INTRODUCTION HOW TO USE THIS MANUAL IDENTIFICATION INFORMATION GENERAL REPAIR INSTRUCTIONS PRECAUTION ABBREVIATIONS USED IN THIS MANUAL, STANDARD BOLT TORQUE ‘SPECIFICATIONS iNM2) INTRODUCTION — HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL INDEX ~ ‘An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. GENERAL DESCRIPTION = At the beginning of each section, a General Description (Precautions} is given that pertains to all rapair operations contained in that seotion. Read these precautions before starting any repair task. TROUBLESHOOTING TROUBLESHOOTING tables are included for sach system to help you diagnose the problem and find the cause. PREPARATION ~ Preparation lists the SST (Special Service Tools), recommended tools, equipment. lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each ane. REPAIR PROCEDURES “ Most ray ‘operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Exampte: Exhaust Manifold Stay O11 Cooler Oil Dipstick + Specified torque ‘® Non-reusable part prINTRODUCTION — HOW TO USE THIS MANUAL mwa ‘The procedures are presented in @ step—by—step format: ‘© The illustration shows what to do and Where to do it. The task heading tells what to do. © The detailed text tells how to perform the task and gives other information such as specifications and wamings, Exapmle: This format provides the experienced technician with a FAST TRACK to the information needed. ‘The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are raquited you are given the page to refer to. SPECIFICATIONS ‘Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found at the end of each section, for quick reference.IN Ns INTRODUCTION — IDENTIFICATION INFORMATION CAUTIONS, NOTICES, HINTS: * CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people, © NOTICES are also presented in bold type, and indicate the possibility of damage to the compo- nents being repaired. * HINTS are separated from the text but do not appear in bold. They provide additional information to help you efficiently perform the repair. ‘SI UNIT ‘The UNIT given in this manual are primarily expressed with the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the yard/pound system. Example ‘Torque: 30 N-m ($10 kgf-cm, 22 ftbf) IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER " The engine serial number is stamped on the engine block as shown.INTRODUCTION — GENERAL REPAIR INSTRUCTIONS Negetive (-) Tenminal Cable GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following: {a} Before performing electrical work, disconnect the negative (—) terminal cable from the battery. {b) fit is necessary to disconnect the battery for inspec- tion or repair, sways disconnect the cable from the negative (—) terminal which is grounded to the vehicle body, {) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it. {d) Clean the battery terminal posts and cable terminals with a shop rag. Do not scrape them with @ file or other abrasive objects. (©) install the cable tarminal to the battery post with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive(+) terminal is prop- erly in place. 4. Chock hose and wiring connectors to make sure that they are secure and correct. 5. Non—reusable parts. (a) “Always replace cotter pins, gaskets, O—rings and oil seals etc. with new ones. (b) Non—reusable parts are indicated in the component illustrations by the “®" symbol. ©. Precoated parts. Precoated parts are bolts and nuts, etc. that are coated with a geal lock adhesive at the factory. (2) If @ precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. Soa! Lock Adhesive (b) When reusing precoated parte, clean off the old adhe- sive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. {c) Precoated parts are indicated in the component illus- trations by the “” symbol. 7. When necessary, use 2 sealer on gaskets to prevent leaks. 8. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.we INTRODUCTION — GENERAL REPAIR INSTRUCTIONS 9. Use of special service tools (SST) and spacial service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work, proce: dure. A list of SST and SSM can be found in the preparation part at the front of each section in this manual. 