Engine - EG1 ENGINE EG2 ENGINE ENGINE MECHANICAL ENGINE...

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Unformatted text preview: EG1 ENGINE EG2 ENGINE ENGINE MECHANICAL ENGINE MECHANICAL PREPARATION SST (SPECIAL SERVICE TOOLS) EG0P209 EG3 ENGINE ENGINE MECHANICAL EQUIPMENT Dial indicator Cylinder gauge CO/HC meter Caliper gauge Connecting rod aligner Compression gauge EG0P409 RECOMMENDED TOOLS EG4 ENGINE ENGINE MECHANICAL EG0P30A SSM (SERVICE SPECIAL MATERIALS) Magnetic finger Vblock Vernier calipers Valve seat cutter Torque wrench Thermometer Steel square Spring tester Precision straight edge Plastigage Piston ring expander Piston ring compressor Micrometer Heater Engine tuneup tester Dye penetrant Mirror 0883300080 08833 00070 0883300070 08826 00080 0882600080 Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent ENGINE Adhesive 1324, THREE BOND 1324 or equivalent Seal Packing Black or equivalent ( (FIPG) ) ENGINE MECHANICAL Valve spring Valve spring Idler pulley pivot bolt ulley ivot Oil pressure switch ressure Drive plate mounting bolt late No. 1 camshaft bearing cap ca Cylinder head y Rear oil seal retainer EG5 EG0PS04 EG6 ENGINE ENGINE MECHANICAL IDLE AND/OR 2,500 RPM CO/HC CHECK EG4M901 1. (a) (b) (c) (d) (e) (f) (g) (h) (i) 2. 3. HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All accessories switched OFF All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. SFI system wiring connectors fully plugged Ignition timing set correctly Transmission in neutral position Tachometer and CO/HC meter calibrated by hand START ENGINE RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. 4. 5. High Low Normal CO High High High HC Rough idle 1. (Black smoke from exhaust) 2. Rough idle (Fluctuating HC reading) Rough idle Symptom 2. 1. 2. 3. 4. 5. 1. Troubleshooting If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (a) Check (main heated) oxygen sensors operation. (See oxygen sensors inspection in SFI System) (b) See the table below for possible causes, and then inspect and correct the applicable causes if necessary. ENGINE S S S S S S S S S S S S S S S S S S Restricted air filter Faulty SFI systems: Faulty fuel pressure regulator Clogged fuel return line Defective ECT switch Faulty ECM Faulty injector Faulty throttle position sensor Faulty volume air flow meter Vacuum leaks: PCV hose EGR valve Intake manifold Air intake chamber Throttle body IAC valve Brake booster line Lean mixture causing misfire ENGINE MECHANICAL Faulty ignitions: Incorrect timing Fouled, shorted or improperly gapped plugs Open or crossed hightension cords Cracked distributor cap Incorrect valve clearance Leaky EGR valve Leaky intake and exhaust valves Leaky cylinder Causes EG7 EG8 ENGINE ENGINE MECHANICAL COMPRESSION CHECK EG4MA01 1. 2. HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. REMOVE THROTTLE BODY WITH INTAKE AIR CONNECTOR ASSEMBLY (See steps 1 to 6 in injectors removal in SFI System) 3. REMOVE SPARK PLUGS (a) Disconnect the hightension cords. (See hightension cords and cord clamps removal in Ignition System) (b) Using a 16 mm plug wrench, remove the 6 spark plugs. 4. DISCONNECT INJECTOR CONNECTORS 5. DISCONNECT DISTRIBUTOR CONNECTOR 6. CHECK CYLINDER COMPRESSION (a) Insert a compression tester into the spark plug hole. (b) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine revolutions of 250 rpm or more. (c) Repeat steps (a) through (b) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression: 1,275 kPa (13.0 kgf/cm2, 185 psi) or more Minimum pressure: 1,079 kPa (11.0 kgf/cm2, 156 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less (d) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (b) for the cylinder with low compression. EG9 ENGINE ENGINE MECHANICAL If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are probably worn or damaged. If pressure stays low, a valve may be sticking or seating improper, or there may be leakage past the gasket. 7. RECONNECT DISTRIBUTOR CONNECTOR 8. RECONNECT INJECTOR CONNECTORS (See step 3 in injectors installation in SFI System) 9. REINSTALL SPARK PLUGS (a) Using a 16 mm plug wrench, reinstall the 6 spark plugs. Torque: 18 Nm (180 kgfcm, 13 ftlbf) (b) Reconnect the hightension cords. (See hightension cords and cord clamps installation in Ignition System) 10. REINSTALL THROTTLE BODY WITH INTAKE AIR CONNECTOR (See steps 8 to 13 in injectors installation in SFI System) EG10 ENGINE ENGINE MECHANICAL VALVE CLEARANCE INSPECTION AND ADJUSTMENT EG4MB01 1. 2. HINT: Inspect and adjust the valve clearance when the engine is cold. REMOVE THROTTLE BODY WITH INTAKE AIR CONNECTOR ASSEMBLY (See steps 1 to 6 in injectors removal in SFI System) DISCONNECT HIGHTENSION CORDS FROM CYLINDER HEAD COVERS (See hightension cords and cord clamps removal in Ignition System) 3. REMOVE NO.3, NO.1 AND NO.2 CYLINDER HEAD COVERS (a) Remove the 4 bolts, 4 nuts and No.3 cylinder head cover. (b) Remove the 4 bolts, No.1 cylinder head cover and gasket. (c) Remove the 4 bolts, No.2 cylinder head cover and gasket. 4. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with the timing mark "0" of the No. 1 timing belt cover. NOTICE: Always turn the crankshaft clockwise. (b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No.4 timing belt cover. If not, turn the crankshaft 1 revolution (360). EG11 ENGINE ENGINE MECHANICAL 5. INSPECT VALVE CLEARANCE (a) Check only those valves indicated in the illustration. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record the valve clearance measurements of those that are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake .150.25 mm (0.0060.010 in.) Exhaust .250.35 mm (0.0100.014 in.) (b) Turn the crankshaft pulley 1 revolution (360_), and align the groove with the timing mark "0" of the No. 1 timing belt cover. (c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 6. ADJUST VALVE CLEARANCE (a) Remove the adjusting shim. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. EG12 ENGINE ENGINE MECHANICAL Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 0924855040 (0924805410, 0924805420) HINT: Apply SST (B) at slight angle on the side marked with "7", at the position shown in the illustration. When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. Using a small screwdriver and a magnetic finger, remove the adjusting shim. (b) Determine the replacement adjusting shim size according to the following formula or Charts on the next 2 pages: Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so the valve clearance comes within specified value. T . . . . Thickness of used shim A . . . . Measured valve clearance N . . . . Thickness of new shim Intake N = T + (A 0.20 mm (0.008 in.)) Exhaust N = T + (A 0.30 mm (0.012 in.)) Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 mm (0.1299 in.). (c) Install a new adjusting shim. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. Press down the valve lifter with SST (A), and remove SST (B). SST 0924855040 (d) Recheck the valve clearance. EG13 ENGINE ENGINE MECHANICAL EG14 ENGINE ENGINE MECHANICAL EG15 ENGINE ENGINE MECHANICAL 7. REINSTALL NO.2, NO.1 AND NO.3 CYLINDER HEAD COVERS (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No. 0882600080 or equivalent (c) Install the gaskets to the No.1 and No.2 cylinder head covers. (d) Install the No.2 cylinder head cover with the 4 bolts. Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) (e) Install the No.1 cylinder head cover with the 4 bolts. Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) (f) Install the No.3 cylinder head cover with the 4 bolts and 4 nuts. Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) 8. 