0 ( 0 .0 3 1 )
R e ve rse id le g e a r a n d re v e rs e lever S ta n d a rd 0 .1 0 -0 .3 5 (0 .0 0 4 -0 .0 1 4 )
m m ( in ) W e a r lim it 0 .8 5 ( 0 .0 3 3 )
Thrust clearance
S ta n d a rd 0 .0 5 -0 .2 8 (0 .0 0 2 -0 .0 1 1 )
1st g e a r m m ( in )
Lim it 0 .3 3 ( 0 .0 1 3 )
S ta n d a rd 0 .1 8 -0 .4 6 (0 .0 0 7 -0 .0 1 8 )
2nd gear m m ( in )
Lim it 0.51 ( 0 .0 2 0 )
S ta n d a rd 0 .0 5 -0 .2 0 (0 .0 0 2 -0 .0 0 8 )
3 rd g e a r m m ( in )
Lim it 0 .2 5 ( 0 .0 1 0 )
S ta n d a rd 0 .1 7 -0 .3 7 (0 .0 0 7 -0 .0 1 5 )
4 th g e a r m m ( in )
Lim it 0 .4 2 ( 0 .0 1 7 )
S ta n d a rd 0 . 1 0 0 - 0 . 2 2 0 ( 0 .0 0 3 9 - 0 .0 0 8 7 )
5 th g e a r m m ( in )
Lim it 0 .2 7 0 (0 .0 1 0 6 )
S ta n d a rd 0 -0 .0 5 (0 -0 .0 0 2 )
0 .2 0 ( 0 .0 0 8 ) , 0 .2 5 ( 0 .0 1 0 ) , 0 .3 0 ( 0 .0 1 2 ) , 0 .3 5 ( 0 .0 1 4 ) ,
P rim a ry s h a ft g e a r m m ( in )
Adjustment shims 0 .4 0 ( 0 .0 1 6 ) , 0 .4 5 ( 0 .0 1 8 ) , 0 .5 0 ( 0 .0 2 0 ) , 0 .5 5 ( 0 .0 2 2 ) ,
0 .6 0 ( 0 .0 2 4 ) , 0 .6 5 ( 0 .0 2 6 ) , 0 .7 0 ( 0 .0 2 8 )
S ta n d a rd 0 .0 3 -0 .0 8 (0 .0 0 1 -0 .0 0 3 )
0 .2 0 ( 0 .0 0 8 ) , 0 .2 5 ( 0 .0 1 0 ) , 0 .3 0 ( 0 .0 1 2 ) , 0 .3 5 ( 0 .0 1 4 ) ,
S e c o n d a ry sh a ft g e a r m m ( in )
Adjustment shims 0 .4 0 ( 0 .0 1 6 ) , 0 .4 5 ( 0 .0 1 8 ) , 0 .5 0 ( 0 .0 2 0 ) , 0 .5 5 ( 0 .0 2 2 ) ,
0 .6 0 ( 0 .0 2 4 ) , 0 .6 5 ( 0 .0 2 6 ) , 0 .7 0 (0 .0 2 8 )
Bearing preload
B e a rin g p re lo a d
1 .4 — 2 .0 ( 1 4 — 20, 1 3 - 1 7 )
N m tkg f-cm , in lb f)
0 .1 0 ( 0 .0 0 4 ) , 0 .2 0 ( 0 .0 0 8 ) , 0 .2 5 ( 0 .0 1 0 ) , 0 .3 0 ( 0 .0 1 2 ) ,
0 .3 5 ( 0 .0 1 4 ) , 0 .4 0 ( 0 .0 1 6 ) , 0 .4 5 ( 0 .0 1 8 ) , 0 .5 0 ( 0 .0 2 0 ) ,
D iffe re n tia l s id e b e a rin g p re lo a d
A d ju s tm e n t shim s 0 .5 5 ( 0 .0 2 2 ) , 0 .6 0 ( 0 .0 2 4 ) , 0 .6 5 ( 0 .0 2 6 ) , 0 .7 0 ( 0 .0 2 8 ) ,
m m ( in ) 0 .7 5 ( 0 .0 3 0 ) , 0 .8 0 ( 0 .0 3 1 ) , 0 .8 5 ( 0 .0 3 3 ) , 0 .9 0 ( 0 .0 3 5 ) ,
0 .9 5 ( 0 .0 3 7 ) , 1 .0 0 ( 0 .0 3 9 ) , 1.05 ( 0 .0 4 1 ) , 1 .1 0 ( 0 .0 4 3 ) ,
0 .1 5 ( 0 .0 4 5 ) , 1.20 ( 0 .0 4 7 )
Differential
B a c k la s h o f s id e g e a r a n d p in io n
S ta n d a rd m m ( in ) 0 .0 5 0 -0 .1 5 0 (0 .0 0 2 0 -0 .0 0 5 9 )
gear
TD TECHNICAL DATA
K1. AUTOMATIC TRANSAXLE
Engine/Transaxle KL
Item GF4A-EL
T o rq u e c o n v e rte r stall to rq u e ratio 2.0 5
1st g e a r 2 .8 0 0
2nd gear 1 .5 40
G e a r ratio T h ird g e a r 1 .0 0 0
F ou rth g e a r 0 .7 0 0
R everse 2 .3 3 3
T yp e D e xro n ® n o r M -III
C a p a c ity
(ATF) 8 .8 (9 .3 , 7 .7 )
B a n d s e rv o (p is to n o u te r d ia /re ta in e r in n e r dia) m m ( in ) 7 8 .0 /4 0 .0 (3 .0 7 /1 .5 7 )
L a rg e sun g e a r 36
S m all sun g e a r 30
iN u m u e i u i p ia n tfic u y yew i
L o n g p in io n g e a r 24
S h o rt p in io n g e a r 22
In te rn a l g e a r 84
N u m b e r o f o u tp u t g e a r te e th 19
N u m b e r o f id le g e a r teeth 42
N u m b e r o f rin g g e a r teeth 79
E n g in e stall s p e e d rp m D, S, L a n d R ra n g e s 2 ,2 7 0 -2 ,5 0 0
N -> D ra n g e A p p ro x . 0 .9 m ax.
T im e la g sec.
N -> R ra n g e A p p ro x . 1.1 m ax.
D, S a n d L ra n g e s 4 2 0 - 5 3 0 ( 4 .2 — 5.5, 6 0 - 7 8 )
A t id le
L in e p re s s u re R ra n g e 7 3 0 -1 ,0 1 0 (7 .4 - 1 0 .3 , 1 1 0 -1 4 6 )
kPa (k g f/c m 2, psi) D, S a n d L ra n g e s 1 ,1 0 0 -1 ,1 7 0 ( 1 1 .2 - 1 2 .0 , 1 6 0 - 1 7 0 )
A t stall
R ra n g e 1 ,9 1 0 -2 ,0 3 0 ( 1 9 .4 - 2 0 .7 , 2 7 6 - 2 9 4 )
S o le n o id re d u c in g p re s s u re kPa k g f/c m 2, p s i) 3 6 0 -4 0 0 ( 3 .6 -4 .1 , 5 2 - 5 8 )
O u te r a n d in n e r ro to r S ta n d a rd 0 . 0 2 - 0 . 0 4 ( 0 .0 0 0 8 - 0 .0 0 1 5 )
c le a ra n c e m m ( in ) M a x im u m 0 .0 5 (0 .0 0 1 9 )
S p o o l o u te r d ia m e te r S ta n d a rd 1 3 .9 7 0 - 1 3 .9 8 0 ( 0 . 5 5 0 0 - 0 . 5 5 0 3 )
O il p u m p m m ( in ) M in im u m 1 3 .9 7 0 (0 .5 5 0 0 )
C le a ra n c e b e tw e e n th e S ta n d a rd 0 .0 4 0 -0 .1 1 5 (0 .0 0 1 6 -0 .0 0 4 5 )
oil p u m p b o ss a n d th e
in n e r ro te r m m ( in ) M a x im u m 0 .1 2 5 (0 .0 0 4 9 )
N u m b e r of d riv e /d riv e n plates 4 /4
D riv e p la te th ic k n e s s S ta n d a rd 1.6 ( 0 .0 6 3 )
m m ( in ) M in im u m 1.4 ( 0 .0 5 5 )
3 -4 c lu tc h
3 -4 c lu tc h c le a ra n c e m m ( in ) 1 .3 -1 .5 (0 .0 5 1 -0 .0 5 9 )
3 .8 ( 0 .1 5 ) , 4 .0 ( 0 .1 6 ) , 4 .2 ( 0 .1 7 ) ,
R e ta in in g p la te size m m ( in )
4 .4 ( 0 .1 7 ) , 4 .6 ( 0 .1 8 ) , 4 .8 ( 0 .1 9 )
N u m b e r o f d riv e /d riv e n plates 3 /3
D riv e p la te th ic k n e s s S ta n d a rd 1.6 (0 .0 6 3 )
m m ( in ) M in im u m 1.4 (0 .0 5 5 )
F o rw a rd c lu tc h
F o rw a rd c lu tc h c le a ra n c e m m ( in ) 1 .0 -1 .2 (0 .0 3 9 -0 .0 4 7 )
2 .0 0 ( 0 .0 7 9 ) , 2 .1 5 ( 0 .0 8 5 ) , 2 .3 0 ( 0 .0 9 1 ) ,
S n a p rin g size m m ( in )
2 .4 5 ( 0 .0 9 7 ) , 2 .6 0 ( 0 .1 0 2 ) , 2 .7 5 ( 0 .1 0 8 )
N u m b e r o f d riv e /d riv e n p la te s 2 /3
m m ( in ) M in im u m 1.4 ( 0 .0 5 5 )
C o a s tin g c lu tc h
C o a s tin g c lu tc h c le a ra n c e m m ( in ) 1 .0 -1 .2 (0 .0 3 9 -0 .0 4 7 )
1.50 ( 0 .0 5 9 ) , 1.65 ( 0 .0 6 5 ) , 1 .8 0 ( 0 .0 7 1 ) ,
1.9 5 ( 0 .0 7 7 ) , 2 .1 0 ( 0 .0 8 3 ) , 2 .2 5 ( 0 .0 8 9 )
TECHNICAL DATA TD
Engine/Transaxle KL
GF4A-EL
N u m b e r o f d riv e /d riv e n p la te s 2/2
m m { in ) M in im u m 1.4 ( 0 .0 5 5 )
R e ve rse c lu tc h
R e v e rs e c lu tc h c le a ra n c e m m { in ) 1 .5 -1 .8 (0 .0 5 9 -0 .0 7 1 )
2.0 (0 .0 7 9 ), 2.2 (0 .0 8 7 ), 2.4 (0 .0 9 4 ),
2.6 ( 0 . 102 ) , 2.8 ( 0 . 110 )__________________
D rive p la te th ic k n e s s S ta n d a rd 1.6 ( 0 .0 6 3 )
L o w a n d re ve rse m m ( in ) M in im u m 1.4 ( 0 .0 5 5 )
b ra k e
Low and reverse brake clearance m m ( in ) 1 .5 -1 .8 (0 .0 5 9 -0 .0 7 1 )
Retai n in g p la te size m m ( in ) 7 .0 ( 0 .2 7 6 ) , 7 .2 ( 0 .2 8 3 ) , 7.4 ( 0 .2 9 1 ) , 7 .6 ( 0 .2 9 9 )
C le a ra n c e b e tw e e n
C a rrie r h u b p in io n w a s h e r a n d M a xim u m 0 .2 — 0 .7 ( 0 . 0 0 8 - 0 . 0 2 8 )
p la n e t c a rrie r mm in
B u s h in g in n e r
S u n g e a r d ru m M a xim u m 3 3 .4 ( 1 .3 1 )
d ia m e te r m m ( in )
B u s h in g in n e r
S m all su n g e a r M a x im u m 2 4 .0 ( 0 .9 4 5 )
d ia m e te r m m ( in )
Torque converter
S ta n d a rd 5 3 .0 3 0 (2 .0 8 7 8 )
B u s h in g in n e r d ia m e te r m m ( in )
M a xim u m 5 3 .0 7 5 (2 .0 8 9 6 )
Gear assembly
T ota l e n d p la y m m ( in ) 0 . 2 5 - 0 . 5 0 (0 .0 1 0 — 0 .0 2 0 )
1.2 ( 0 .0 4 7 ) , 1.4 ( 0 .0 5 5 ) , 1.6 ( 0 .0 6 3 ) ,
E n d p la y a d ju s t ra c e m m ( in )
1.8 ( 0 .0 7 1 ) , 2 .0 ( 0 .0 7 8 ) , 2 .2 ( 0 .0 8 7 )
Id le g e a r b e a rin g p re lo a d N-m (k g fc m , in-lbf) 0 .0 3 — 0 .8 8 ( 0 .3 — 9.0, 0 . 3 - 7 . 8 )
4 .5 40 (0 .1 7 9 ), 4.575 (0 .1 8 0 ), 4.610 (0 .1 8 1 ), 4.645 (0 .1 8 3 ),
4.680 ( 0 .1 8 4 ), 4.715 (0 .1 8 6 ), 4.750 (0 .1 8 7 ), 4.785 (0 .1 8 8 ),
4 .8 20 (0 .1 9 0 ), 4.855 (0 .1 9 1 ), 4.890 (0 .1 9 3 ), 4 .9 25 (0 .1 9 4 ),
P re lo a d a d ju s t s p a c e rs m m ( in )
4 .9 60 (0 .1 9 5 ), 4.995 (0 .1 9 7 ), 5.030 (0 .1 9 8 ), 5.065 (0 .1 9 9 ),
5 .100 ( 0 .2 0 1 ), 5.135 (0 .2 0 2 ), 5.170 (0 .2 0 4 ), 5.205 (0 .2 0 5 ),
5 .240 (0 .2 0 6 ), 5.275 (0 .2 0 8 ), 5.310 (0 .2 0 9 ) _______________
O u tp u t g e a r b e a rin g p re lo a d N-m (kgf-cm , in-lbf) 1 .1 -1 .9 ( 1 1 - 2 0 , 1 0 -1 7 )
0 .3 5 0 (0 0138 0 .3 7 5 (0 .0 1 4 8 ) 0 .4 0 0 (0 .0 1 5 7 )
0 .4 2 5 (0 0167 0 .4 5 0 (0 .0 1 7 7 ) 0 .4 7 5 (0 .0 1 8 7 )
0 .5 0 0 (0 0197 0 .5 2 5 (0 .0 2 0 7 ) 0 .5 5 0 (0 .0 2 1 7 )
0 .5 7 5 (0 0226 0 .6 0 0 (0 .0 2 3 6 ) 0 .6 2 5 (0 .0 2 4 6 )
0 .6 5 0 (0 0256 0 .6 7 5 (0 .0 2 6 6 ) 0 .7 0 0 (0 .0 2 7 6 )
0 .7 2 5 (0 0285 0 .7 5 0 (0 .0 2 9 5 ) 0 .7 7 5 (0 .0 3 0 5 )
0 .8 0 0 (0 0315 0 .8 2 5 (0 .0 3 2 5 ) 0 .8 5 0 (0 .0 3 3 5 )
P re lo a d a d ju s t sh im s mm in 0 .8 7 5 (0 0344 0 .9 0 0 (0 .0 3 5 4 ) 0 .9 2 5 (0 .0 3 6 4 )
0 .9 5 0 (0 0374 0 .9 7 5 (0 .0 3 8 4 ) 1.000 (0 .0 3 9 4 )
1 .0 2 5 (0 0404 1 .0 50 (0 .0 4 1 3 ) 1 .0 75 (0 .0 4 2 3 )
1.100 (0 0 4 3 3 1 .1 25 (0 .0 4 4 3 ) 1 .1 50 (0 .0 4 5 3 )
1 .1 7 5 (0. 0 4 6 3 1.200 (0 .0 4 7 2 ) 1.225 (0 .0 4 8 2 )
1 .2 5 0 (0. 0 4 9 2 1 .2 75 (0 .0 5 0 2 ) 1 .3 00 (0 .0 5 1 2 )
1 .3 2 5 (0. 0 5 2 2 1 .3 5 0 (0 .0 5 3 1 ) 1.375 (0 .0 5 4 1 )
1 .4 0 0 (0. 0551
Differential
B e a rin g p re lo a d N-m (k g fc m , in -lb f) 3 .0 — 3 .9 ( 3 0 - 4 0 , 2 7 - 3 4 )
0 .1 0 ( 0 .0 0 4 ) , 0 .1 5 ( 0 .0 0 6 ) , 0 .2 0 ( 0 .0 0 8 ) , 0 .2 5 ( 0 .0 1 0 ) ,
0 .3 0 ( 0 .0 1 2 ) , 0 .3 5 ( 0 .0 1 4 ) , 0 .4 0 ( 0 .0 1 6 ) , 0 .4 5 ( 0 .0 1 8 ) ,
0 .5 0 ( 0 .0 2 0 ) , 0 .5 5 ( 0 .0 2 2 ) , 0 .6 0 ( 0 .0 2 4 ) , 0 .6 5 ( 0 .0 2 6 ) ,
P re lo a d a d ju s t sh im s m m ( in )
0 .7 0 ( 0 .0 2 8 ) , 0 .7 5 ( 0 .0 3 0 ) , 0 .8 0 ( 0 .0 3 1 ) , 0 .8 5 ( 0 .0 3 3 ) ,
0 .9 0 ( 0 .0 3 5 ) , 0 .9 5 ( 0 .0 3 7 ) , 1.00 ( 0 .0 3 9 ) , 1.0 5 ( 0 .0 4 1 ) ,
1 .1 0 ( 0 .0 4 3 ) , 1.15 ( 0 .0 4 5 ) , 1.20 (0 .0 4 7 )________________
S ta n d a rd 0 .0 5 - 0 .1 5 (0 .0 0 2 0 -0 .0 0 5 9 )
B a c k la s h o f s id e g e a r a n d p in io n m m ( in )
Maximum 0.50 ( 0 .0 2 0 )
TD TECHNICAL DATA
-- -------------------- - Engine/T ransaxle KL

