1 9 92 CONTENTS: F Mazda General Information oe Cesare Tn B2600i fet 32200 Workshop Lubrication System Manual Cooling System Fuel and Emission | Carburetor Control Systems Eq) FOREWORD Engine Electrical System This workshop manual is intended for use by service technicians of Authorized Mazda | Clutch ‘Dealers to help them service Mazda vehicles. Fot ‘proper repair and maintenance, a | Manual thorough familiarization with this manualisim- | Tranemission portant, and it should always be kept in a han- dy place for quick and easy reference. | Teanater.Cese Al the contents of this manual, including drawings and spectications, are the latest avai able al the {ime of printing. As modifications | Automatic affecting tepair or maintenance occur, relevant | Transmission Carona information supplementary to this volume will be made available at Mazda dealers. This Transfer Case manual should be kept up-to-date. Propeller Shaft Mazda Motor Corporation reserves the right to alter the specifications and contents of this _| Front and Rear Axles manual without obligation or advance notice. esering Allrights reserved. No part of this bookmay | Steering System be reproduced or used in any form or by any | means, electronic or mecharical—inclucing _Br@king System photocopying and recording and the use of | Wheels and Tires any kind of information storage and retrieval system—without permission in writing, ‘Suspension Mazda Motor Corporation HIROSHIMA, HIMA, JAPAN | Gody Electrical System APPLICATION: This manual is applicable to vehicles beginning | Heater and Alr Conditioner Systems with the Vehicle Identification Numbers (VIN) | Teghnical Data shown on the following page. Special Tools Parts index Wiring Diagram {bere gopcany © 1991 Mazda Motor Corporation PRINTED IN USA, JUL. ‘91 1269-10-91G (8999-95-022B-92)VEHICLE IDENTIFICATION NUMBERS (VIN) JM2UF123 «NO 250001 ~ JM2UF223 «NO 250001 ~ JM2UF323 «NO 250001 ~ JM2UF113 *NO 250001 ~ JM2UF213 «NO 250001 ~ ‘JM2UF313 «NO 250001 ~ JM2UF114«NO 250001 ~ ‘JM2UF314%NO 250001 ~ JM2UF414*NO 250001 ~ JM2UF614*NO 250001 ~ JM2UF514%NO 250001 ~ ‘JM2UF223+NO 250001 ~ a =FGENERAL INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS. SAFETY RISK. POSSIBLE LOSS OF WARRANTY WARNING ON LUBRICANTS AND GREASES. HOW TO USE THIS MANUAL. PROTECTION OF THE VEHICLE .. A WORD ABOUT SAFETY esse PREPARATION OF TOOLS AND MEASURING EQUIPMENT ... SPECIAL TOOL! REMOVAL OF PARTS.. DISASSEMBLY . REASSEMBLY ADJUSTMENTS RUBBER PARTS JACK AND SAFETY STAND (RIGID POSITIONS. a VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS. TOWING.. WITH MANUAL TRANSMISSION, WITH AUTOMATIC TRANSMISSION CHASSIS NUMBER LOCATION. ENGINE MODEL AND NUMBER LOCATION .. ABBREVIATIONS CAUTION ELECTR TOOLS .. CAUTION WITH ELECTRICAL PARTS. ‘ssvarcoat Gl PO onGl IMPORTANT INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS This workshop manual assumes that you have certain special tools that are necessary for the safe and eff cient performance of service operations on Mazda vehicles and that you know how to use them properly Italso assumes that you are familar with automobile systems and basic service and repair procedures. You should not attempt to use this manual unless these assumptions are correct and you understand the conse- ‘quences described below. SAFETY RISK This manual contains certain notes, warnings, and other precautionary information that you should carefully read and follow to reduce the risk of personal injury to yourself or others and the risk of improper service that may damage the vehicle or render it unsafe. If there is no such information in regard to any specific service method, this does not mean there is no possiblity that personal safety or vehicle safety will be jeopardized by the use of incorrect methods o tools. POSSIBLE LOSS OF WARRANTY ‘The manufacturer's warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Mazda Dealer. WARNING ON LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated uring service (e.g., engine sump ails) are more irritating and more likely to cause serious effects, including skin cancer, in the event of gross and prolonged skin contact. ‘Wash skin thoroughly after work involving oil. Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not use gasoline, paraffin, or other solvents to remove oil from the skin. Lubricants and greases may be slightly irritating to the eyes. Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particu lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be con- taminated with oil. Dry clean or launder such clothing at regular intervals. sntusoc 002 GI-2 } SYGl HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL PREPARATION PREPARATION points cut the needed SST for the service operation that follows. Itis best to gather al necessary SST before beginning work. Gl Example: N ie-Rop END BOOT AND STEERING GEAR BOOT ‘SST NUMBER, ‘TIE-ROD END BOOT AND STEERING GEAR BOOT ‘ssT NAME SST ILLUSTRATION omveixoas REPAIR PROCEDURE 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and visual parts inspections. If a damaged or worn partis found, repair or replace it ‘as necessary. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview istration, 8, Pages related 10 service procedures are shown under the illustration. Refer to this information when ser- vicing the related part. Example: sows Fao sows 5 ee Rae | |e. ea a n | ae = Wy oe Bohr |\ a eee Ne Se mexaasy | ORG UT 2 lode See, ee ‘shows § Seerpg et tee INSPECTION RELATED Sis INFORMATION te ee rapt sins a eh waa Sats sence fA BEY“ Keuanent ot hog ‘pepe nae a fl The numbering (ex@)y shows service procedure. *2: Units shown in Nm (m-kg, ft-lb) unless otherwise specified. GI-3GI How To usE THIs MANUAL/FUNDAMENTAL PROCEDURES SYMBOLS There are 6 symbols for oil, grease, and sealant. These show the points of applying oil, grease, or sealant during servicing. a = = Wawa Wow rg o'r geo 2 eprptte Sou oe i oo 1. _— — ee ere ao o Apply petroleum jelly Appropriate petroleum jelly a Note When special oil or grease is needed, this is shown in the illustration. NOTES, CAUTIONS, AND WARNINGS {As you fead through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each ‘one is there for a specific purpose. NOTES give you added information that will help you to complete @ particular procedure, CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause per- sonal injury. The following list contains some general WARNINGS you should follow when you work on a vehicle, saavancoss FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas be- fore starting work. mEFUNDAMENTAL PROCEDURES Gl ava TOT ‘A WORD ABOUT SAFETY The folowing precautions must be folowed when jacking up the vehicle, 1. Block the wheels, 2. Use only the specied jacking postions 3. Support the vehicle wih safety stands Start the engine only after making certain the engine compart- ment is clear of tools and people. PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment are available before starting any work ‘SPECIAL TOOLS Use special tools when they are required. REMOVAL OF PARTS While correcting @ problem, try also to determine its cause. Begin work only after first learning which parts and subassem- blies must be removed and disassembled ior replacement or repair. DISASSEMBLY IWthe disassembly procedure is complex, requiring many parts to be disassembled, al parts shouid be disassembled ina way that will not affect their performance or external appearance {and identified so that reassembly can be periormed easly and efficiently GI-5FUNDAMENTAL PROCEDURES 1. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. ra 2. Arrangement of parts All disassembled parts should be carefully arranged for re- assembly, Be sure fo separate or otherwise identity the parts to be replaced from those that will be reused. mae Cleaning parts for reuse Al parts to be reused should be carefully and thoroughly cleaned in the appropriate method. REASSEMBLY Standard values, such as torques and certain adjustments, must 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: 4. Oil seals 2. Gaskets 3. Orings 4, Lock washers 55. Cotter pins 6. Nylon nuts RARER Depending on location: 1. Sealant should be applied to gaskets. 2. Oil should be applied to the moving components of pats. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. mao Gi-6FUNDAMENTAL PROCEDURES Gl ADJUSTMENTS Use suitable gauges and/or testers when making adjustments. RUBBER PARTS AND TUBING Prevent gasoline or ol from getting on rubber parts or tubing. GI-7Gl JACK AND SAFETY STAND (RIGID RACK) POSITIONS JACK AND SAFETY STAND (RIGID RACK) POSITIONS FRONT et Jack position: Safety stand positions: : At the center of the crossmember On both sides of the Jack point L EGO EROS \ 2 REAR Safety stand positions: Jack position: ‘On both sides of the ‘At the center of the differential diferential oy area oo Gi-8VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS Gl VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS FRONT Jack point: On both sides of the jack point AR Oo aq. TL % ie ; \ Bry BAY \ SA Eo Gi-9| gtategrleteee FOR au SEr THE REMOTE FREE WHEEL SYSTEM YO FREE MODE BUR TOWING TOWING Proper towing equipment is necessary to prevent damage to the vehicle during any towing operation. Laws and regulations applicable to vehicles in tow must always be observed. Release the parking brake, place the shift lever in neutral, anc set the ignition key in the ACC position. As a rule, towed vehi cles should be pulled with the driving wheels off the ground, WITH MANUAL TRANSMISSION If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels, it any of these components are damaged, use