9. RECONNECT HIGHTENSION CORDS TO CYLINDER HEAD COVERS (See hightension cords and cord clamps installation in Ignition System) REINSTALL THROTTLE BODY WITH INTAKE AIR CONNECTOR ASSEMBLY (See steps 8 to 13 in injectors installation in SFI System) EG16 ENGINE ENGINE MECHANICAL IGNITION TIMING INSPECTION AND ADJUSTMENT EG4MC01 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE Connect the tester probe of a tachometer to terminal IG of the DLC1. NOTICE: Never allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use. CHECK IDLE SPEED (See step 3 in idle speed inspection) 4. ADJUST IGNITION TIMING (a) Using SST, connect terminals TE1 and E1 of the DLC 1. SST 0984318020 3. (b) Using a timing light, check the ignition timing. Ignition timing: 10 BTDC @ idle (Transmission in neutral position) (c) Loosen the nut, and adjust by turning the distributor. (d) Tighten the nut, and recheck the ignition timing. Torque: 19 Nm (195 kgfcm, 14 ftlbf) (e) Remove the SST from the DLC1. 5. FURTHER CHECK IGNITION TIMING Ignition timing: 719 BTDC @ idle (Transmission in neutral position) EG17 ENGINE ENGINE MECHANICAL 6. HINT: The timing mark moves in a range between 7 and 19. DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE IDLE SPEED INSPECTION EG4MD01 1. (a) (b) (c) (d) (e) INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All accessories switched OFF All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. SFI system wiring connectors fully plugged Ignition timing set correctly Transmission in neutral position CONNECT TACHOMETER Connect the tester probe of a tachometer to terminal IG the DLC1. (f) (g) (h) 2. of NOTICE: Never allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use. 3. INSPECT IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed: 700 50 rpm 4. If the idle speed is not as specified, check the IAC valve. DISCONNECT TACHOMETER EG18 ENGINE ENGINE MECHANICAL EG0PJ06 TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION EG19 ENGINE ENGINE MECHANICAL EG4ME01 TIMING BELT REMOVAL 1. 2. 3. 4. DRAIN ENGINE COOLANT REMOVE ENGINE UNDER COVER REMOVE AIR CLEANER DUCT REMOVE DRIVE BELT, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY (See step 5 in water pump removal in Cooling System) REMOVE RADIATOR ASSEMBLY (See steps 5 and 6 in radiator removal in Cooling System) 5. 6. REMOVE NO.3 TIMING BELT COVER (a) Remove the oil filler cap. (b) Using a 5 mm hexagon wrench, remove the 6 bolts and belt cover. 7. REMOVE NO.2 TIMING BELT COVER Using a 5 mm hexagon wrench, remove the 3 bolts, belt cover and gasket. If you are unable to loosen the bolt on the right because the PS pump pulley interferes with the hexagon wrench, first remove the pulley as follows. (a) Using SST to hold the pulley, remove the nut. SST 0996010010 (b) Remove the pulley. 8. REMOVE DRIVE BELT TENSIONER Remove the 3 bolts and tensioner. EG20 ENGINE ENGINE MECHANICAL 9. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. NOTICE: Always turn the crankshaft clockwise. (b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No.4 timing belt cover. If not, turn the crankshaft 1 revolution (360). 10. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS HINT (Reusing timing belt): Place matchmarks on the timing belt and camshaft timing pulleys as shown in the illustration. (a) Alternately loosen the 2 bolts, and remove them, the tensioner and dust boot. (b) Disconnect the timing belt from the camshaft timing pulleys. 11. REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt for the timing pulley. Remove both timing pulleys. SST 0996010010 (0996201000, 0996301000) 12. REMOVE CRANKSHAFT PULLEY (a) Using SST, loosen the pulley bolt. SST 0921370010, 0933000021 (b) Remove the SST and pulley bolt. EG21 ENGINE ENGINE MECHANICAL HINT: If necessary, remove the pulley with SST and crankshaft pulley bolt. SST 0995050010 (0995405030, 0955105010, 0955205010, 0955305020) 13. REMOVE PS PUMP FRONT BRACKET Remove the 3 bolts, plate washer and pump front bracket. 14. REMOVE NO.1 TIMING BELT COVER Remove the 5 bolts, timing belt cover and gasket. 15. REMOVE TIMING BELT GUIDE 16. REMOVE TIMING BELT HINT: (When reusing timing belt): Draw an arrow on the timing belt in the direction of engine revolution, and place matchmarks on the timing belt and crankshaft timing pulley. 17. REMOVE IDLER PULLEY Using a 10 mm hexagon wrench, remove the pivot bolt, plate washer and idler pulley. EG22 ENGINE ENGINE MECHANICAL 18. REMOVE CRANKSHAFT TIMING PULLEY If the pulley cannot be removed by hand, use SST and service bolt to remove the crankshaft timing pulley. SST 0995050010 (0995105010, 0995205010, 0995305020, 0995405010) EG4MF01 TIMING BELT COMPONENTS INSPECTION 1. INSPECTION TIMING BELT NOTICE: Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to come into contact with oil, water or steam. Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. (a) (b) (c) (d) (e) If there are any defects, as shown in the illustrations, check the following points. Premature parting Check for proper installation. Check the timing cover gasket for damage and proper installation. If the belt teeth are cracked or damaged, check to see if either camshaft is locked. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. 3. INSPECT IDLER PULLEY Check the turning smoothness of the idler pulley. If necessary, replace the idler pulley. INSPECT DRIVE BELT TENSIONER Check the turning smoothness of the tensioner. If necessary, replace the tensioner. EG23 ENGINE ENGINE MECHANICAL 4. INSPECT TIMING BELT TENSIONER (a) Visually check tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace tensioner. (b) Hold the tensioner with both hands and push the push rod strongly against the floor or wall to check that it doesn't move. If the push rod moves, replace the tensioner. (c) Measure the protrusion of the push rod from the housing end. Protrusion: 8.08.8 mm (0.3150.346 in.) If the protrusion is not as specified, replace the tensioner. EG4MG01 TIMING BELT INSTALLATION 1. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key with the key groove of the pulley. (b) Slide on the timing pulley facing the flange side inward. 2. INSTALL IDLER PULLEY (a) Apply adhesive to 2 or 3 threads of the pivot bolt. Adhesive: Part No. 0883300080, THREE BOND 1344, LOCTITE 242 or equivalent (b) Using a 10 mm hexagon wrench, install the plate washer and pulley with the pivot bolt. Torque: 34 Nm (350 kgfcm, 25 ftlbf) (c) Check that the pulley bracket moves smoothly. EG24 ENGINE ENGINE MECHANICAL 3. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Use the crankshaft pulley bolt to turn the crankshaft and align the timing marks on the crankshaft timing pulley and on the oil pump body. (b) Remove any oil or water on the crankshaft timing pulley and idler pulley, and keep them clean. (c) Install the timing belt on the crankshaft timing pulley and idler pulley. HINT (When reusing timing belt): Align the match marks of the crankshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution. 4. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. 5. INSTALL NO.1 TIMING BELT COVER (a) Install the gasket to the timing belt cover. (b) Install the timing belt cover with the 5 bolts. 6. INSTALL PS PUMP FRONT BRACKET (a) Install the pump front bracket with the 2 bolts. Torque: 58 Nm (590 kgfcm, 43 ftlbf) (b) Install the plate washer and bolt to the oil pump. Torque: 52 Nm (530 kgfcm, 38 ftlbf) 7. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install and torque the bolt. SST 0921370010, 0933000021 Torque: 324 Nm (3,300 kgfcm, 239 ftlbf) EG25 ENGINE ENGINE MECHANICAL 8. INSTALL CAMSHAFT TIMING PULLEYS (a) Align the camshaft knock pin with the groove on the pulley, and slide on the timing pulley. (b) Temporarily install the timing pulley bolt. (c) Using SST to hold the pulley, torque the pulley bolt. SST 0996010010 (0996201000, 0996301000) Torque: 79 Nm (810 kgfcm, 59 ftlbf) 9. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the No.1 timing belt cover. NOTICE: Always turn the crankshaft clockwise. (b) Using SST, align the timing marks of the camshaft timing pulleys and No.4 timing belt cover. SST 0996010010 (0996201000, 0996301000) 10. INSTALL TIMING BELT HINT (When reusing timing belt): Align the matchmarks of the timing belt and camshaft timing pulleys. (a) Remove any oil or water on the camshaft timing pulley, and keep it clean. (b) Install the timing belt, checking the tension between the crankshaft timing pulley and exhaust camshaft timing pulley. EG26 ENGINE ENGINE MECHANICAL 11. SET TIMING BELT TENSIONER (a) Using a press, slowly press in the push rod using 981 9,807 N (1001,000 kgf, 2202,205 lbf) of force. (b) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the push rod retracted. (c) Release the press. (d) Install the dust boot onto the tensioner. 