Item ------------------------ GF4A-EL
Note
H e ig h t d iffe re n c e b e tw e e n th e re ve rse a n d fo rw a rd d ru m
0 . 7 - 1 . 9 { 0 . 0 2 8 - 0 . 0 7 5 } m ax.
a n d th e tra n s a x le c a s e m m ( in )
D is ta n c e A b e tw e e n th e e n d o f th e to rq u e c o n v e rte r a n d
14 .0 ( 0 .5 5 1 )
th e fa c e o f th e c o n v e rte r h o u s in g m m ( in )
Spring specifications
Outer diameter Free length Wire diameter Identification
Spring name No. of coils
mm (in) mm {in} mm {in} color
Premain control valve body
P re ssu re m o d ifie r a c c u m u la to r
8 .2 { 0 .3 2 } 3 8 .2 { 1 .5 0 } 16.5 1.2 { 0 .0 4 7 } L ig h t g re e n
s p rin g
3 -2 tim in g s p rin g 8 .2 5 { 0 .3 2 5 } 3 5 .4 { 1 .3 9 4 } 12.5 0 .8 5 { 0 .0 3 3 } L ig h t b lu e
C u t b a c k s p rin g 8 .2 { 0 .3 2 } 2 9 .8 { 1 .1 7 } 7 .4 0 .6 { 0 .0 2 } P u rp le
B y p a s s s p rin g 6 .3 { 0 .2 5 } 2 9 .5 { 1 .1 6 } 11.7 0 .6 { 0 .0 2 } D a rk g re e n
Sm all 1 4 .8 { 0 .5 8 3 } 8 1 .6 { 3 .2 1 } 17.7 1.7 { 0 .0 6 7 } G ray
1-2 a c c u m u la to r s p rin g
L a rg e 2 0 .2 { 0 .7 9 5 } 8 1 .6 { 3 .2 1 } 12.5 2 .3 { 0 . 0 9 1 } D a rk g re e n
N -D a c c u m u la to r s p rin g 9 .8 { 0 .3 9 } 5 2 .9 { 2 .0 8 } 12.0 1.0 { 0 .0 3 9 } W h ite
Sm all 7 .2 { 0 .2 8 } 60.1 { 2 .3 7 } 2 6 .2 1.0 { 0 .0 3 9 } —
N -R a c c u m u la to r s p rin g
L a rg e 11 .2 { 0 .4 4 1 } 5 6 .0 { 2 .2 0 } 15.2 1.6 { 0 .0 6 3 } —
Main control valve body
C o n v e rte r relief s p rin g 7 .4 { 0 .2 9 } 3 2 .3 { 1 .2 7 } 13.5 1.1 { 0 .0 4 3 } L ig h t b lu e
S o le n o id re d u c in g s p rin g 8 .0 { 0 .3 1 } 3 9 .7 { 1 .5 6 } 1 2 .0 0 .9 { 0 .0 3 } Red
L o w re d u c in g s p rin g 8 .7 { 0 .3 4 } 3 8 .3 { 1 .5 1 } 12.5 0 .9 { 0 .0 3 } Y e llo w
1-2 sh ift s p rin g 7 .4 { 0 .2 9 } 3 6 .6 { 1 .4 4 } 1 2 .0 0 .8 { 0 .0 3 1 } P u rp le
2 -3 sh ift s p rin g 7 .4 { 0 .2 9 } 3 6 .6 { 1 .4 4 } 12.0 0 .8 { 0 .0 3 1 } P u rp le
C o a s t tim in g s p rin g 6 .2 { 0 .2 4 } 2 8 .0 { 1 .1 0 } 16.0 0 .6 { 0 .0 2 } L ig h t b lu e
L o c k u p sh ift s p rin g 6 .0 { 0 .2 4 } 4 0 .0 { 1 .5 7 } 13.8 0 .5 { 0 .0 2 } W hite
3 -4 sh ift s p rin g 7 .4 { 0 .2 9 } 3 6 .6 { 1 .4 4 } 12.0 0 .8 { 0 .0 3 1 } P u rp le
Rear control valve body
P re ssu re re g u la to r s p rin g 1 2 .0 { 0 .4 7 2 } 3 3 .9 { 1 .3 4 } 7 .0 1.1 { 0 .0 4 3 } —
L o c k u p c o n tro l s p rin g 5 .8 { 0 .2 3 } 33.1 { 1 .3 0 } 12.6 0 .5 5 { 0 .0 2 2 } W hite
2 -3 tim in g s p rin g 4 .7 { 0 .1 9 } 2 2 .3 { 0 .8 7 8 } 14.0 0 .6 5 { 0 .0 2 6 } W h ite
Oil pump
S p rin g 13 .0 { 0 .5 1 2 } 5 3 .0 { 2 .0 9 } 1 2 .0 1.2 { 0 .0 4 7 } —
3-4 clutch
R e tu rn s p rin g 8 3 .3 { 3 .2 8 } 4 3 .5 { 1 .7 1 } 1.0 5 .5 { 0 .2 2 } —
Low and reverse brake
S p rin g — 2 1 .5 {0 .8 4 6 } — — —
2-4 brake band
S e rvo re tu rn s p rin g 2 7 .7 { 1 .0 9 } 3 9 .3 { 1 .5 5 } 3.8 3 .5 { 0 .1 4 } —
2-3 accumulator
2 -3 a c c u m u la to r s p rin g 1 1 .5 { 0 .4 5 3 } 7 7 .7 { 3 .0 6 } 2 3 .3 1.4 { 0 .0 5 5 } P ink
Orifice check spring
O rific e c h e c k s p rin g 8 .0 { 0 .3 1 5 } 15 .4 {0 .6 0 6 } 5.7 0 .4 { 0 .0 1 6 } —
Coasting clutch
S p rin g 2 0 .6 {0 .8 1 1 } — —
TECHNICAL DATA TD
Vehicle Speed Shiftpoint Table (KL)
Throttle condition
Vehicle speed km/h
Range Mode (Throttle sensor Shift Drum speed rpm
[m ph)
voltage)
D 1- D 2 6 ,0 0 0 - 6 , 6 5 0 5 7 -6 3 (3 5 -3 9 )
F ully o p e n (3 .0 — 4.4V ) D 2->D 3 5 , 7 5 0 - 6 ,2 0 0 9 9 -1 0 7 (6 1 -6 6 )
D 3 -»D 4 6 ,1 0 0 -6 ,5 0 0 1 6 2 -1 7 2 (1 0 0 -1 0 7 )
D 1-+D 2 4 ,2 0 0 -5 ,1 5 0 4 0 - 4 9 (2 5 — 3 0 )
H a lf th ro ttle D 2-+D 3 4 , 0 0 0 - 5 ,0 5 0 6 9 -8 7 (4 3 -5 4 )
Power
D 3->D 4 4 , 3 0 0 - 5 ,2 5 0 1 1 4 -1 3 9 ( 7 1 - 8 6 )
D 4-+D 3 3 0 0 -4 5 0 1 1 -1 7 (7 -1 1 )
F ully c lo s e d (0 .1 - 1 . 1 V )
D3-+D1 4 0 0 -6 5 0 1 1 -1 7 (7 -1 1 )
D 4-»D 3 3 ,5 5 0 -3 ,8 0 0 1 3 5 -1 4 5 ( 8 4 - 9 0 )
K ic k d o w n D 3-+D 2 3 , 2 5 0 - 3 ,5 5 0 8 6 -9 4 (5 3 -5 8 )
D 2 -D 1 2 , 5 5 0 - 2 ,9 0 0 4 4 -5 0 (2 7 -3 1 )
D 1 -D 2 6 , 0 0 0 - 6 ,6 5 0 5 7 -6 3 (3 5 -3 9 )
D
D 2 -»D 3 5 , 7 5 0 - 6 ,2 0 0 9 9 -1 0 7 (6 1 -6 6 )
F u lly o p e n (3 .0 — 4.4 V )
D 3->D 4 6 , 1 0 0 - 6 ,5 0 0 1 6 2 -1 7 2 (1 0 0 -1 0 7 )
‘ L o c k u p O N (D 4) 3 , 8 5 0 - 4 ,1 5 0 1 4 7 -1 5 7 ( 9 1 - 9 7 )
D 1- D 2 3 , 5 0 0 - 4 ,3 0 0 3 3 -4 1 (2 0 -2 5 )
D 2- D 3 3 , 1 5 0 - 4 ,0 0 0 5 4 - 6 9 (3 3 — 4 3 )
Normal
H a lf th ro ttle
D 3->D 4 3 , 5 0 0 - 4 ,5 0 0 9 3 -1 2 0 (5 8 -7 4 )
’ L o c k u p O N (D 4) 3 , 2 5 0 - 3 ,9 5 0 1 2 4 -1 4 9 ( 7 7 - 9 2 )
D 4->D 3 3 0 0 -4 5 0 1 1 - 1 7 (7 — 11)
F u lly c lo s e d (0 .1 — 1.1V)
D3- D 1 4 0 0 -6 5 0 1 1 -1 7 (7 - 1 1 )
D4 - D 3 3 ,5 5 0 -3 ,8 0 0 1 3 5 — 145 ( 8 4 - 9 0 )
K ic k d o w n D 3- D 2 3 , 2 5 0 - 3 ,5 5 0 8 6 -9 4 (5 3 -5 8 )
D 2- D 1 2 , 5 5 0 - 2 ,9 0 0 4 4 -5 0 (2 7 -3 1 )
S 1- S 2 6 , 0 0 0 - 6 ,6 5 0 5 7 -6 3 (3 5 -3 9 )
F ully o p e n (3 .0 — 4.4V ) S2-»S3 5 ,7 5 0 -6 ,2 0 0 9 9 -1 0 7 (6 1 -6 6 )
‘ L o c k u p O N (S3) 4 ,0 5 0 -4 ,3 5 0 1 0 8 -1 1 6 ( 6 7 - 7 2 )
S 1- S 2 4 , 2 0 0 - 5 ,1 5 0 4 0 -4 9 (2 5 -3 0 )