a towing dally WITH AUTOMATIC TRANSMISSION If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use a wheel dolly. With all 4 wheels on the ground, the vehicle may be towed only forward. In this case, do not exceed the following towing speed andlor distance or transmission damage could result we wa Toving speed 5 tanh G6 mph] | 66 ev 85 my “Towing tans 8 em (10-rites) —| 58 kr 5 rls) Ittowing speed andor distance will excead above-mentioned specifications, use one of three methods: 1, Place the rear wheels on a dolly 2. Tow with the rear wheels off the ground, 3. Disconnect the propeller shaft. (4x4: rear propeller shat) Ifthe transmission or rear axle is inoperative, tow the vehicle with its rear wheels off the ground or have the propeller shatt disconnected, CAUTION a) The power assist for the brakes is inoperable while the engine is off. b) When either of the towing hooks Is used, pull the cable or chain straight away from the hook and do not apply any sideways force to It. To further help prevent damage, do not take up slack too quickly in the cable or chain. ©) The rear towing hook should be used only in an emergency situation (for example, to pull the vehi- cle from a ditch, snow, or mud).CHASSIS & ENGINE NUMBER LOCATION/UNITS/ABBREVIATIONS. Gl CHASSIS NUMBER LOCATION UNITS Tm (kg Wb). Torque i Pareions per mine A Ampere(s) : von a Ot (estiance) 168 Want po) Prose (ual poet) mmtig (a He)... Presne (ety nog) Ie w Wa rm tenet Ta ENGINE MODEL AND NUMBER LOCATION ABBREVIATIONS Basoo! ETRBUTER 777 Se 186... Aer bolo dead car ABS. Antec eke avn & A0Attuootas & AiG AF conten, AV At conte A062 Aker op ea eer Mino Altona anarosen AE Alora aramid Sn Bypoo ar come BBD.” Bee oti Sead conor | Bio. Bote top das senor ECAT Ecvencabyconued sromate avarice EOU. Engi eae anh ED. Enegeaive ere conta oan EGR nnn Beha go touton Eu Emorgerby log eer EIR Beste Reg nae Bee ena Fg we PR Hiroe convoed erate weccicase HUA ou OE Lh eo heap cheat fac (ne Nam ane aR IN torment 180. sped cont So Rare 16. Lina a rete Was" our ade een Wi Mate ede nt A" Mant pera NF Macartney todo OB Ot agree OF Sten Se Sth on FEV Proeniing by pase vas Po polar sakes venoaion PB Power desing FEW" Ronee ee hoa hub Bee Riek han Sa Sete Ta te aut crow Toe top aed bance FPS eto toy iene aUaKoR Gi-11CAUTION ke aero “Se VOLTMETER aaa BaEKOe aca Gi-12 CAUTION 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 check ing for short circuits. Caution When checking the control unit, never use a bulb over 3.4W. Jumper Wire ‘The jumper wite is used for testing by shorting across switch terminals and ground connections. Caution Do not connect a jumper wire from the power source line to a body ground; this may cause burning or oth- er damage to harnesses or electronic components. Voltmeter The DC voltmeter is used to measure of circuit voltage. A vol meter with a range of 15V or more is used by connecting the postive (+) 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 ina circult and also to check for continuity and diagno- sis of short circuits. Caution Do not attempt to connect the ohmmeter to any cir- cuit to which voltage is applied; this may burn or other- wise damage the ohmmeter. CAUTION WITH ELECTRICAL PARTS Battery Cable Before disconnecting connectors or replacing electrical parts, disconnect the negative battery cable.CAUTION Gl eee = ra se ow » a EB RTT Connectors Removal of connector Never pull on the wiring harness when disconnecting con- neciors. Connectors can be removed by pressing or pulling the lock lever as shown, Locking of connector When locking connectors, make sure to listen for @ click that will indicate they are securely locked. Inspection When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wire harness side, Terminals Inspection Pull lightly on individual wires to check that they are secured in the terminal GI-13aaa \ CAUTION Replacement of terminals Use the appropriate tools to remove the terminal as shown. When installing the terminal, be sure to insert it until it locks Gay securely. Insert @ 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. Same as the female type. Wiring Hamess Wiring color codes Two-color wires are indicated by a two-color code symbol The firs letter indicates the base color ofthe wire and the sec- cond the color of the stripe. ~ (CODE ‘coLon cope | COLOR : 3 Bleck ° Orange BR Brown P Pok | 6 Green a Rea oy Gray v Vile t Bue w wre | 18 ont Bue ¥ Yellow is Light Green 7 = Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do not drop them or strike them against other parts.BUS Eero CAUTION Gl Fuse Replacement 1. When replacing a fuse, be sure to replace it with one of specified capacity |'a fuse again fails after it hes been replaced, the circuit probably has @ short circuit and the wiring should be ‘checked. 