12. INSTALL TIMING BELT TENSIONER (a) Temporarily install the tensioner with the 2 bolts. (b) Alternately tighten the 2 bolts. Torque: 26 Nm (270 kgfcm, 20 ftlbf) (c) Remove the 1.5 mm hexagon wrench from the tensioner with pliers. 13. CHECK VALVE TIMING (a) Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTICE: Always turn the crankshaft clockwise. EG27 ENGINE ENGINE MECHANICAL (b) Check that each pulley aligns with the timing marks as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. 14. INSTALL DRIVE BELT TENSIONER Torque: 21 Nm (210 kgfcm, 15 ftlbf) NOTICE: Be careful not to drop the bolts inside the timing belt cover. 15. INSTALL NO.2 TIMING BELT COVER 16. INSTALL NO.3 TIMING BELT COVER 17. INSTALL RADIATOR ASSEMBLY (See steps 4 and 5 in radiator installation in Cooling System) 18. INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND DRIVE BELT (See step 9 in water pump installation in Cooling System) 19. INSTALL AIR CLEANER DUCT 20. FILL ENGINE WITH COOLANT 21. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL 22. START ENGINE CHECK FOR LEAKS 23. CHECK IGNITION TIMING (See ignition timing inspection and adjustment) 24. INSTALL ENGINE UNDER COVER 25. ROAD TEST VEHICLE Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 26. RECHECK ENGINE COOLANT LEVEL EG28 ENGINE ENGINE MECHANICAL CYLINDER HEAD COMPONENTS FOR REMOVAL AND INSTALLATION EG2FV06 EG29 ENGINE ENGINE MECHANICAL EG30 ENGINE ENGINE MECHANICAL EG31 ENGINE ENGINE MECHANICAL EG4MH01 CYLINDER HEAD REMOVAL 1. 2. 3. DRAIN ENGINE COOLANT REMOVE ENGINE UNDER COVER DISCONNECT CONTROL CABLES FROM THROTTLE BODY (See step 2 in throttle body removal in SFI System) REMOVE AIR CLEANER DUCT REMOVE AIR CLEANER, VAF METER AND INTAKE AIR CONNECTOR PIPE REMOVE DRIVE BELT, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY (See step 5 in water pump removal in Cooling System) REMOVE NO.2 FRONT EXHAUST PIPE (See step 1 in front catalytic converter replacement in Emission Control Systems) 4. 5. 6. 7. 8. REMOVE EXHAUST MANIFOLDS (a) Disconnect the 2 (main heated) oxygen sensor connectors. (b) Remove the 4 nuts, exhaust manifold and gasket. Remove the No.1 and No.2 exhaust manifolds. 9. 10. (a) (b) 11. REMOVE AIR HOSE REMOVE VSV FOR EGR Disconnect the 2 vacuum hoses. Remove the nut and VSV. REMOVE THROTTLE BODY BRACKET AND THROTTLE BODY (See steps 4 and 5 in throttle body removal in SFI System) 12. DISCONNECT ENGINE WIRE AND HEATER WATER VALVE FROM COWL PANEL (a) Remove the 2 nuts, and disconnect the engine wire protector and ground strap. (b) Remove the 2 bolts, and disconnect the heater water valve. EG32 ENGINE ENGINE MECHANICAL (c) Pull out the engine wire protector and heater water hose from the cowl panel. 13. (a) (b) 14. REMOVE EGR PIPE Loosen the union nut of the EGR pipe. Remove the 2 bolts, EGR pipe and gasket. REMOVE EGR GAS TEMPERATURE SENSOR 15. REMOVE EGR VALVE AND VACUUM MODULATOR (a) Remove the bolt holding the vacuum modulator bracket to the intake air connector. (b) Disconnect the 3 vacuum hoses from the No.1 vacuum pipe. (c) Remove the 2 nuts, the EGR valve, vacuum modulator assembly and gasket. 16. 17. 18. (a) (b) (c) REMOVE PCV HOSE DISCONNECT BRAKE BOOSTER VACUUM HOSE REMOVE NO.2 VACUUM PIPE ASSEMBLY Disconnect the 4 vacuum hoses from the No.2 vacuum pipe. Disconnect the vacuum hose from the air intake chamber. Disconnect the EGR gas temperature sensor connector from the claw of the No.2 vacuum pipe. EG33 ENGINE ENGINE MECHANICAL (d) Disconnect the VSV connector for the EVAP. (e) Disconnect the 2 vacuum hoses from the vacuum control valve set. (f) Remove the 2 nuts and No.2 vacuum pipe. 19. REMOVE INTAKE AIR CONNECTOR (a) Remove the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber. (b) Disconnect the vacuum hose (from the actuator) from the No.1 vacuum pipe. (c) Remove the intake air connector and gasket. (d) Disconnect the vacuum hose from the intake air port. (e) Remove the 3 bolts and No.1 vacuum pipe from the intake air connector. 20. DISCONNECT HIGHTENSION CORDS FROM CYLINDER HEAD COVERS (See hightension cords and cord clamps removal in Ignition System) 21. REMOVE DISTRIBUTOR AND HIGHTENSION CORDS ASSEMBLY (See steps 1 and 3 in distributor removal in Ignition System) 22. REMOVE SPARK PLUGS EG34 ENGINE ENGINE MECHANICAL 23. REMOVE WATER BYPASS OUTLET AND NO.1 WATER BYPASS PIPE (a) Remove the 2 bolts, water bypass outlet and No.1 water bypass pipe. (b) Remove the 3 Orings from the water bypass outlet and No.1 water bypass pipe. 24. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS (See steps 7 to 10 in timing belt removal) 25. (a) (b) (c) REMOVE DATA LINK CONNECTOR 1 (DLC1) BRACKET Disconnect the DLC1 from the bracket. Disconnect the VSV connector. Disconnect these hoses: (1) PS air hose from air intake chamber (2) Vacuum sensing hose from fuel pressure regulator (3) Vacuum hose from air intake chamber (d) Remove the bolt, DLC1 bracket and VSV assembly. 26. REMOVE AIR INTAKE CHAMBER (a) Remove the bolt, nut and intake chamber stay. Remove the No.1 and No.2 stays. (b) Remove the union bolt, brake booster union and 2 gaskets. (c) Remove the 2 bolts, accelerator cable bracket and hose clamp. (d) Remove the 5 bolts, nut, air intake chamber and gasket. EG35 ENGINE ENGINE MECHANICAL 27. DISCONNECT FUEL RETURN HOSE 28. REMOVE PS PUMP REAR STAY Remove the 2 bolts and pump rear stay. 29. REMOVE INTAKE MANIFOLD STAY (a) Remove the bolt and hose clamp. (b) Remove the 2 bolts and manifold stay. 30. REMOVE OIL DIPSTICK GUIDES FOR ENGINE AND TRANSMISSION (a) Remove the 2 mounting bolts. (b) Pull out the dipstick guide together with the dipstick. (c) Remove the Oring from the dipstick guide. 31. REMOVE VACUUM CONTROL VALVE SET (a) Disconnect the VSV connector. (b) Remove the 2 nuts and vacuum control valve set 32. DISCONNECT ENGINE WIRE (a) Remove the bolt, and disconnect the engine wire bracket from the water pump. (b) Remove the 2 bolts, and disconnect the 2 ground straps from the intake manifold. (c) Remove the bolt, and disconnect the wire clamp from the intake manifold. (d) Disconnect these connectors: (1) ECT sensor connector (2) ECT sender gauge connector (3) 2 knock sensor connectors (4) Oil pressure switch connector EG36 ENGINE ENGINE MECHANICAL (5) Oil level sensor connector (6) A/C compressor connector (7) 6 injector connectors (e) Remove the 3 nuts, and disconnect the engine wire protector from the intake manifold. 33. REMOVE WATER OUTLET AND NO.1 BYPASS HOSE Remove the 2 nuts, bolt and water outlet. 34. REMOVE FUEL PRESSURE PULSATION DAMPER (See fuel pressure pulsation damper removal in SFI System) 35. REMOVE NO.1 AND NO.2 FUEL PIPES (a) Remove the 2 clamp bolt from the intake manifold. (b) Remove the union bolt and 2 gaskets, and disconnect the fuel pipe. HINT: Put a suitable container or shop rag under the delivery pipe. Slowly loosen the union bolt. 36. REMOVE DELIVERY PIPE AND INJECTORS (See step 13 in injectors removal in SFI System) 37. REMOVE INTAKE MANIFOLD Remove the 6 bolts, 2 nuts, intake manifold and gasket. 38. REMOVE NO.3, NO.1 AND NO.2 CYLINDER HEAD COVERS (a) Remove the PCV valve. (b) Remove the 4 bolts, 4 nuts and No.3 cylinder head cover. (c) Remove the 4 bolts, No.1 cylinder head cover and gasket. (d) Remove the 4 bolts, No.2 cylinder head cover and gasket. EG37 ENGINE ENGINE MECHANICAL 39. REMOVE CAMSHAFT TIMING PULLEYS Hold the hexagon portion of the camshaft with a wrench, and remove the pulley mounting bolt and camshaft pulley. 40. REMOVE NO.4 TIMING BELT COVER 41. REMOVE CAMSHAFTS (a) Uniformly loosen and remove the 4 No.1 bearing cap bolts. (b) Using a screwdriver, pry out the 2 No.1 camshaft bearing caps and oil seals. NOTICE: Be careful not to damage the cap. Tape the screwdriver tip. (c) Uniformly loosen and remove the 12 bearing cap bolts in several passes, in the sequence shown, and remove the 6 bearing caps and camshaft. (d) Remove the intake and exhaust camshafts. 