H a lf th ro ttle S 2 -*S 3 4 ,0 0 0 — 5 ,0 5 0 6 9 -8 7 (4 3 -5 4 )
S
‘ L o c k u p O N (S3) 3 ,9 0 0 -4 ,3 5 0 1 0 4 -1 1 6 ( 6 4 - 7 2 )
S4(D4)->S3 4 , 2 5 0 - 4 ,4 5 0 1 6 2 -1 6 8 (1 0 0 -1 0 4 )
F u lly c lo s e d (0 .1 — 1.1V)
S 3 -* S l 4 0 0 -6 5 0 1 1 -1 7 (7 - 1 1 )
S3->S2 3 , 2 5 0 - 3 ,5 5 0 8 6 -9 4 (5 3 -5 8 )
K ic k d o w n
S2 - S 1 2 , 5 5 0 - 2 ,9 0 0 4 4 -5 0 (2 7 -3 1 )
F ully o p e n (3 .0 — 4.4V ) L 1 -*L 2 6 , 0 0 0 - 6 ,6 5 0 5 7 -6 3 (3 5 -3 9 )
H a lf th ro ttle L i -* L 2 4 ,2 0 0 -5 ,1 5 0 4 0 - 4 9 (2 5 — 3 0 )
L
F u lly c lo s e d (0 .1 — 1.1V) L 2 -> L i 6 5 0 -1 ,0 0 0 1 1 -1 7 (7 - 1 1 )
K ic k d o w n L 2 -» L i 2 , 5 5 0 - 2 ,9 0 0 4 4 -5 0 (2 7 -3 1 )
D 2-»D 3 8 5 0 -1 ,4 5 0 1 5 -2 5 (9 - 1 6 )
‘ L o c k u p O N (D 3) 3 ,9 5 0 -4 ,3 5 0 1 0 5 -1 1 5 ( 6 5 - 7 1 )
D —
D 4-»D 3 4 ,2 5 0 — 4 ,4 5 0 1 6 2 -1 6 8 (1 0 0 -1 0 4 )
D 3->D 2 2 5 0 -5 0 0 7 -1 3 (4 -8 )
Hold
‘ L o c k u p O N (S3) 3 , 9 5 0 - 4 ,3 5 0 1 0 5 -1 1 5 ( 6 5 - 7 1 )
S — S4 (D4)-»S3 4 , 2 5 0 - 4 ,4 5 0 1 6 2 -1 6 8 (1 0 0 -1 0 4 )
S3-»S2 3 , 7 0 0 - 3 ,9 0 0 9 8 -1 0 4 (6 1 -6 4 )
L — L2->L1 2 , 5 0 0 - 2 ,8 5 0 4 3 -4 9 (2 7 -3 0 )
‘ C o m p le te lo c k u p 0
TD TECHNICAL DATA
K2. AUTOMATIC TRANSAXLE
Engine/Transaxle FS
Item LA4A-EL
1 st g e a r 2 .8 8 9
2nd gear 1.501
G e a r ratio T h ird g e a r 1 .0 00
F ourth g e a r 0 .6 9 8
R everse 2 .3 1 0
T yp e M -ffl o r M ercon®
M u iu m tu iu u a iis o A ie iiu iu
C a p a c ity
(ATF) 6 .9 5 (7 .3 5 , 6 .1 2 )
E n g in e stall s p e e d rp m D, S, L a n d R ra n g e s 2 ,2 0 0 -2 ,5 0 0
D, S a n d L ra n g e s 3 1 0 - 3 6 5 ( 3 .1 7 - 3 .7 2 , 4 5 - 6 3 )
A t id le
L in e p re s s u re R ra n g e 4 4 1 - 5 2 4 ( 4 .5 0 - 5 .3 4 , 6 4 - 7 6 )
kPa |k g f/c m 2, p s i] D, S a n d L ra n g e s 1 , 1 5 8 - 1 ,2 6 9 ( 1 1 .8 1 - 1 2 .9 3 , 1 6 8 - 1 8 4 )
A t stall
R ra n g e 1 ,7 8 6 -2 ,0 2 7 (1 8 .2 1 -2 0 .6 6 , 2 5 9 - 2 9 4 )
C le a ra n c e b e tw e e n e a ch g e a r a n d th e
O il p u m p 0 .0 2 7 -0 .0 6 (0 .0 0 1 -0 .0 0 2 )
p u m p b o d y fa c e m m ( in )
D rive p la te th ic k n e s s S ta n d a rd 1.6 (0 .0 6 3 )
m m ( in ) M in im u m 1.4 (0 .0 5 5 )
3 -4 c lu tc h c le a ra n c e m m ( in ) 0 .5 2 -1 .1 2 (0 .0 2 - 0 .0 4 )
D ire c t c lu tc h
1 .2 8 — 1.3 8 (0 .0 5 0 -0 .0 5 4 )
1 .3 9 — 1.4 9 (0 .0 5 4 -0 .0 6 0 )
R e ta in in g p la te size m m ( in )
1 .5 2 -1 .6 2 (0 .0 6 0 -0 .0 6 3 )
1 .6 5 -1 .7 5 (0 .0 6 4 -0 .0 6 8 )
N u m b e r o f d riv e /d riv e n Forward clutch 3 /2
p la te s Coasting clutch 2/2
m m ( in ) M in im u m 1.4 ( 0 .0 5 5 )
F o rw a rd a n d F o rw a rd a n d c o a s tin g c lu tc h
c o a s tin g c lu tc h 0 .5 -1 .0 9 ( 0 .0 2 - 0 .0 4 )
c le a ra n c e m m ( in )
1 .2 8 -1 .3 8 (0 .0 5 2 -0 .0 5 4 )
1 .3 9 -1 .4 9 (0 .0 5 5 — 0 .0 5 9 )
R e ta in in g ring m m ( in )
1 .5 2 -1 .6 2 (0 .0 6 0 -0 .0 6 4 )
1 .6 5 -1 .7 5 (0 .0 6 5 -0 .0 6 9 )
m m ( in ) M in im u m 1.4 (0 .0 5 5 )
R e ve rse c lu tc h R e v e rs e c lu tc h c le a ra n c e m m ( in ) 0 .3 3 -0 .8 9 (0 .0 1 - 0 .0 4 )
1 .3 9 -1 .4 9 (0 .0 5 5 -0 .0 5 9 )
S n a p rin g size m m ( in ) 1 .5 3 -1 .6 3 (0 .0 6 0 -0 .0 6 4 )
1 .6 8 — 1.7 8 (0 .0 6 6 — 0 .0 7 0 )
m m ( in ) M in im u m 1.4 ( 0 .0 5 5 )
L o w /re v e rs e
Low and reverse brake clearance m m { in ) 0 .5 4 -1 .1 7 ( 0 .0 2 - 0 .0 5 )
c lu tc h
2 .5 7 -2 .4 7 ( 0 .1 -0 .0 9 7 )
R e ta in in g p la te size m m ( in ) 2 .3 6 -2 .2 6 (0 .0 9 2 -0 .0 8 8 )
2 .1 6 -2 .0 6 (0 .0 8 5 -0 .0 8 1 )
L o w -in te rm id ia te c a rrie r e n d p la y m m ( in ) 0 .1 5 -0 .7 2 (0 .0 0 5 -0 .0 3 9 )
R e ve rse -4 th c a rrie r e n d p la y m m ( in ) 0 .1 6 -0 .7 1 (0 .0 0 6 -0 .0 2 8 )
TECHNICAL DATA TD
Engine/Transaxle FS
Item LA4A-EL
# 1 2 d riv e n s p ro c k e t th ru s t b e a rin g c le a ra n c e m m ( in ) 1 2 .0 8 -1 2 .1 7 ( 0 .4 7 6 - 0 .4 7 9 )
2 .2 0 -2 .1 0 (0 .0 8 6 -0 .0 8 3 )
2 .0 2 -1 .9 2 (0 .0 7 9 -0 .0 7 6 )
1 .8 5 -1 .7 5 (0 .0 7 2 -0 .0 6 9 )
# 11 th ru s t b e a rin g shim m m ( in )
1 .6 7 -1 .5 7 (0 .0 6 5 -0 .0 6 2 )
1 .5 0 — 1 .4 0 (0 .0 5 9 — 0 .0 5 6 )
1 .3 2 -1 .2 2 (0 .0 5 1 -0 .0 4 9 )
C le a ra n c e b e tw e e n th e d riv e s p ro c k e t a n d th e tra n sa xle
2 .2 7 -2 .6 3 (0 .0 9 0 -0 .1 0 3 )
case m m { in )
1 .5 1 — 1.41 (0 .0 5 9 -0 .0 5 6 )
1 .7 7 - 1 .6 7 (0 .0 6 9 -0 .0 6 6 )
# 10 th ru s t w a s h e r m m ( in )
2 .0 3 -1 .9 3 (0 .0 7 9 -0 .0 7 6 )
2 .2 9 -2 .1 9 (0 .0 9 0 -0 .0 8 6 )
C le a ra n c e b e tw e e n th e d iffe re n tia l c a s e a n d th e tra n sa xle
1 3 1 .4 4 - 1 3 1 .8 4 ( 5 . 1 7 5 - 5 . 1 9 0 )
case m m ( in )
1 .0 8 -0 .9 8 (0 .0 4 2 -0 .0 3 9 )
1 .3 8 -1 .2 8 (0 .0 5 4 -0 .0 5 1 )
# 1 4 d iffe re n tia l c a s e th ru s t shim m m ( in ) 1 .6 7 -1 .5 7 (0 .0 6 5 -0 .0 6 2 )
1 .9 7 -1 .8 7 (0 .0 7 7 -0 .0 7 4 )
2 .2 7 -2 .1 7 (0 .0 8 9 -0 .0 8 6 )
0: 108.1 ( 4 .2 6 )
S e rvo ro d le n g th m m ( in ) 1: 107.1 ( 4 .2 2 )
2: 1 0 5 .7 (4 .1 6 )
TD TECHNICAL DATA
M. FRONT AND REAR AXLES
' ------------------ --------------------------------------------Engine FS KL