2. Be sure the negative battery terminat is disconnected be- fore replacing a main fuse (804), 8. When replacing a pull out fuse, use the fuse puller supplied in the fuse box cover. GI-15PRE-DELIVERY INSPECTION AND SCHEDULED MAINTENANCE SERVICES PRE-DELIVERY INSPECTION .. PRE-DELIVERY INSPECTION TABL! SCHEDULED MAINTENANCE SERVI (USA)... « ‘SCHEDULE 4 {NORMAL DRIVING CONDITION) 82600) SCHEDULE 1 (NORMAL DRIVING CONDITION) 82200... A= 7 SCHED! (eNIovE ‘CaN CONDITION) B2600i.. SCHEDU (UNIQUE ‘DAIVING CONDITION) 82200 eos A> SCHEDULED MAINTENANCE SERVICES (CANADA) aesPRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. [4 EXTERIOR + INSPECT and, necessary, ADJUST the folowing tems to specications: 12 Gis, exarior bright metal, and paint for damage Gi Wheel tug nuts Nowsted 88-118 Ne» (0-120 mrtg, 6587 fe) Styiod! 118147 Nev (12.0—18.0 ekg, 87-106 tb) ‘Al waathorstips for damage ox detachment Overaton of haod release and lock 1D Operston 0! tua id opener (I eaupped) 5 Door oporeton and algnment 1 Heaigne arn * INSTALL tho folowing parts: i Wheel cantor caps ft equipped) 5 Outside rearview meron) 2. UNDER HOOD—ENGINE OFF * INSPECT and, necessary, ADJUST the folowing items 1 spectations: 1D Fue), coolant anc hydraulic ines, ftings, connections, and ‘components for leaks. Engine oF leve! 1 Ollfeval in steering gearbox 5 Power stoering fud level equipped) 1 Brake ana clutch master cylinder td levels 1D Windehlald washer resarvor fic level 1D Headlight cleaner reservor fd level (if equippec) 1D Raciator coolant level D Tightness of batiory terminals 3. INTERIOR = INSTALL the following pans: 1 Rubber stopper for inside rearview mirror © CHECK the operations of the folowing roms: 1D Seat coniros (siding and recining) and head rest 1D Boor Socks: 1D Foe-Down rear seats (Cab Pius only) ‘© Seat bets and warning system 5 Igaiton switch and steering iook Sartor interlock switch (MPT only) 5B Shitiock systen and inhibitor sutch (AIT only) D Al iat, Incucing warring anc incicator its (equipped) I Horn, windshield wipers, and washers (f equipped) 1D Headlight cloaner ( equipped) 5) Radio and antenna (i equipoec) 1 Cigaratie lighter and clock (f equippsc) INTERIOR (cont'd) i Healer, dose, and al conditioner at iferent modest eqarped + GREEK he folowing tems: D Fresence of spare fase 1 Upotsery and miro rich Following items must be done just before the delivery 1D Load test battery and charge if necessary vate 1B Adjust ire pressure tothe specification {Pater to Section Q) © Ciean outside of vehicie A-2 '» CHECK and, # necessary, ABMUST the folowing items: 1 Pedal ne ght Wah earoed and ree piay 0! breke and clutch pedal Pada heght mm Te] Free play mm (a) Caioh [BEBO [91207 (7527.8 ; pec) eze00 Her—rar g.1e=75q) °° $0028 Brake pedal 160185 (7 08—7.28)| 407.0 16-028) 1 Peting 660K wanna. 712 Nolchos!196N (20 kg, 44 Ib) UNDER HOOD—ENGINE RUNNING AT OPERATING TEMPERATURE 4 CHECK the falowing Heme: 5 Trois sere (€) 1 Operation of loleu system for. = Airconditoner and automete tranemission (Carburetor) 1D Automate transmission uid leve Ci Operation of dashpot (Carburetor & Carburetor oat level intial igntlon tering: 6 & 1° BTDC (82200) & Idle speed: 800 “Y rpm AT; in P range (82200) © Operation of EGR contral valve (Carburetor) 1D Operation of lole switch (Carburetor) ‘ON HOIST ‘CHECK tne folowing tems: B Operation of remota freewhee! (4x4 only) 5 Manuel varemiesion of level 1G Transfer oo89 ol love (4x4 oni) 1D Front ade a level (x4 only). 1 Rear axe oll evel 1H Underside fuel, coolant and hydraulic nes tings, connec- ‘ions and components for leaks 1D Tres for cuts or bruisos| U Stosting Invage, suspension, exhaust sytem and all under- side harcware for looseness or damage 6, ROAD TEST © CHECK ihe folowing tems: 1D Brake oporaton © Clutch operation 5) Steering control 1D Operation of metere and gauge 1D Squeaks, ratles of unusual noises | Emergency lock relractore 5 Cruse contol eyetom (it equippec) 1B Operation of ranster caso (4x4 ony) 7 AFTER ROAD TEST = CHECK for necessary owner's information material, tool ‘and spare te in vehicle to your customer. 1D Install fuses tor accessories [U1 Remove seat and foor mat protective covers 1D Vacuum and clean interior of vehicle 1B Inspect instalation of option pans with invelce eeuaaccozSCHEDULED MAINTENANCE SERVICES (USA) owo}ed eq O32 Tei PuewuIOD9: am “JOADMO}, "BWLOMED Klooxe SaIES Ife PUE ’pBUED 40} Poulnbe: S| coUEUEIUIEL SIL ¢, IOeINUEW 10 @BErGAOD AIUELsEM UO|SSHWWE 10} KtBSSBOSU JOU SI “OASMOH| "EPZEW Aq PapUeWUIOOEI s| BOUEUOINTEW SL ZL “SQUBUSTUIB PACLOSEp OY 167 sOTPO;PUY UOHOUNIEWY 94 ‘9IOIYOA BIUIOWED 10) OOK] L HO} 94) 910U “ueYD BOUEUO|UIEL SIM UI SWOY PEW , 10} Sy 10} 01 enuyuaD "(w4 000'96) SAIL OOO‘OR 40 SYUOW O9 JOMY TOMEWO ‘NO S8LUOO 1 41 ‘S9)tU O0'DR PU SA! 