42. REMOVE CYLINDER HEAD (a) Using a 10 mm bihexagon wrench, uniformly loosen and remove the 14 cylinder head bolts in several passes, in the sequence shown. NOTICE: Cylinder head warpage or cracking could result from removing in the correct order. (b) Remove the 14 plate washers. EG38 ENGINE ENGINE MECHANICAL (c) Lift the cylinder head from the dowels on the cylinder block. (d) Place the head on wooden blocks on a bench. If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block projection. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. EG4MJ01 CYLINDER HEAD DISASSEMBLY 1. REMOVE VALVE LIFTERS AND SHIMS HINT: Store the valve lifters and shims in correct order. 2. REMOVE VALVES (a) Using SST, compress the valve spring and remove the 2 keepers. SST 0920270010 (b) Remove the spring retainer, valve spring, valve and spring seat. HINT: Store the valves, valve springs, spring seats and spring retainers in correct order. (c) Using needlenose pliers, remove the oil seal. 3. 4. 5. REMOVE ENGINE HANGERS REMOVE ECT SENSOR AND SENDER GAUGE REMOVE THROTTLE CABLE BRACKET AND GROUND STRAP EG39 ENGINE ENGINE MECHANICAL 6. REMOVE EGR COOLER Remove the 8 bolts, EGR cooler and gasket. EG0PR09 CYLINDER HEAD COMPONENTS INSPECTION AND REPAIR 1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK (a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. (b) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using highpressure compressed air. 2. A. CLEAN CYLINDER HEAD Remove gasket material Using a gasket scraper, remove all the gasket material from the cylinder block surface. NOTICE: Be careful not to scratch the cylinder block contact surface. B. Clean combustion chambers Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. EG40 ENGINE ENGINE MECHANICAL C. Clean valve guide bushings Using a valve guide bushing brush and solvent, clean all the guide bushings. D. Clean cylinder head Using a soft brush and solvent, thoroughly clean the cylinder head. 3. A. INSPECT CYLINDER HEAD Inspect for flatness Using precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block, intake and exhaust manifolds for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head. B. Inspect for cranks Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. EG41 ENGINE ENGINE MECHANICAL 4. CLEAN VALVES (a) Using a gasket scraper, chip off any carbon from the valve head. (b) Using a wire brush, throughly clean the valve. 5. INSPECT VALVE STEMS AND GUIDE BUSHINGS (a) Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 6.0106.030 mm (0.23660.2374 in.) (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.9705.985 mm (0.23500.2356 in.) Exhaust 5.9655.980 mm (0.23480.2354 in.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake .0250.060 mm (0.00100.0024 in.) Exhaust .0300.065 mm (0.00120.0026 in.) Maximum oil clearance: Intake .08 mm (0.0031 in.) Exhaust .10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing. EG42 ENGINE ENGINE MECHANICAL 6. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS (a) Using SST and a hammer, tap out the guide bushing. SST 0920110000 (0920101060) 0960830022 (0960805010) (b) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Both intake and exhaust Bushing bore diameter mm (in.) 10.985 11.006 mm (0.4325 0.4333 in.) 11.035 11.056 mm(0.4344 0.4353 in.) Bushing size Use STD Use O/S 0.05 V00726 (c) Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bushing bore to the following dimension: 11.03511.056 mm (0.43440.4353 in.) If the bushing bore diameter of the cylinder head is greater than 11.056 mm (0.4353 in.), replace the cylinder head. (d) Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 0920110000 (0920101060) 0960830022 (0960805010) Protrusion height: Intake 12.312.7 mm (0.4840.500 in.) Exhaust 11.411.8 mm (0.4490.465 in.) HINT: Different bushings are used for the intake and exhaust. EG43 ENGINE ENGINE MECHANICAL (e) Using a sharp 6 mm reamer, ream the guide bushing to obtain the standard specified clearance (See step 5) between the guide bushing and valve stem. 7. INSPECT AND GRIND VALVES (a) Grind the valve enough to remove pits and carbon. (b) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5 (c) Check the valve head margin thickness. Standard margin thickness: 0.81.2 mm (0.0310.047 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. (d) Check the valve overall length. Standard overall length: Intake 98.2998.79 mm (3.86973.8894 in.) Exhaust 98.8499.34 mm (3.89133.9110 in.) Minimum overall length: Intake 98.19 mm (3.8657 in.) Exhaust 98.74 mm (3.8874 in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than the minimum overall length. EG44 ENGINE ENGINE MECHANICAL 8. INSPECT AND CLEAN VALVE SEATS (a) Using a 45_ carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. (b) Check the valve seating position. Apply a thin coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate the valve. (c) Check the valve face and seat for the following: If blue appears 360_ around the face, the valve is concentric. If not, replace the valve. If blue appears 360_ around the valve seat, the guide and face are concentric. If not, resurface the seat. Check that the seat contact is in the middle of the valve face with the following width: Intake 1.01.4 mm (0.0390.055 in.) Exhaust 1.21.6 mm (0.0470.063 in.) If not, correct the valve seats as follows: (1) If the seating is too high on the valve face, use 15 and 45 cutters to correct the seat. (2) If the seating is too low on the valve face, use 60 and 45 cutters to correct the seat. (d) Handlap the valve and valve seat with an abrasive compound. (e) After handlapping, clean the valve and valve seat. EG45 ENGINE ENGINE MECHANICAL 9. INSPECT VALVE SPRINGS (a) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If deviation is greater than maximum, replace the valve spring. (b) Using vernier calipers, measure the free length of the valve spring. Free length: Blue painted mark 41.74 mm (1.6433 in.) Yellow painted mark 41.70 mm (1.6417 in.) If the free length is not as specified, replace the valve spring. (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 186206 N (19.021.0 kgf, 4246 lbf) at 34.5 mm (1.358 in.) If the installed tension is not as specified, replace the valve spring. 10. A. (a) (b) INSPECT CAMSHAFTS AND BEARINGS Inspect camshaft for runout Place the camshaft on Vblocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.08 mm (0.0031 in.) If the circle runout is greater than maximum, replace the camshaft. B. Inspect cam lobes Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 44.57044.670 mm (1.75471.7587 in.) Exhaust 44.77044.870 mm (1.76261.7665 in.) EG46 ENGINE ENGINE MECHANICAL Minimum cam lobe height: Intake 44.42 mm (1.7488 in.) Exhaust 44.62 mm (1.7567 in.) If the cam lobe height is less than minimum, replace the camshaft. C. Inspect camshaft journals Using a micrometer, measure the journal diameter. Journal diameter: 28.94928.965 mm (1.13971.1404 in.) If the journal diameter is not as specified, check the oil clearance. D. Inspect camshaft bearings Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. E. (a) (b) (c) Inspect camshaft journal oil clearance Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps. (See step 2 in cylinder head installation) Torque: 20 Nm (200 kgfcm, 14 ftlbf) NOTICE: Do not turn the camshaft. EG47 ENGINE ENGINE MECHANICAL (e) Remove the bearing caps. (f) Measure the Plastigage at its widest point. Standard oil clearance: 0.0350.072 mm (0.00140.0028 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the Plastigage. F. Inspect camshaft thrust clearance (a) Install the camshafts. (See step 2 in cylinder head installation) (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.0800.190 mm (0.00310.0075 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 11. INSPECT VALVE LIFTERS AND LIFTER BORES (a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.00031.016 mm (1.22051.2211 in.) (b) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.96830.976 mm (1.21911.2195 in.) EG48 ENGINE ENGINE MECHANICAL (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.0240.050 mm (0.00090.