Item ~ — — ------ Transaxles MTX ATX MTX ATX
Front axle
M a x im u m w h e e l b e a rin g p la y m m ( in ) 0 .0 5 (0 .0 0 2 )
Rear axle
M a x im u m w h e e l b e a rin g p la y m m ( in ) 0 .0 5 ( 0 .0 0 2 )
Drive shaft
W heel sid e B irtie ld jo in t (BJ)
J o in t ty p e
D iffe re n tia l sid e DOJ TJ DOJ TJ
3 8 7 .0 3 8 0 .0 3 8 2 .0 3 8 0 .0
R ig h t sid e
L e n g th o f jo in t (1 5 .2 4 ) ( 1 4 .9 6 ) ( 1 5 .0 4 ) ( 1 4 .9 6 )
(b e tw e e n c e n te r o f jo in t) m m ( in ) 3 8 7 .0 3 8 0 .0 3 8 2 .0 3 8 0 .0
Le ft sid e
(1 5 .2 4 ) ( 1 4 .9 6 ) ( 1 5 .0 4 ) ( 1 4 .9 6 )
R ig h t sid e 2 4 .0 0 .9 4 ) 2 6 .0 ( 1 .0 2 ) 2 6 .3 ( 1 .0 3 )
S h a ft d ia m e te r m m ( in )
Le ft sid e 2 4 .0 (0 .9 4 ) 2 6 .0 ( 1 .0 2 ) 2 6 .3 ( 1 .0 3 )
L e n g th o f jo in t s h a ft m m ( in ) 3 7 6 .0 1 4 .8 0 )
J o in t s h a ft d ia m e te r m m ( in ) 2 6 .0 (1 .0 2 )
"T J : T rip o d jo in t D O J: D o u b le o ffse t jo in t
N. STEERING SYSTEM
---------------------------- Engine KL
FS
Item -------------- _
Steering wheel
O u te r d ia m e te r m m ( in ) 3 8 0 ( 1 5 .0 )
F re e p la y m m ( in ) 0 - 3 0 (0 -1 .1 8 )
W h e e l e ffo rt N (k g f, Ib f) 2 8 - 2 9 ( 2 .8 — 3 .0 , 6 . 2 - 6 . 6 )
L o c k -to -lo c k tu rn s 3.1
Steering shaft
S h a ft ty p e C o lla p sib le
J o in t ty p e 2 -cro ss jo in t
Power steering system
P o w e r assist ty p e E n g in e s p e e d se n sin g
G e a r ty p e R a ck-a n d -p in io n
G e a r ratio o o (infinite)
R a c k s tro k e m m ( in ) 137 ( 5 .3 9 )
P o w e r s te e rin g flu id AT F D e xro n ® !! o r M -III
F lu id c a p a c ity L (U S qt, Im p q t) 1.25 (1 .3 2 , 1 .1 0 ) 1 .3 0 (1 .3 7 , 1 .1 4 )
F lu id p re s s u re kPa ( k g f/c m 2, p s i) 8 , 3 4 0 - 8 , 8 2 0 ( 8 5 . 0 - 9 0 . 0 , 1 ,2 1 0 - 1 , 2 8 0 )
New 7 .5 — 9 .0 ( 0 . 3 0 - 0 . 3 5 ) 6 .0 — 7 .0 ( 0 . 2 4 - 0 . 2 8 )
D riv e b e lt d e fle c tio n
U se d 8 .0 — 9 .5 ( 0 . 3 2 - 0 . 3 7 ) 7 .0 — 8 .0 ( 0 . 2 8 - 0 . 3 1 )
m m ( i n ) /9 .8 N ( 1 0 k g f, 22 Ib f)
L im it 1 1 .0 ( 0 .4 3 ) 9 .0 ( 0 .3 5 )
P. BRAKING SYSTEM
________ ___________ Type FS KL