10. When replacing fuses, be sure the new fuse has the correct amperage rating . DO NOT exceed the rating oF use one with a lower rating. Equal Amperage Rating —egGo—— —_| MEDIUM CURRENT FUSE MUSE a ict CURRENT FUSE HFUSE ge — | FUSIBLE LINK FL a ecru les woos 11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. {2} If the vehicle is to be jacked up only at the front or rear ‘end, be sure to block the wheels at the opposite end in order to ensure safety.In? INTRODUCTION — GENERAL REPAIR INSTRUCTIONS WRONG ‘CORRECT (b) After the vehicte is jacked up, be sure to support it on stands. Its extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly, 12. Observe the following precautions to avoid damage to the parts: ; (2) Do not open the cover or case of the ECU unless absolutely necessary. (If the 1C terminals are tou- ched, the IC may be destroyed by static electricity.) (b) To disconnect vacuum hoses, pull on the end, not the middle of the hose. {c)_ To pull apart electrical connectors, pull on the connec-. tor itself, not the wires. (d)_ Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. fe) When steam cleaning an engine, protect the distribu- tor, air filter, and VCV from water. () Never use an impact wrench to remove or install temperature switches or temperature sensors. (9) When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. (h) When using @ vacuum gauge, never force the hose ‘onto a connector that is too large. Use 8 step—down adapter instead. Once the hose has besn stretched, it may leak. 13, Tag hoses before disconnecting them: (2) When disconnecting vacuum hoses, use tags to iden- tify how they should be raconnected. {b) After completing a job. double check that the vacuum hoses are property connected. A label under the hood shows the proper layout. 14, Unless otherwise stated, all resistance is measured at an ambient temperature of 20°C (68°F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurements should be made when the engine has cooled downIa INTRODUCTION — PRECAUTION PRECAUTION FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions end explain them to your customer. 1. Use only unleaded gasoline. 2. Avoid prolonged idling. Avoid running the engine idle speed for more than 20 minutes. 3. Avoid spark jump test. (2) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possi {b) While testing, never race the engine, 4. Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible, 8. Donot run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. 6. Avoid coasting with ignition turned off and prolonged braking. 7. Do not dispose of used catalyst a with parts contaminated with gasoline or oil. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two—way radios and cellular tele- phones, observe the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic system. (2) Install the antenna feeder at east 20 cm (7.87 in) away from the ECU and sensors of the vehicle’s electronics systems. For details about ECU and sensors locations, refer to the section on the applicable component. (2) Do not wind the antenna feeder together with the other wiring. As much as possible, elso avoid running the antenna feeder parallel with ather wire harnesses. (4) Confirm that the antenna and feeder ara correctly adjusted. (8) Do not install powerful mobile communications system,INTRODUCTION — ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL We APPROX AUT. ATM BTDC ev BiwalsVeuur Swing VORP ca Cat Beker Done Dale Ger Hod Com oF Cea Pot er chovoisGoted Terrien Fes Seeoie Goal Unt A reve Fo ict car Bint Gr Feit ESA | Bectranio Spark Advance me a Fre Fomed Pose Gat re Fea ine Fae Tigh Cent Foe ioiton W ak ws ide Sed Ce ve eter eo tH Toh Hon oa Cot Hand az asin a 0 Nalbupee Mt ‘Manual Tranemission of Oversize rr Pacis Cones Voaion [rer re oh ~Had 70 hand Bie su Soni Sere uta sr Spel Sov Tool 00 Senco ow See Toe op Deed Coe To Timea we Thee Way Ga us 7 wv Vecuan ova Vane w om whe WienIN-10 HOW TO DETERMINE BOLT STRENGTH INTRODUCTION ~ STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS Mark aT Grooved er Welded bolt a a =p = a =| 5 Bolt 6- or Wwe] 4 8— 8T Comme | on — flange bolt ran wc head bolt 2 CO) iewie |r lines race flange bolt 2 washer pcneme oT ia rea head bolt 3 protruding 7 a Hexagon head bolt 4 protruding eT atINTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS: SPECIFIED TORQUE FOR STANDARD BOLTS: int Species tocqee Chane | Serger | ce Hexogon head bot Hexagon flange bolt Nm ighem fei | im __aghom fab 8 1 5 sat | 6 6082 int 8 128 | 128 08 1“ us 10 a) % 128 | 26 0 018 2 0 t 2 vas | 47 4003s 53 4089 1% 1s 74 70058 8 380 Bt 16 us | 5480 a - oo 6 1 658 78 75 Binh 8 as | 155 1002 751783 s | 125 | 32 33024 3 38028 12 125 | 58 004s 8s 67048 “ 18 3 e306? 100 1,080 78 ' 6 45 | 14014000 - - 6 1 e %0 ® 8 78mnwibr 8 12s | 48 1988 a 2045 «| a) 4002 “ “4032 12 1.28 n 730 83 80 810 59 a us | 01.1008 125 1.25090 6 us| 170178027 = a 8 1 10.5 110 8 12 120 3 3 125 | 2s 2019 2 202 af 125 | 82 53038 58 53043 2 135 | 95 970 70 10s 08078 4 18 | 145 1.500108 ws 1.700123 16 1s | 290 2300168 = - 2 128 | 28 30022 3 5a eT 10 1.26 61 620 45 68 690 60 2 125 | 1104100 a0 120 ©4250 3 12s | 38 mo 37 3007 st | 0 125 | 70 no | I 70 2 125 | 125130094 140 1.450108 8 1.25 36 290 28 42 4” a ror} 10 125 | 78 30058. 8 880 at 2 128 | 1401480108 138160018 8 12s | 42 «000 47 4035 ur{ 10 12s | a7 3906. 97 90 072 12 125 | 1554600118 175 1.800130eee INTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS —MEMO~