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(Inspect, and if necessary replace...Air cleaner element 2200 only) R: Replace or change T: Tighten L! Lubricate Clean Aiter 60 months or 96,000 km (60,000 miles), continue to follow the described maintenance items and inter- vals periodically ‘As for *marked items in this maintenance chart, pleace pay attention to the following points. "1: Replacement of the timing belt is required at every 96,000 km (60,000 miles) Failure to replace the timing belt may result in damage to the engine. * 2: This maintenance operation is recommended by Mazda, However, this maintenance is not neces- sary for emission warranty coverage or manufacturer recall lability *3: The Maltunction Indicator Light (MIL) comes ON at every 96,000 km and 128,000 km, If it comes ON, foliow the described maintenance. PauonoisENGINE (B2200) TROUBLESHOOTING GUIDE .. ENGINE TUNE-UP PROCEDURE DRIVE BELT. HLA TROUBLESHOOTING GUIDE . COMPRESSION COMPRESSION .. ON-VEHICLE MAINTENANCE. TIMING BELT wessseu CYLINDER HEAD GASKET .. FRONT OIL SEAL. REAR OIL SEAL. REMOVAL .... PREPARATI ENGINE STAND INSTALLATION. PREPARATION INSTALLATION DISASSEMBLY. PREPARATION. AUXILIARY PARTS .. TIMING BELT CYLINDER HEAD. CYLINDER BLOCK CYLINDER BLOCK INSPECTION AND REI PREPARATION ASSEMBLY. PREPARATION... CYLINDER BLOCK T.... CYLINDER BLOCK IT CYLINDER HEAD. TIMING BELT AUXILIARY PARTS ENGINE STAND REMOVAL .. REMOVAL... INSTALLATION, PREPARATION B1| B1 INDEX INDEX \ ~ i Goes Caouennies 1 mpethcnc pace Bes ve cowpneseion Wee] SOME N ae 10 We} STANDARD; 1,197 KPa (12.2 kglem’, 173 psi300 rpm L eee etre aati : RAS Ay 2-02 EET ey de : a it i a FRSINE boon INSPECTION, SEONEESSRENN ® — exene on nsrecron, | SSN SeOCRTD ORVE BELT ADJUSTING, PAGE BI=S DEFLECTION a cave aT a =) | ERO —| wees RET) | woo saw || 1 a ‘AIG COMPRESSOR | 10.0—12.0 (0.99--0.47) | 120—14.0 (0.47055) — | 1. engine 2.Timing belt | Removal page 81-20 TEOMA wusseencennenncnsnnn POD BI 8 : Bieaesoribiy page B1-24 instalation fege BI10 he Inspection and Repair ee page B1-34 Inspection sesssssessssareney PAGE BI-A4 } P a i Assembly....... page B1-46 3. Cylinder head gasket i Installation age 61-69 Romovel snsnnemsnee page 61-18 instalation page BI1-15 Bi-2 SeOUTLINE, TROUBLESHOOTING GUIDE Bi OUTLINE SPECIFICATIONS: == Es a en aa i [ie in Fa a aay ota i ofa eared cone wp J ‘ies Sie tain [Banaras aaa Ba Gg Soon ae SMO cabasat eaze ee Tea —— = Gun BS = | oe Close ABDC Ea aaa lex Open BBDC 58° rear — se ie ry iN mm (ny 0; Maintenance free ra aeeee xX mmm (in) 0; Maintenance free — ver a a wae ise [Pm [AIT range) 30028 770 20 zt a TROUBLESHOOTING GUIDE Problem | Possible Cause Remedy Page Dita ering | Wainstn a one ra combo Bas reo ss Sa an eo oe Bae [aes eine es Bs Nseon ol aon par nF Msarton festa sien fb for rg Hefner of nested onsen iter ees ep Mee tet cot Become | BH ra Sr na fs a | anette fie 6 SOF li slong st Faro Sea Scene ad ——] bron Seamct | SUNTETETE acne erste oon emo | Rca sie DBS ee REE | ofete wong own Sexes sie av Mi eh ase ies a Oi sap Fa an B1-3: TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page TInsutficient power | insufficient compression Malfunction of HLA Replace e140 CComoression Isakage from valve seat Repair BI27 Seized valvo stem Foplace 51-35 ‘Weak o° broken valve spring Ropiace 51-38 Faies eyindor head gacket Replace 81-13 Cracked or distorted cylinder head Replace Bias Sfcking, damaged, of worn piston ring Replace Bie Cracked of worn piston Replace Bie [Matfunction of fuel system Reter fo Sections Ft, F2 Malfunction of ignition system Reler ta Section G ‘Others Sipping clutch Reler ta Section Dragging brakes eter to Section P Wrong siz fires Fate: to Section O ‘Abnormal Malfunction of engine-related components ‘eombustion Malfunction of HLA Replace B40 Steking or burned valve Replace 81-35 ‘Weak or broken valve spring Replace 1-38 ‘Carbon secumulaion in combustion chamber Eliminate carbon = Maitunction of fuel system Fler to Sections FY, F2 Malfunction of ignition system lar to Section G Engine noise ‘Crankshaft oF bearing related parts Excessive main bearing oll clearance Replace or repair Bi-a9 Main bearing seized or heat-damaged Replace Bias Excessive crankshait end play Replace or repair 1-50 Exceceve connecting rod beeting al clearance Replace or repait Bist Gonnscting rod boating seized or heat-damaged Repiace Bias iston-related parts Worn eyinger Foplaco oF repair Bio Wom piston oF piston pin Replace Bis Seized piston Replace Bia Damaged piston ting Replace B14 Bent connecting rod Replace a1-43 Valves of timing-related parte Malfunction of HLA" Replace BI-40 Broken valve spring Replace Bi-33 Excessive valve guide clearance Repiace I-35 Insufciet Movication of rocker arm Repiace 8140 Malfunction of cooling system ater to Section E ‘Malfunction of fuel system Fifer to Sections F1, F2 Others Malfunction of water pump bearing Refer to Section E Improper dtve-belt tension Adjust Bis Mattunction of alternator bearing | Refer to Section G Exhaust gas leakage Fifer to Sections Ft, F2 Maltunetion of timing belt tensioner Replace Bin 8 od = Tappet noige may occur the engine is not operated for an extended period. The noise shoud disappear ater the engine has reached normal operating temperaire. Bi-4 featsENGINE TUNE-UP PROCEDURE B1 ENGINE TUNE-UP PROCEDURE DRIVE BELT 1. Check the drive bells for wear, cracks, or fraying; replace if necessary. 