non ABS ABS non ABS ABS
H e ig h t (w ith c a rp e t) m m ( in ) 1 9 1 .5 - 1 9 6 .5 ( 7 . 5 4 - 7 . 7 4 )
F re e p la y m m ( in ) 4 -1 2 (0 .1 6 - 0 .4 7 )
B ra k e p e d a l R e s e rv e tra v e l m m ( in )
(w ith o u t c a rp e t, c le a ra n c e w h e n p e d a l is 85 ( 3 .3 5 )
d e p re s s e d at 5 8 9 N ( 6 0 kgf, 132 Ib f))
T ype T andem
M a ste r
B o re m m ( in ) 23.81 (0 .9 3 7 )
c y lin d e r
F luid ty p e F M V S S 116, D O T-3
TD—22
TECHNICAL DATA TD
ABS
Type D isc (Ve ntilated)
T h ic h n e s s o f p a d S ta n d a rd 10 .0 ( 0 .3 9 )
m m ( in ) L im it 2 .0 ( 0 .0 8 )
F ro n t b ra k e
T h ic k n e s s o f d is c p la te S ta n d a rd 2 4 .0 ( 0 .9 4 )
(D isc)
m m ( in ) L im it 2 2 .0 ( 0 .8 7 )
D is c p la te ru n o u t m m ( in ) 0.1 ( 0 .0 0 4 ) m ax.
C y lin d e r b o re m m ( in ) 5 7 .1 5 (2 .2 5 0 )
Type — D isc (Solid)
T h ic k n e s s o f p a d S ta n d a rd — 8 .0 ( 0 .3 1 )
m m ( in ) L im it — 1.0 ( 0 .0 4 )
R e a r b ra k e
T h ic k n e s s o f d is c p la te S ta n d a rd — 10 .0 ( 0 .3 9 )
(D isc)
m m ( in ) Lim it — 8 .0 ( 0 .3 1 )
D isc p la te ru n o u t m m ( in ) — 0.1 ( 0 .0 0 4 ) m ax.
C y lin d e r b o re m m ( in ) — 3 0 .1 6 ( 1 .1 8 7 )
Type Leading-trailing —
W h e e l c y lin d e r in n e r d ia m e te r m m ( in ) 1 7 .4 6 ( 0 .6 8 7 ) —
R e a r d ru m L in in g d im e n s io n s m m ( in ) 30x219.3x4.5
—
b ra ke (w id th x le n g th x th ickn e ss) (1.18x8.63x0.18)
D ru m in n e r d ia m e te r m m ( in ) 2 2 8 .6 ( 9 .0 0 0 ) —
S h o e c le a ra n c e a d ju s tm e n t Automatic adjuster —
L e v e r n o tc h e s
P a rk in g b ra k e 5 - -7
[P u lle d a t 9 8 N (1 0 kgf, 2 2 Ib f)
Type M TX: S in g le d ia p h ra m ATX: T a n d e m d ia p h ra m
D ia m e te r m m ( in ) M TX: 2 3 9 ( 9 .4 ) ATX: 1 88 + 2 1 5 ( 7 . 4 + 8 .5 )
W h e n v a c u u m a p p lie d to th e u n it is a p p ro x .
P ush ro d -to -p is to n c le a ra n c e m m ( in )
P o w e r b ra k e 5 0 0 m m H g (1 9 .7 in H g ) 0 .1 - 0 . 4 m m ( 0 . 0 0 4 - 0 . 0 0 1 6 in )
u n it F luid p re s s u re w h e n Power brake unit at
8 8 3 (9 , 1 2 8 )
p e d a l d e p re s s e d at 0 mmHg, (0 inHg)
2 0 0 N ( 2 0 kgf, 4 4 Ib f) Power brake unit at
M TX: 7,061 (7 2 , 1 ,0 2 4 ) ATX: 8 ,8 2 6 (9 0 , 1 ,2 8 0 )
k P a (k g f/c m 2, p s i) 500 mmHg (19.7 inHg)
Rear w heel Type Dual P ro p o rtio n in g v a lve
h y d ra u lic B e n d p o rtio n (R ear b ra k e p rssu re )
3 ,4 0 0 (3 5 ,5 0 0 )
c o n tro l system kP a ( k g f/c m 2, p s i)
Q.WHEEL AND TIRES
Engine FS KL
Item
Size 1 4 x 5 1/2 JJ 1 4 x 6 JJ 1 5 x 6 JJ
O ffset m m ( in ) 4 5 ( 1 .7 7 )
P itch c irc le d ia m e te r m m ( in ) 1 1 4 .3 (4 .5 0 )
M ate ria l Steel A lu m in u m a llo y
Size P 1 9 5 /6 5 R 1 4 88S P 2 0 5 /5 5 R 1 5 8 7 V
T ire A ir p re s s u re F ro n t 2 2 0 (2 .2 , 3 2 )
kP a ( k g f/c m 2, p s i) R ear 180 (1 .8 , 2 6 )
Temporary spare tire
Item Specifications
Size 15x4T
O ffse t m m ( in ) 4 5 ( 1 .7 7 )
P itch c irc le d ia m e te r m m ( in ) 1 1 4 .3 ( 4 .5 0 )
M ate ria l Steel
Size T 1 2 5 /7 0 D 1 5
T ire
A ir p re s s u re kPa ( k g f/c m 2, p s i) 4 1 5 (4 .2 , 6 0 )
TD TECHNICAL DATA
R. SUSPENSION
___________ Model
Item ---------------------------___ MX-6 626
S u sp e n s io n ty p e St ■ut
S h o c k a b s o rb e r ty p e C ylin d rica l, d o u b le -a c tin g (oil-filled)
F ro n t S tra ig h t w o u n d
Type
C o il s p rin g R ear Taper w ound
D im e n s io n See co il s p rin g s p e c ific a tio n
Type T o rsio n b a r
S ta b ilize r D ia m e te r F ro n t 2 5 .4 (1 .0 0 ) 2 2 .2 ( 0 .8 7 )
m m ( in ) R ear 12 ( 0 .4 7 )
M a x im u m In n er 37° ± 2°
ste e rin g a n g le O u te r 32° ± 2°
m m ( in ) 3 ± 3 (0 .1 2 ± 0 .1 2 )
T ota l to e -in
D e g re e 0 °1 7 ’ ± 0 °1 7 ’ *J
F ro n t
T oe -in (p e r side) 0 ° 0 8 ’3 0 ’ ’ ± 0 ° 0 8 '3 0 ” * 2
C a m b e r a n g le -0 °4 2 ± 45’ - 0 ° 3 6 ’ ± 45'
W heel
a lig n m e n t C a s te r a n g le 3 °0 1 ' ± 45’ 2 °3 7 ' ± 45'
( * 'U n la d e n ) K in g p in a n g le 1 5 °2 5 ’ 1 5 °0 4 '
m m ( in ) 3 ± 3 (0 .1 2 ±0 .1 2 )
T otal toe-in
D e g re e 0 °1 7 ' ± 0 °1 7 ’ *2
R ear T oe -in (p e r side) 0 ° 0 8 '3 0 ” ± 0 ° 0 8 '3 0 ” * 2
C a m p e r a n g le -0 °2 2 ’ ± 45’ -0 °0 9 ’ ± 45’
T h ru s t a n g le 0 ° ± 0 .1 ° * 2
* ‘ F uel ta n k full; ra d ia to r c o o la n t a n d e n g in e oil at sp e c ifie d level, a n d s p a re tire, ja c k a n d to o ls in d e s ig n a te d position.