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. 12. INSPECT AIR INTAKE CHAMBER Using a precision straight edge and feeler gauge, measure the surfaces contacting the intake manifold for warpage. Maximum warpage: 0.15 mm (0.0059 in.) If warpage is greater than maximum, replace the chamber. 13. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and air intake chamber for warpage. Maximum warpage: 0.15 mm (0.0059 in.) If warpage is greater than maximum, replace the manifold. 14. INSPECT EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head for warpage. Maximum warpage: 0.50 mm (0.0196 in.) If warpage is greater than maximum, replace the manifold. 15. INSPECT CYLINDER HEAD BOLTS Using a vernier caliper, measure the thread outside diameter of the bolt. Standard outside diameter: 10.811.0 mm (0.4250.433 in.) Minimum outside diameter: 10.7 mm (0.421 in.) If the diameter is less than minimum, replace the bolt. EG49 ENGINE ENGINE MECHANICAL EG4MK01 CYLINDER HEAD ASSEMBLY HINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones. 1. INSTALL HEATER UNION HINT: When using a new cylinder head, a new heater union must be installed. (a) Apply adhesive to the end of the heater union as shown in the illustration. Adhesive: Part No.0883300070, THREE BOND 1324 or equivalent (b) Using a wooden block and hammer, tap in a new heater union, leaving 48 mm (1.89 in.) protruding from the cylinder head. NOTICE: Do not tap it in too far. 2. INSTALL EGR COOLER Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 3. 4. INSTALL ECT SENSOR AND SENDER GAUGE Torque: 20 Nm (200 kgfcm, 14 ftlbf) INSTALL GROUND STRAP AND THROTTLE CABLE BRACKET INSTALL ENGINE HANGERS Torque: 39 Nm (400 kgfcm, 29 ftlbf) 5. 6. INSTALL VALVES (a) Install a new oil seal on the valve guide bushing. (b) Install these parts: (1) Valve (2) Spring seat (3) Valve spring (4) Spring retainer EG50 ENGINE ENGINE MECHANICAL HINT: Install the valve spring, facing the painted mark upward. (c) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 0920270010 (d) Using a plasticfaced hammer, lightly tap the valve stem tip to assure proper fit. 7. INSTALL VALVE LIFTERS AND SHIMS (a) Install the valve lifter and shim. (b) Check that the valve lifter rotates smoothly by hand. EG4ML01 CYLINDER HEAD INSTALLATION 1. INSTALL CYLINDER HEAD A. Place cylinder head on cylinder block (a) Place a new cylinder head gasket in position on the cylinder block. NOTICE: Be sure to install it correctly. (b) Place the cylinder head in position on the cylinder head gasket. EG51 ENGINE ENGINE MECHANICAL B. Install cylinder head bolts HINT: The cylinder head bolts are tightened in 2 progressive steps (steps (c) and (f)). If any of bolts break or deform, replace them. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Install the 14 plate washers to each cylinder head bolt. (c) Using a 10 mm bihexagon wrench, uniformly tighten the cylinder head bolts, in several passes, in the sequence shown. Torque: 34 Nm (350 kgfcm, 25 ftlbf) If any of the bolts do not meet the torque specification, replace the bolt. (d) Mark the front of the cylinder head bolt head with paint. (e) Retighten the cylinder head bolts 90_ in the numerical order shown in the illustration on previous page. (f) Retighten cylinder head bolts by an additional 90_ shown in the illustration on previous page. (g) Check that the painted mark is now turned to the rear. 2. INSTALL CAMSHAFTS (a) Apply engine oil to the thrust portion of the camshaft. (b) Place the camshaft on the cylinder head with the cam lobe facing up as shown. EG52 ENGINE ENGINE MECHANICAL (c) Place the No.3 and No.7 bearing caps in their proper location. (d) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (e) Temporarily tighten these bearing cap bolts uniformly and alternately, in several passes, until the bearing caps are snug with the cylinder head. (f) Apply MP grease to a new camshaft oil seal lip. (g) Install the 2 oil seals to the camshafts. (h) Clean the installed surfaces of the No.1 bearing cap and cylinder head with cleaner. (i) Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 0882600080 or equivalent EG53 ENGINE ENGINE MECHANICAL (j) Install the No.1, No.2, No.4, No.5 and No.6 bearing caps in their proper locations. (k) (l) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the 14 bearing cap bolts on one side, in several passes, in the sequence shown. Torque: 20 Nm (200 kgfcm, 14 ftlbf) (m) Using SST, push the 2 oil seals in as far as they can go. SST 0931660010 (0931600010, 0931600050) (n) Rotate the camshaft with a wrench at the hexagon position, bring the forward straight pin up. (o) Loosen the 3 bearing cap bolts as shown, until they can be turned by hand; retighten in several passes. Torque: 20 Nm (200 kgfcm, 14 ftlbf) EG54 ENGINE ENGINE MECHANICAL (p) Turn the camshaft 1/3 of a revolution. (q) Loosen the 2 bearing cap bolts as shown, until they can be turned by hand; retighten in several passes. Torque: 20 Nm (200 kgfcm, 14 ftlbf) (r) (s) Turn the camshaft a further 1/3 of a revolution. Loosen the 2 bearing cap bolts as shown, until they can be turned by hand; retighten in several passes. Torque: 20 Nm (200 kgfcm, 14 ftlbf) 3. 4. 5. CHECK AND ADJUST VALVE CLEARANCE (See step 5 in valve clearance inspection and adjustment) INSTALL NO.4 TIMING BELT COVER Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) INSTALL CAMSHAFT TIMING PULLEYS Torque: 79 Nm (810 kgfcm, 59 ftlbf) 6. 7. 8. INSTALL NO.3, NO.1 AND NO.2 CYLINDER HEAD COVERS (See step 7 in valve clearance inspection and adjustment) INSTALL INTAKE MANIFOLD Torque: 21 Nm (210 kgfcm, 15 ftlbf) INSTALL INJECTORS AND DELIVERY PIPE (See step 1 in injectors installation in SFI System) 9. INSTALL NO.1 AND NO.2 FUEL PIPES (a) Connect the No.1 fuel pipe with 2 new gaskets and the union bolt. Torque: 42 Nm (420 kgfcm, 30 ftlbf) (b) Connect the No.2 fuel pipe with 2 new gaskets and the union bolt. Torque: 27 Nm (280 kgfcm, 20 ftlbf) (c) Install the 2 clamp bolts to the intake manifold. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 10. INSTALL FUEL PRESSURE PULSATION DAMPER (See steps 1 and 2 in fuel pressure pulsation damper installation in SFI System) 11. INSTALL WATER OUTLET AND NO.1 BYPASS HOSE Torque: 21 Nm (210 kgfcm, 15 ftlbf) 12. CONNECT ENGINE WIRE (a) Install the engine wire protector to the intake manifold with the 3 nuts. EG55 ENGINE ENGINE MECHANICAL (b) Install the wire clamp to the intake manifold with the bolt. (c) Install the 2 ground straps to the intake manifold with the bolts. (d) Connect these connectors: (1) ECT sensor connector (2) ECT sender gauge connector (3) 2 knock sensor connectors (4) Oil pressure switch connector (5) Oil level sensor connector (6) A/C compressor connector (7) 6 injector connectors HINT: The No.1, No.3 and No.5 injector connectors are gray, and the No.2, No.4 and No.6 injector connectors are dark gray. (e) Install the engine wire bracket to the water pump with the bolt. 13. INSTALL VACUUM CONTROL VALVE SET Torque: 21 Nm (210 kgfcm, 15 ftlbf) 14. INSTALL OIL DIPSTICK GUIDES FOR ENGINE AND TRANSMISSION (a) Install a new Oring on the dipstick guide. (b) Apply soapy water on the Oring. (c) Connect the dipstick guide end to the oil pan. (d) Install the 2 dipstick guides with the 2 bolts. 15. INSTALL INTAKE MANIFOLD STAY Torque: 39 Nm (400 kgfcm, 29 ftlbf) 16. INSTALL PS PUMP REAR STAY Torque: 39 Nm (400 kgfcm, 29 ftlbf) 17. CONNECT FUEL RETURN HOSE 18. INSTALL AIR INTAKE CHAMBER (a) Install a new gasket and the intake chamber with the 5 bolts and nut. Torque: 27 Nm (280 kgfcm, 20 ftlbf) (b) Install the accelerator bracket and hose clamp with the 2 bolts. (c) Install the brake booster union with 2 new gaskets and the union bolt. 19. INSTALL AIR INTAKE CHAMBER STAYS Install the intake chamber stay with the bolt and nut. Install the No.1 and No.2 stays. Torque: 18 Nm (185 kgfcm, 13 ftlbf) HINT: The No.1 stay is marked "F" and No.2 stay is marked with "R". EG56 ENGINE ENGINE MECHANICAL 20. INSTALL DATA LINK CONNECTOR 1 (DLC1) BRACKET (a) Install the DLC1 bracket and VSV assembly with the bolt. (b) Connect these hoses: (1) PS air hose to air intake chamber (2) Vacuum sensing hose to fuel pressure regulator (3) Vacuum hose to air intake chamber (c) Connect the VSV connector. (d) Connect the DLC1 to the bracket. 