2, Check the drive belt deflection by applying moderate pres- sure (98 N, 10 kg, 22 1b) midway between the pulleys shown in the figure. Adjust if necessary aaa Deflection mm (i ‘PrS OWL PUMP: ADJUSTING BOLT ao Dave bet New eet | ane lees 88 _(028-031) (031-035) 70-80 30-90 P98 ol pump 025-031) (031025 os 700-720 720140 AIG comoresio 29-047) (047058) 3. Check the drive belt tension with the tension gauge, . Note ee aera cot Belt tension can be measured among any pulleys. \ Mest No.) Dive bat New T Used 31580 320-481 | Aerator ose tociey | ao sabe t110) 2s—294 198-25 mounma 80uT PIS of pump (25-20, 55-05) | 20-25, 4455) 441540 348 —aat ‘AVC compressor cama (ass, 99-129 | @5—95, 77-29) Adjustment (1) Alternator belt lf necessary, loosen the aiternator bolts and adjust the belt deflection, Tightening torque Bolt A: 31—46 Nm (3.2—4.7 m-kg, 23-34 ft-lb) Bolt B: 3752 Nm (3.8—5.3 m-kg, 27—38 ft-lb) (2) PIS oil pump belt lf necessary, loosen the locknut and adjust the bett deflection by turning the adjusting bot Tightening torqu 37-52 Nm (3.8—5.3 m4 27—38 ft-lb) Bi-5HLA TROUBLESHOOTING GUIDE ENGINE TUNE-UP: PROCEDURE, COMPRESSION | (8) AIC compressor bett If necessary, loosen the mounting bolts and adjust the bbelt defiection by turning the adjusting bot. Tightening torque: ‘37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) 2 5 Problem Possible Cause ‘ion |]. [temo wen oname s sed Hamedaay [Ol eatage nol) Fin angie wt 20005000 ron is | Getot's chanaes passage Foe slope after 2 sacord—10 minutes’, HLA s A | 2, Nose unten engine i tated after seting formal APG LE. aprox one ay. Wek replace HLA Lo. [Nese when encira is sarod afer cank- | Ol eakageir” | Tyme requied for enging oo cree TPee Te eee neato re me {it ncuvos tera for engine of conten ard 1 4, Noise when engine is started after new ambient temperature. Aas [2 NtA‘sineated 3 Hows contmucs more fan 10 minutes | (reuicant of | Check a pressure. (ler Secton 0) pressure Ilower then specication, Shock fr cause Oli pressure; 304—402 KPa (G14. kgfer, 44—58 ps!)-3000 rpm Fauly WA] (Raa to pane 82-69) Pree down fecker art by hand ihe moves, place HLA {Ft ases not move, HLA nora ‘Meanie vave sosrance. tinove than Bram (0) replace HLA 3. Nal casas danny Wo aor Fgh opeed | Wcorec Gt | Check of Fal runing amour Bran of ed ol as neces Bateraior oF | Check ot quality W Seer. ace wn sects yp ad aro oot Tar Tnoearor COMPRESSION tt the engine exhibits iow power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to Section G.) 2. Compression 3. Fuel system (Refer to Sections F1, F2.) COMPRESSION 1. Check that the battery is fully charged. Recharge it if necessary, 2. Warm up the engine to the normal operating temperature. 3. Tum it off for about 10 minutes to allow the exhaust mani: fold to cool. 4, Remove all spark plugs. 5, Disconnect the primary wire connector from the ignition coil ,COMPRESSION B1 6. Connect a compression gauge to the No.1 spark plug hole, 7. Fully depress the accelerator pedal and crank the engine, 8. Note the maximum gauge reading. 9. Check each cylinder. Compression: 1,197 kPa (12.2 kg/em?, 173 psi)-300 rpm Minimum: a 834 kPa (8.5 kg/cm’, 121 psi)-300 rpm ty SaTORT Possible Cause i.compression i iow, pour heavy a int tho onder and tun fe erankshait sovra mes i hack compression ance more I Is compression increased? 1, Wor piston ot piston rings 2 Worn eyinder wi 1. Delecive oyinder head gasket No 2 Boned Sno head | eS ves : : Ts canpesson in aden der? no 1 tapope sao wong | 2 Wipe Si guce 3. Defective cyinder head gasket wae B1-7| Bi ON-VEHICLE MAINTENANCE (TIMING BELT) ||| ON-VEHICLE MAINTENANCE TIMING BELT |, Removal 1. Disconnect the negative battery cable. | 2. Drain the engine coolant |. 