* 2 In d ic a te s m e a s u re m e n ts m a d e b y u sin g th e 4 -w he e l a lig n m e n t tester.
Coil Spring Specifications
Identification mark color Wire diameter Coil outer Free length

Item Coil number
M *1 A mm (in) diameter mm (in) mm (in)
A P u rp le — 13 ( 0 .5 1 ) 2 9 3 ( 1 1 .5 ) 2 .7 8
B L ig h t b lu e — 13 ( 0 .5 1 ) 301 ( 1 1 .8 ) 2 .9 4
C O ra n g e — 13 ( 0 .5 1 ) 3 0 9 ( 1 2 .2 ) 3.11
Front D W h ite W h ite 13 ( 0 .5 1 ) 175 ( 6 .9 ) 3 3 7 ( 1 3 .3 ) 3 .2 4
E W h ite P u rp le 13 ( 0 .5 1 ) 3 4 5 ( 1 3 .6 ) 3 .4 6
F W h ite G ree n 13 ( 0 .5 1 ) 3 5 3 ( 1 3 .9 ) 3 .5 7
G W h ite Y e llo w 14 ( 0 .5 5 ) 3 4 9 ( 1 3 .7 ) 3 .6 3
H Y e llo w — 11 ( 0 .4 3 ) 2 7 5 ( 1 0 .8 ) 3 .9 4
I P ink — 11 ( 0 .4 3 ) 1 2 2 -1 5 2 2 7 9 ( 1 1 .0 ) 4 .0 8
Rear ( 4 .8 — 6 .0 )
J B lue 11 ( 0 .4 3 ) 3 3 2 ( 1 3 .1 ) 4 .9 2
K R ed 11 ( 0 .4 3 ) 3 3 8 ( 1 3 .3 ) 5 .2 4
* ‘ M a in id e n tific a tio n m a rk c o lo r on s e c o n d c o il fro m b o tto m

* 2 A u x ilia ry id e n tific a tio n m a rk c o lo r on th ird c o il fro m b o ttom
Coil Spring Applications
Model Engine Transaxle Front Rear right Rear left
FS M TX D J K
FS ATX E J K
626
KL M TX F J K
KL ATX G J K
FS M TX A H I
FS ATX A H I
MX-6
KL M TX B H I
KL ATX C H I
TECHNICAL DATA TD
STANDARD BOLT AND NUT TIGHTENING TORQUE
Diameter Pitch 4T 6T 8T
mm (in ) mm fin) N-m kgf-m ftlb f N-m kgf-m ftlb f N-m kgf-m ftlb f
6 ( 0 .2 3 6 ) 1 ( 0 .0 3 9 ) 4 .2 — 6 .2 0 . 4 3 - 0 .6 3 3 .1 — 4 .6 6 .9 -9 8 0 .7 -1 .0 5 .0 — 7.2 7 .8 -1 1 .8 0. 8 - 1 . 2 5 .8 — 8 .8
8 ( 0 .3 1 5 ) 1 .2 5 ( 0 .0 4 9 ) 9 .8 -1 4 .7 1. 0 - 1 . 5 7 .2 -1 0 .8 1 6 -2 3 1 .6 -2 .3 1 2 -1 7 1 8 -2 6 1 .8 -2 .7 1 3 -2 0
10 ( 0 .3 9 4 ) 1 .2 5 ( 0 .0 4 9 ) 2 0 -2 8 2 .0 — 2 .9 14— 21 3 1 -4 6 3 .2 — 4 .7 2 3 -3 4 3 6 — 54 3 .7 — 5 .5 2 7 -4 0
12 ( 0 .4 7 2 ) 1.5 ( 0 .0 5 9 ) 3 4 -5 0 3 .5 — 5.1 2 5 — 37 55— 80 5 .6 — 8 .2 4 1 -5 9 6 3 — 93 6 .4 — 9 .5 4 6 -6 9
14 ( 0 .5 5 1 ) 1.5 ( 0 .0 5 9 ) — — — 7 5 -1 0 3 7 .7 -1 0 .5 5 6 -7 6 1 0 2 -1 3 7 1 0 -1 4 7 5 -1 0 1
16 ( 0 .6 3 0 ) 1.5 ( 0 .0 5 9 ) — — — 1 1 6 -1 5 7 1 2 -1 6 8 5 -1 1 6 1 5 6 -2 1 1 1 6 -2 2 1 1 5 -1 5 6
18 ( 0 .7 0 9 ) 1.5 ( 0 .0 5 9 ) — — — 1 6 7 -2 2 5 1 7 -2 3 1 2 3 -1 6 6 2 2 1 -2 9 9 2 3 -3 1 1 6 3 -2 2 1
2 0 ( 0 .7 8 7 ) 1.5 ( 0 .0 5 9 ) — — — 2 3 1 -3 1 4 2 4 -3 2 1 7 1 -2 3 1 3 0 8 -4 1 7 3 1 -4 3 2 2 7 -3 0 7
22 ( 0 .8 6 6 ) 1.5 ( 0 .0 5 9 ) — — — 3 1 4 -4 2 3 3 2 -4 3 2 3 1 -3 1 2 4 1 7 -5 6 4 4 3 -5 8 3 0 7 -4 1 6
2 4 ( 0 .9 4 5 ) 1.5 ( 0 .0 5 9 ) — — — 4 7 5 -5 4 6 4 1 -5 6 2 9 8 -4 0 3 5 3 6 -7 2 6 5 5 -7 4 3 9 6 -5 3 6