3. Remove in the order shown in the figure referring to the Removal note, TSO <4) 1.Cooling fan 7, Crankshaft pulley 2 Radiator cowiing 8. Timing belt cover upper 8. Alternator drive belt 9. Timing belt cover lower 4, Cooling fan pulley 40. Timing belt tensioner and spring 5. Cooling fan bracket 11. Timing belt 6. Secondary air pipe assembly (Carburetor) Bi-8ON-VEHICLE MAINTENANCE (TIMING BELT) Bi DIRECTION ARROW Removal note Timing belt tensioner 1. Tum the crankshaft to align the $1 mark of the camshaft pulley with the front housing matching mark 2, Remove the tensioner and spring, Timing belt Mark the timing belt rotation for proper reinstallation if itis reused. Caution Be careful not to allow oil, grease, or water on the belt. Inspection Inspection of timing belt related parts. (Refer to page B1-44,) seunero%e B1-9ON-VEHICLE MAINTENANCE (TIMING BELT) Installation Install in the reverse order of removal referring to the Installation note. oe Caution After radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. If the fan touches the cowling, adjust the radiator cowling mounting position. Note a)Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to ensure a good fit. if |, Torque Specifications b I | onan (7O=100 cart, 6187 i) (as 73, 9-19) en ook mb) TBUOBI CTS B1-10aa ON-VEHICLE MAINTENANCE (TIMING BELT) Bi Installation note Timing belt 1. Check that the mark on the timing belt pulley is aligned with the matching mark. 2. Check that the #11 mark of the camshaft pulley is aligned with the matching mark. If tis not aligned, turn the came shatt to align, 8. Install the timing belt tensioner and spring. Temporarily se- ‘cure it with the spring fully extended, 4. Install the timing belt so that there is no looseness at the water pump pulley and idler pulley side. Caution 9) if the timing belt is being reused, it must be rein- stalled to rotate in the original direction. b) Check that there is no oil, grease, or dirt on the tim- ing belt. Note Remove all spark plugs for easier rotation. 5. Tum the crankshatt twice clockwise in the direction of ro- tation. 6. Check that the matching marks are correctly aligned. If not, repeat the above-mentioned procedure. 7. Loosen the tensioner lock bolt and apply tension to the belt Bi-11nea B1-12 ON-VEHICLE MAINTENANCE (TIMING BELT) 8, Tighten the timing belt tensioner lock bot. Tightening torque: 37—52 Nan (3.8—5.3 m4 27-38 ft-lb) 9, Turn the crankshaft twice in the direction of rotation and align the matching marks. 10. Check the timing belt deflection, If the deftection is not cor- rect, repeat the adjustment from step § above, Timing belt deflection/98 N (10 kg, 22 Ib) New : 8.0—8.0mm (0.31—0.35 in) Used: 8.0—10.0mm (0.35—0.39 in) Caution Be sure not to apply tension other than that of the ten- sloner spring. Spark plug 1. Install the spark plugs Tightening torque: 15—23 Nm (1.5—2.3 m , 11-17 ftlb) Steps After Installation 1. Adjust the drive belt tension. (Refer to page B1-5.) 2. Add engine coolant to the specified levels. 3. Connect the negative battery cable. 4, Start the engine and do the following: (1) Check for leakage of engine coolant. (2) Perform engine adjustments if necessary. (8) Recheck the coolant leveis. souosroreON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Bi CYLINDER HEAD GASKET Removal Warning: Release the fuel pressure. (Refer to Sections F1, F2.) 1, Disconnect the negative battery cable, 2. Remove the engine undercover. 3. Drain the engine coolant. 4, Remove in the order shown in the figure referring to the Removal note (CARQURETOR ® 1. Air cleaner assembly (Carburetor) 2. Air intake hose (EG) 3. Cooling fan.and radiator cowiing 4, Accelerator cable 5. Fuel hoses 6. Fuel pump (Carburetor M/T) 7. Heater hoses 8. Brake vacuum hose 9. Three-way solenoid valve assembly 10. Duty solenoid valve assembly 11. Canister hoses 12, Engine harriess 18. High-tension leads and spark plugs 14. Distributor Ser, | REPLACE, Eo 18. Secondary air pipe assembly (Carburetor) 16. Radiator hose, upper 17. Water by-pass hose 18. Intake manifold assembly 19, Exhaust manifold insulator 20. Exhaust manifold 21. Timing bett cover, upper 22. Timing belt tensioner and spring 23, Timing belt 24. Engine ground 25. Cylinder head cover 26. Cylinder head bolt 27. Cylinder head 28, Cylinder head gasket B1-13B1 ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) [GARQURETOR a @. © @ g TORT Removal note Fuel hose Note a) Cover the hose with a rag because fuel will spray out when disconnecting. b)Keep sparks and open flame away from the fuel area. Plug the disconnected hoses to avoid {uel leakage. Timing belt 1. Before removing the timing bett, turn the orankshaftto align the 41 mark of the camshaft pulley with the front housing matching mark. 2, Loosen the timing belt tensioner lock bolt 3, Shit the tensioner outward as far 2s possible, then temporer- ily tighten it 4, Remove the timing bet and secure it out of the way to pre- vent damage during removal and instalation of the cylin- der heed. Cylinder head bolt Loosen the cylinder head bolts in two or three steps in the order shown in the figure.ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B1 ] Disassembly of Cylinder Head | Refer to page B1-28. Inspection of Cylinder Head Refer to page 81-34, Assembly of Cylinder Head Reter to page B1~56. wea Installation Install in the reverse order of removal referring to the Installation note. Caution Alter radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. If the fan touches the cowling, adjust the radiator cowling mounting position. Note a) Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to ensure a good fit. Torque Specifications (20110 crag, 6525 in) 12s (18F6, 419)Bi ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Installation note | Cylinder head | 1 Thoroughiy remove all dir and oi from the top of the eylin- ax der block with a rag. 2, Place a new cylinder head gasket in postion. 3. Set the cylinder head in place. 4. Apply engine oll to the bolt threads and seat faces, 5, Tighten the cylinder head bolts in two or three steps in the order shown in the figure, Tightening torque: '80—B6 Nm (8.2. .8 m-kg, 59—64 ft-b) Cylinder head cover +1. Apply engine oll ta the valves and rocker arms. 2 Apply silicone sealant to the shaded areas shown in the figure 3. Install the cylinder head cover. aes Tightening torque: 2.93.9 Nim (30—40 cm-kg, 26—36 in-lb) mae Timing belt + Align the 441 mark ofthe camshaft pulley with the front hous: 19 matching mark 2. Install the timing bet. (Refer to page B1-10.) Distributor 4. Apply engine cil to the new O-ring, and position it on the distributor. 2. Apply engine oll to the distributor driven gear. 3. Align the distributor housing and driven gear marks. 4, Install the distributor into the front housing, 5, Loosely tighten the distributor mounting bolt. oe ERTSON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B1 DST Spark plug 1. Apply ant-seize compound or molybdenum-based lubricant to the spark piug threads, 2. Install the spark plugs, Tightening torque: 15—23 Nem (1.52.3 m-kg, 11—17 ft-lb) Steps After Installation 1. Add engine coolant to the specified levels. 2. Connect the negative battery cable 3, Start the engine and do the following: (1) Check for leakage ot engine coolant (2) Perform engine adjustments if necessary. {@) Recheck the oil and coolant levels sezose B1-17Bi ON-VEHICLE MAINTENANCE (FRONT OIL SEAL) FRONT OIL SEAL |p. Preparation ssT 495120710 so 4011 101A ®) 4 | Holder, couping == | crankshatiock wed | ange tool # eam 4 aE TS Removal 1. Disconnect the negative battery cable. 2. Drain the engine ol. 3. Remove the timing belt. (Refer to page B18.) 4 Remove the timing belt pulley with the SST. 5. Remove the oil seal with @ screwdriver and a rag. Installation Install in the reverse order of removal referring to the instal lation note. Installation note Front oll seal +. Apply engine oil to the new seal lip. 2 Fit the oil seal onto the oll pump body. 8, Tap the oil seal in evenly using a suitable pipe. il seal outer diameter: 48mm (1.89 in) Caution The oil seal must be tapped in until itis flush with the edge of the oil pump body. Timing belt pulley Install the timing bett pulley with the SST. Tightening torque: 457—167 Nem (16.0—17.0 m-kg, 116-128 ft-lb) ‘Steps After Installation +. Add engine oil to the specified levels. 2.Connect the negative battery cable. 8 Start the engine and do the following: (1) Check for leakage of engine oil {2) Perform engine adjustments if necessary. {@) Recheck the oil levets. wearsON-VEHICLE MAINTENANCE (REAR OIL SEAL) B1 REAR OIL SEAL Preparation sst 49 E011 140 49 SE01 910 Ring gear brake " Clutch aise sel centering took BaD Bare Removal 1. Disconnect the negative battery cable. 2. Drain the engine oil ‘8. Remove the manual transmission, (Refer to Sections J1, J2, J3,) Remove the automatic transmission. (Refer to Sections K1, K2, K3.) 4. Remove the cluich cover, clutch dise, and flywheel with the SST. (Refer to Section H.) Remove the plate, drive plate, and adapter with the SST. (Refer to Sections Ki, K2, KS.) 5, Remove the oil seal with a screwdriver and a rag. Installation Install in the reverse order of removal reterting to the Installation note. Installation note Rear oil seal 1. Apply engine oil to the new oil seal lip. 2. Fit the oil seal onto the rear cover. 8, Tap the oil seal in evenly using a suitable pipe. Oil seal outer diameter: 140mm (4.33 in) Caution The oll seal must be tapped in until it is flush with the i edge of the rear cover, Steps After Installation 1. Add engine oil to the spectied levels 2. Connect the negative battery cable. 8. Start the engine and do the following: (1) Check for leakage of engine cil (2) Perform engine adjustments if necessary. (3) Recheck the oil levels, xno Bi-19B1 REMOVAL | |REMOVAL | | PREPARATION [| osst 49 wo2a 5054 ‘dus wronch — waa § | Warning: Release the fuel pressure. (Refer to Sections Ft, F2.) 1 | 4. Disconnect the negative battery cable. £ | 2, Remove the starter (Refer to Section G) and transmission. (Refer to Sections J1 U2, J3 and K1, K2, K3.) 3, Drain the engine oil and coolant. | 4. Remove in the order shown in the figure referring to the Removal note. | BI-20