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1994 CONTENTS

Mazda General Information

626/MX-6 Pre-Delivery Inspection and

© 1993 Mazda Motor Corporatior

This manual contains "Warnings” and “ Cautions" applicable to

The procec^es recommended and described in this manual are

Parts shou;d be replaced with genuine Mazda replacement parts,

© 1993 Mazda Motor Corporation

PRE-DELIVERY INSPECTION..............A - 2 INSPECTION OF STEERING

Schedule 2 (Unique driving conditions)

Chassis and body

Air conditioner system (if equipped)

Chassis and body

Air conditioner system (if equipped)

Chassis and body

Air conditioner system (if equipped)

2. If the tension is not within specified, adjust it.

4. If the deflection is not within specifications, adjust it.

Drive belt tension check

1. Using the SST, check the belt tension.

2. If the tension is not within specification, adjust it.

Alternator + A/C belt

3. Tighten the pulley.

3. Tighten the pulley.

ENGINE OIL REPLACEMENT

5. Refit the oil filler cap.

ENGINE TIMING BELT REPLACEMENT

6. Start the engine and check for leaks.

Oil filter capacity: 0.2 L {0.21 US qt, 0.18 Imp qt}

Oil filter capacity: 0.3 L {0.3 US qt, 0.3 Imp qt}

Coolant Level (Engine cold)

1. Measure the coolant temperature and specific gravity with

Antifreeze solution mixture percentage

ENGINE COOLANT REPLACEMENT

ADJUSTMENT OF IDLE SPEED

Idle speed (Neutral): 600—700 (650 ± 50) rpm

7. If not within the specification, connect the SST to the data

12. Disconnect the SST.

Fuel Line Safety Procedures

INSPECTION OF EMISSION HOSES AND TUBES

1. Remove and install the high-tension leads carefully.

2. Remove and install the spark plug with a plug socket.

16E0AX-108 INSPECTION OF DISC BRAKE

INSPECTION OF STEERING OPERATIONS AND

Free play: 0—30mm (0—1.18 in}

2. Check the steering for proper operation and for looseness

5. Bleed air as described below.

(1) Jack up the vehicle and support it with safety stands.

INSPECTION OF DRIVE SHAFT DUST BOOTS

INSPECTION OF PCV VALVE

6. Remove the PCV valve.

Fluid specification: ATF Dexron®n or M-m

3. Check damage, cracks or foreign matter (metal pieces, nails,

USA: Every 6,000 km {3,750 miles)

6. Install a new washer and the oil level plug.

INSPECTION OF AUTOMATIC TRANSAXLE FLUID

60—70°C (140—1 5 8 °F )...............................GF4A-EL

4. While depressing the brake pedal, shift the selector lever

DO NOT DRIVE MARK

Step Procedure Sight glass Action

1 1. Turn ACS to ON and blower Too much or proper amount of

2. Replace the element if necessary.

TIGHTENING OF BOLTS AND NUTS ON CHASSIS AND

6. Verify that the camshaft settles horizontally when two bear

3. If not as specified, adjust the cable free play by turning stop