21. INSTALL TIMING BELT (See steps 10 to 15 in timing belt installation) 22. INSTALL WATER BYPASS OUTLET AND NO.1 WATER BYPASS PIPE Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 23. INSTALL SPARK PLUGS 24. INSTALL DISTRIBUTOR AND HIGHTENSION CORDS (See steps 3 and 6 in distributor installation in Ignition System) 25. CONNECT HIGHTENSION CORDS TO CYLINDER HEAD COVERS (See steps 1 to 3 in hightension cords and cord clamps installation in Ignition System) 26. (a) (b) (c) INSTALL INTAKE AIR CONNECTOR Install the No.1 vacuum pipe with the 3 bolts. Connect the vacuum hose to the intake air port. Place the new gasket so the protrusion face the air intake chamber, and set the intake air connector. (d) Connect the vacuum hose to the No.1 vacuum pipe. (e) Install the intake air connector with the 4 bolts and 2 nuts. Torque: 27 Nm (280 kgfcm, 20 ftlbf) 27. INSTALL NO.2 VACUUM PIPE ASSEMBLY Torque: 27 Nm (280 kgfcm, 20 ftlbf) 28. 29. 30. 31. CONNECT BRAKE BOOSTER VACUUM HOSE INSTALL PCV HOSE INSTALL EGR VALVE AND VACUUM MODULATOR INSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 Nm (200 kgfcm, 14 ftlbf) EG57 ENGINE ENGINE MECHANICAL 32. INSTALL EGR PIPE (a) Temporarily install the union nut of the EGR pipe. (b) Install a new gasket and the EGR pipe with the 2 bolts. Torque: 27 Nm (280 kgfcm, 20 ftlbf) (c) Tighten the union nut of the EGR pipe. Torque: 64 Nm (650 kgfcm, 47 ftlbf) 33. INSTALL ENGINE WIRE AND HEATER WATER VALVE TO COWL PANEL 34. INSTALL THROTTLE BODY AND THROTTLE BODY BRACKET (See steps 4 and 5 in throttle body removal in SFI System) 35. INSTALL VSV FOR EGR 36. INSTALL AIR HOSE 37. INSTALL EXHAUST MANIFOLDS (a) Install a new gasket and the exhaust manifold with new 4 nuts. Install the No.1 and No.2 exhaust manifolds. Torque: 39 Nm (400 kgfcm, 29 ftlbf) (b) Connect the 2 (main heated) oxygen sensor connectors. 38. INSTALL NO.2 FRONT EXHAUST PIPE (See step 2 in front catalytic converter replacement in Emission Control Systems) 39. INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND DRIVE BELT (See step 9 in water pump installation in Cooling System) 40. INSTALL AIR CLEANER, VAF METER AND INTAKE AIR CONNECTOR PIPE 41. INSTALL AIR CLEANER DUCT 42. CONNECT CONTROL CABLES TO THROTTLE BODY (See step 2 in throttle body removal in SFI System) 43. FILL WITH ENGINE COOLANT 44. START ENGINE AND CHECK FOR LEAKS 45. CHECK IGNITION TIMING (See ignition timing inspection and adjustment) 46. INSTALL ENGINE UNDER COVER 47. ROAD TEST VEHICLE Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 48. RECHECK ENGINE COOLANT LEVEL EG58 ENGINE ENGINE MECHANICAL EG2EZ04 CYLINDER BLOCK COMPONENTS FOR ENGINE REMOVAL AND INSTALLATION EG59 ENGINE ENGINE MECHANICAL EG60 ENGINE ENGINE MECHANICAL EG4MM01 ENGINE REMOVAL REMOVE HOOD INSULATOR DISCONNECT HOOD SUPPORTS FROM HOOD REMOVE HOOD NOTICE: Be careful not to damage the body or glass with the hood end. 4. REMOVE ENGINE UNDER COVER 5. DRAIN ENGINE COOLANT 6. DRAIN ENGINE OIL 7. DRAIN FUEL FROM FUEL TANK 8. DISCONNECT CONTROL CABLES FROM THROTTLE BODY (See step 2 in throttle body removal in SFI System) 9. REMOVE AIR CLEANER DUCT 10. REMOVE AIR CLEANER, VAF METER AND INTAKE AIR CONNECTOR PIPE 11. REMOVE DRIVE BELT 1. 2. 3. EG61 ENGINE ENGINE MECHANICAL 12. REMOVE RADIATOR ASSEMBLY (See steps 4 to 6 in radiator removal in Cooling System) 13. (a) (b) (c) DISCONNECT WIRES AND CONNECTORS Disconnect the igniter connector. Disconnect the ignition coil connector. Disconnect the wire harness from the wire clamp and coolant reservoir. (d) Disconnect the generator connector. (e) Remove the rubber cap and nut, and disconnect the generator wire. (f) Remove the bolt, and disconnect the ground strap from the LH engine mounting bracket. (g) Remove the rubber cap and nut, and disconnect the starter wire. 14. DISCONNECT FUEL HOSES (a) Remove the union bolt and 2 gaskets, disconnect the fuel inlet hose, and suspend the hose union end upward. HINT: Put a suitable container or shop rag under the fuel pipe support. Slowly loosen the union bolt. (b) Disconnect the fuel return hose from the intake manifold stay and No.2 fuel pipe. Plug the hose end. 15. DISCONNECT PS PUMP WITHOUT DISCONNECTING HOSES (a) Disconnect these hoses: (1) Air hose from No.4 timing belt cover (2) Air hose from air intake chamber (b) Remove the 2 bolts and pump rear stay. EG62 ENGINE ENGINE MECHANICAL (c) Remove the 3 bolts, plate washer and pump front bracket. (d) Remove the 2 bolts and pump bracket, and disconnect the pump housing from the engine. HINT: Put aside the pump housing, and suspend it securely. 16. DISCONNECT A/C COMPRESSOR DISCONNECTING HOSES (a) Loosen the 2 mounting bolts. (b) Remove the nut. WITHOUT (c) Using a torx socket (E10), remove the stud bolt. (d) Disconnect the compressor connector. (e) Remove the 2 mounting bolts and nut, and disconnect the compressor from the engine. HINT: Put aside the compressor, and suspend it securely. EG63 ENGINE ENGINE MECHANICAL 17. 18. 19. 20. DISCONNECT BRAKE BOOSTER VACUUM HOSE DISCONNECT EVAP HOSE DISCONNECT HEATER WATER HOSES DISCONNECT HEATER WATER VALVE AND ENGINE WIRE FROM COWL PANEL (a) Disconnect the water valve control cable. (b) Remove the 2 nuts, and disconnect the ground strap and engine wire protector. (c) Remove the 2 bolts holding the heater water valve to the cowl panel. (d) Remove the cruise control actuator cover. (e) Disconnect the engine wire clamp from the bracket. (f) Remove the 2 bolts holding the engine wire retainer to the cowl panel. 21. DISCONNECT ENGINE WIRE FROM CABIN (a) Remove the scuff plate. HINT: Tape a screwdriver tip before use. Using the screwdriver, pry out the front side of the clip. Using a clip remover, the scuff plate. (b) Remove the instrument panel under cover. HINT: Tape a screwdriver tip before use. Using the screwdriver, pry out the under cover, and disconnect it from the instrument panel. Disconnect the step light from the under cover. (c) Remove the air heater guide. (d) Take out the front side of the floor carpet. (e) Remove the bolt, 2 nuts and ECM protector. EG64 ENGINE ENGINE MECHANICAL (f) Remove the nut, and disconnect the ECM from the floor panel. (g) Disconnect the connector from the ECM. (h) Disconnect the connector from the cowl wire connector. (i) Pull out the engine wire from the cabin. 22. DISCONNECT SUB HEATED OXYGEN SENSOR FROM FRONT EXHAUST PIPE (a) Disconnect the wire grommet from the floor. (b) Remove the 2 bolts and sensor cover. (c) Disconnect the oxygen sensor from the exhaust pipe. 23. REMOVE EXHAUST PIPE ASSEMBLY (a) Remove the 2 bolts and nuts holding the front exhaust pipe to the No.2 front exhaust pipe. (b) Remove the 2 bolts and pipe support bracket. (c) Remove the gasket and disconnect the front exhaust pipe. (d) Disconnect the 2 hooks of the tailpipe from the rings. (e) Disconnect the 2 rings on the exhaust pipe from the exhaust pipe brackets, and remove the exhaust pipe. EG65 ENGINE ENGINE MECHANICAL 24. REMOVE NO.2 FRONT EXHAUST PIPE Remove the 4 nuts, No.2 front exhaust pipe and 2 gaskets. 25. REMOVE EXHAUST PIPE HEAT INSULATOR Remove the 6 bolts and heat insulator. 26. REMOVE REAR CENTER FLOOR CROSSMEMBER BRACE Remove the 4 bolts and crossmember brace. 27. DISCONNECT TRANSMISSION CONTROL ROD Remove the nut and disconnect the control rod from the shift lever. 28. REMOVE PROPELLER SHAFT (See step 5 in propeller shaft removal in Propeller Shaft) 29. PLACE JACK UNDER TRANSMISSION Be sure to put a wooden block between a jack and the transmission oil pan to prevent damage. EG66 ENGINE ENGINE MECHANICAL 30. REMOVE REAR SUPPORT MEMBER (a) Remove the 4 nuts holding the member to the engine rear mounting insulator. (b) Remove the 4 bolts and rear support member. 31. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE (a) Attach the engine hoist chain to the 2 engine hangers. (b) Remove the 2 hole plugs. (c) Remove the 2 nuts holding the engine front mounting insulators to the front suspension crossmember. (d) Lift the engine out of the vehicle slowly and carefully. NOTICE: Remove carefully without damaging the A/C compressor or cooling fan. (e) Make sure the engine is clear of all wiring, hoses and cables. (f) Place the engine and transmission assembly onto the stand. EG67 ENGINE ENGINE MECHANICAL EG0PX0A COMPONENTS FOR ENGINE & TRANSMISSION SEPARATION AND ASSEMBLY EG2F103 ENGINE & TRANSMISSION SEPARATION 1. (a) (b) (c) REMOVE OIL DIPSTICK GUIDE FOR TRANSMISSION Remove the mounting bolt. Pull out the dipstick and guide from the transmission. Remove the Oring from the dipstick guide. EG68 ENGINE ENGINE MECHANICAL 2. DISCONNECT ENGINE WIRE FROM TRANSMISSION (a) Disconnect the 5 connectors. (b) Disconnect the 5 wire clamps from the brackets. 3. REMOVE STARTER (a) Disconnect the starter connector. (b) Remove the 2 bolts, engine wire bracket and starter. 4. DISCONNECT THROTTLE CABLE (a) Disconnect the throttle cable from the throttle body. (b) Disconnect the throttle cable from the cable bracket on the cylinder head. EG69 ENGINE ENGINE MECHANICAL 5. REMOVE A/T OIL COOLER PIPES FOR TRANSMISSION (a) Remove the 3 clamp mounting bolts. (b) Loosen the 2 union nuts, and remove the oil cooler pipes. 6. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLTS (a) Remove the hole plug. (b) Turn the crankshaft to gain access to each bolt. Remove the 6 bolts. 7. SEPARATE ENGINE AND TRANSMISSION Remove the 10 bolts and transmission. EG70 ENGINE ENGINE MECHANICAL EG0PX0B COMPONENTS FOR CYLINDER BLOCK DISASSEMBLY AND ASSEMBLY EG71 ENGINE ENGINE MECHANICAL EG2F203 PREPARATION FOR DISASSEMBLY 1. REMOVE DRIVE PLATE (a) Uniformly loosen the 8 bolts in several passes, in the sequence shown. (b) Remove the 8 bolts, rear plate, drive plate and front spacer. 2. 3. 4. INSTALL ENGINE TO ENGINE STAND DISASSEMBLY REMOVE GENERATOR REMOVE TIMING BELT AND PULLEYS (See steps 4 and, 6 to 18 in timing belt removal) FOR 5. 6. REMOVE WATER PUMP AND BYPASS PIPE REMOVE CYLINDER HEAD (See steps 8 to 11 and, 13 to 42 in cylinder head removal) 7. REMOVE OIL PRESSURE SWITCH AND KNOCK SENSORS SST 0981630010 8. 9. 10. 11. 12. REMOVE OIL FILTER BRACKET REMOVE RH ENGINE MOUNTING BRACKET REMOVE LH ENGINE MOUNTING BRACKET REMOVE FUEL PIPE SUPPORT REMOVE OIL PUMP (See steps 7 to 14 in oil pump removal in Lubrication System) EG72 ENGINE ENGINE MECHANICAL EG4MN01 CYLINDER BLOCK DISASSEMBLY 1. REMOVE REAR OIL SEAL RETAINER (a) Remove the 6 bolts of the retainer. (b) Remove the oil seal retainer by prying the area between the oil seal retainer and main bearing cap with a screwdriver. 2. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rods back and forth. Standard thrust clearance: 0.2500.402 mm (0.00980.0158 in.) Maximum thrust clearance: 0.50 mm (0.0197 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 25.89825.950 mm (1.01961.0217 in.) 3. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly. (b) Remove the connecting rod cap bolts. Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. (d) Clean the crank pin and bearings. (e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. (f) Lay a strip of Plastigage across the crank pin. (c) EG73 ENGINE ENGINE MECHANICAL (g) Install the connecting rod cap with the 2 bolts. (See step 7 in cylinder block assembly) Torque: 1st 29 Nm (300 kgfcm, 22 ftlbf) 2nd Turn extra 90 NOTICE: Do not turn the crankshaft. (h) Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above) (i) Measure the Plastigage at its widest point. Standard oil clearance: STD .0350.053 mm (0.00140.0021 in.) U/S 0.25 0.0400.078 mm (0.00160.0031 in.) Maximum oil clearance. STD 0.08 mm (0.0031 in.) U/S 0.25 0.09 mm (0.0035 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. HINT: If using a standard bearing, replace with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly. EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4") V00727 EG74 ENGINE ENGINE MECHANICAL Reference: Connecting rod big and inside diameter: Mark "1" 55.02555.031 mm (2.16632.1666 in.) Mark "2" 55.03155.037 mm (2.16662.1668 in.) Mark "3" 55.03755.043 mm (2.16682.1670 in.) Crankshaft crank pin diameter: Mark "0" 51.99452.000 mm (2.04702.0472 in.) Mark "1" 51.98851.994 mm (2.04682.0470 in.) Mark "2" 51.98251.988 mm (2.04652.0468 in.) Bearing center wall thickness: Mark "1" 1.4921.495 mm (0.05870.0589 in.) Mark "2" 1.4951.498 mm (0.05890.0590 in.) Mark "3" 1.4981.501 mm (0.05900.0591 in.) Mark "4" 1.5011.504 mm (0.05910.0592 in.) Mark "5" 1.5041.507 mm (0.05920.0593 in.) (j) Completely remove the Plastigage. 4. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES (a) Using a ridge reamer, remove all the carbon from the top of the cylinder. (b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in correct order. EG75 ENGINE ENGINE MECHANICAL 5. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.0200.220 mm (0.00080.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 1.9401.990 mm (0.07640.0783 in.) 6. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE (a) Uniformly loosen and remove the 14 main bearing cap bolts, in several passes, in the sequence shown. (b) Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No.4 main bearing cap only). HINT: Keep the lower bearing and main bearing cap together. Arrange the main bearing caps and lower thrust washers in correct order. (c) Lift out the crankshaft. HINT: Keep the upper bearing and upper thrust washers together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. EG76 ENGINE ENGINE MECHANICAL (f) Place the crankshaft on the cylinder block. (g) Lay a strip of Plastigage across each journal. (h) Install the main bearing caps. (See step 4 in cylinder block assembly) Torque: 1st 44 Nm (450 kgfcm, 33 ftlbf) 2nd Turn extra 90 NOTICE: Do not turn the crankshaft. (i) Remove the main bearing caps. (See procedures (a) and (b) above) (j) Measure the Plastigage at its widest point. Standard clearance: STD .0260.040 mm (0.00100.0016 in.) U/S 0.25 .0250.061 mm (0.00100.0024 in.) Maximum clearance: STD .06 mm (0.0024 in.) U/S 0.25 .08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. EG77 ENGINE ENGINE MECHANICAL HINT: If using a standard bearing, replace with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly. EXAMPLE: Cylinder block "3" (A) + Crankshaft "4" (B) = Total number 7 (Use bearing "3") V00728 Reference: Cylinder block main journal bore diameter (A): Mark "0" 66.02066.022 mm (2.599222.59929 in.) Mark "1" 66.02266.024 mm (2.599292.59936 in.) Mark "2" 66.02466.026 mm (2.599362.59944 in.) Mark "3" 66.02666.028 mm (2.599442.59952 in.) Mark "4" 66.02866.030 mm (2.599522.59960 in.) Mark "5" 66.03066.032 mm (2.599602.59968 in.) Mark "6" 66.03266.034 mm (2.599682.59976 in.) Mark "7" 66.03466.036 mm (2.599762.59984 in.) Crankshaft main journal diameter (B): Mark "0" 61.99862.000 mm (2.440862.44094 in.) Mark "1" 61.99661.998 mm (2.440782.44086 in.) Mark "2" 61.99461.996 mm (2.440702.44078 in.) Mark "3" 61.99261.994 mm (2.440632.44070 in.) Mark "4" 61.99061.992 mm (2.440552.44063 in.) Mark "5" 61.98861.990 mm (2.440472.44055 in.) EG78 ENGINE ENGINE MECHANICAL Mark "6" 61.98661.988 mm (2.440392.44047 in.) Mark "7" 61.98461.986 mm (2.440312.44039 in.) Bearing center wall thickness: Mark "1" 1.9941.997 mm (0.07850.0786 in.) Mark "2" 1.9972.000 mm (0.07860.0787 in.) Mark "3" 2.0002.003 mm (0.07870.0789 in.) Mark "4" 2.0032.006 mm (0.07890.0790 in.) Mark "5" 2.0062.009 mm (0.07900.0791 in.) Standard sized Bearing Selection chart (k) 7. REMOVE CRANKSHAFT (a) Lift out the crankshaft (b) Remove the upper bearings and upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order. Crankshift number mark b k 0 1 2 3 4 5 6 7 Cylinder block number mark 2 1 2 2 2 3 3 3 4 3 2 2 2 3 3 3 4 4 4 2 2 3 3 3 4 4 5 5 2 3 3 3 4 4 5 5 0 1 1 1 2 2 2 3 3 1 1 1 2 2 2 3 3 3 6 3 3 3 4 4 5 5 5 7 3 3 4 4 4 5 5 5 EXAMPLE: Cylinder block "3" Crankshaft "4" = Use bearing "3" V00736 Completely remove the Plastigage. EG79 ENGINE ENGINE MECHANICAL EG0Q008 CYLINDER BLOCK INSPECTION 1. A. CLEAN CYLINDER BLOCK Remove gasket material Using a gasket scraper, remove all the gasket material from the cylinder block surface. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. INSPECT CYLINDER BLOCK SURFACE FOR FLATNESS Using precision straight edge and feeler gauge, measure the top surfaces of the cylinder block for warpage. Maximum warpage: 0.07 mm (0.0028 in.) B. 2. If warpage is greater than maximum, replace the cylinder block. 3. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block. 4. INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 86.00086.013 mm (3.38583.3863 in.) Maximum diameter: 86.02 mm (3.3866 in.) If the diameter is greater than maximum, replace the cylinder block. EG80 ENGINE ENGINE MECHANICAL 5. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. 6. INSPECT MAIN BEARING CAP BOLTS Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point. Standard diameter: 9.969.97 mm (0.39210.3925 in.) Minimum diameter: 9.7 mm (0.382 in.) If the diameter is less than minimum, replace the bolt. EG4MP01 PISTON AND CONNECTING ROD DISASSEMBLY 1. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. 2. REMOVE PISTON RINGS (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the 2 side rails and oil ring expander by hand. HINT: Arrange the piston rings in correct order only. 3. DISCONNECT CONNECTING ROD FROM PISTON (a) Using a small screwdriver, remove the 2 snap rings. (b) Gradually heat the piston to about 805C (1765F). EG81 ENGINE ENGINE MECHANICAL (c) Using a plasticfaced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. EG00209 PISTON AND CONNECTING ROD INSPECTION 1. CLEAN PISTON (a) Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves. (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. 2. INSPECT PISTON A. Inspect piston oil clearance (a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 34 mm (1.34 in.) from the piston head. Piston diameter: 85.93585.945 mm (3.38333.3837 in.) EG82 ENGINE ENGINE MECHANICAL (b) Measure the cylinder bore diameter in the thrust directions. (See step 4 in cylinder block inspection) (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.0550.078 mm (0.00220.0031 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block. B. Inspect piston ring groove clearance Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove. Ring groove clearance: No.1 .0110.070 mm (0.00040.0028 in.) No.2 .0300.070 mm (0.00120.0028 in.) If the clearance is not as specified, replace the piston. C. Inspect piston ring end gap (a) Insert the piston ring into the cylinder bore. (b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. (c) Using a feeler gauge, measure the ring end gap. Standard ring end gap: No.1 .3000.470 mm (0.01180.0185 in.) No.2 .3500.520 mm (0.01380.0205 in.) Oil (Side rail) .1300.450 mm (0.00510.0177 in.) EG83 ENGINE ENGINE MECHANICAL Maximum ring end gap: No.1 1.07 mm (0.0421 in.) No.2 1.12 mm (0.0441 in.) Oil (Side rail) 1.05 mm (0.0413 in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. D. Inspect piston pin fit At 80C (176F), you should be able to push the piston pin into the piston pin hole with your thumb. 3. A. INSPECT CONNECTING ROD Inspect connecting rod alignment Using a feeler gauge and rod aligner, check the connecting rod alignment. Check for outofalignment Maximum outofalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If outofalignment is greater than maximum, replace the connecting rod assembly. Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly. EG84 ENGINE ENGINE MECHANICAL B. Inspect piston pin oil clearance (a) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.00522.014 mm (0.86630.8667 in.) (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.99722.006 mm (0.86600.8664 in.) (c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.0050.011 mm (0.00020.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set. C. If necessary, replace connecting rod bushing (a) Using SST and a press, press out the bushing. SST 0922230010 (b) Align the oil holes of a new bushing and the connecting rod. (c) Using SST and a press, press in the bushing. SST 0922230010 EG85 ENGINE ENGINE MECHANICAL (d) Using a pin hole grinder, bore the bushing to obtain the standard specified clearance (see step B) between the bushing and piston pin. (e) Check the piston pin fit at room temperature. Coat the piston pin with engine oil and push it into the connecting rod with your thumb. D. Inspect connecting rod bolts Using vernier calipers, measure the minimum diameter of the compressed bolt at the measuring point. Standard diameter: 8.18.3 mm (0.3190.327 in.) Minimum diameter: 8.0 mm (0.315 in.) If the diameter is less than minimum, replace the connecting rod bolt. EG4MQ01 CRANKSHAFT INSPECTION 1. INSPECT CRANKSHAFT FOR RUNOUT (a) Place the crankshaft on Vblocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft. 2. INSPECT MAIN JOURNALS AND CRANK PINS (a) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: STD 61.98462.000 mm (2.44032.4409 in.) U/S 0.25 61.74561.755 mm (2.43092.4313 in.) EG86 ENGINE ENGINE MECHANICAL Crank pin diameter: STD 51.98252.000 mm (2.04652.0472 in.) U/S 0.25 51.74551.755 mm (2.03722.0376 in.) If the diameter is not as specified, check the oil clearance. (See pages EG72 and 75) (b) Check each main journal and crank pin for taper and outofround as shown. Maximum taper and outof round: 0.02 mm (0.0008 in.) 3. If the taper or outofround is greater than maximum, grind or replace the crankshaft. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure step 2). Install new main journal and/or crank pin undersized bearings. EG4MR01 CRANKSHAFT OIL SEALS REPLACEMENT 1. REPLACE CRANKSHAFT FRONT OIL SEAL HINT: There are 2 methods A and B to replace the oil seal as follows: A. If oil pump is removed from cylinder block: (a) Using a screwdriver, pry out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 0931660010 (0931600010) (c) Apply MP grease to the oil seal lip. B. If oil pump is installed on cylinder block: (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. EG87 ENGINE ENGINE MECHANICAL (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 0931660010 (0931600010) 2. REPLACE CRANKSHAFT REAR OIL SEAL HINT: There are 2 methods A and B to replace the oil seal as follows: A. If rear oil seal retainer is removed from cylinder block: (a) Using a screwdriver and hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 0922315030, 0960830022 (0960805010) (c) Apply MP grease to the oil seal lip. B. If rear oil seal retainer is installed on cylinder block: (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 0922315030, 0960830022 (0960805010) EG88 ENGINE ENGINE MECHANICAL EG4MS01 PISTON AND CONNECTING ROD ASSEMBLY 1. ASSEMBLE PISTON AND CONNECTING ROD (a) Install a new snap ring at one end of the piston pin hole. HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. (b) Gradually heat the piston to about 80_C (176_F). (c) Coat the piston pin with engine oil. (d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. (e) Install a new snap ring at the other end of the piston pin hole. HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. 2. INSTALL PISTON RINGS (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compression rings with the code mark facing up. Code mark: No.1: 1T No.2: 2T (c) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the piston ring ends. 3. INSTALL BEARINGS (a) Align the bearing claw with the groove of the connecting rod and connecting cap. (b) Install the bearings in the connecting rod and connecting rod cap. EG89 ENGINE ENGINE MECHANICAL EG4MT01 CYLINDER BLOCK ASSEMBLY HINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, Orings and oil seals with new parts. NOTICE: Apply a generous amount of oil on the sliding surface of the bearing, and not on the back of it or on the surface to which it is installed. 1. INSTALL MAIN BEARINGS HINT: Main bearings come in widths of 20.0 mm (0.787 in.) and 23.0 mm (0.906 in.). Install the 23.0 mm bearings in the No.1 cylinder block journal position with the main bearing cap. Install the 20.0 mm bearings in the other positions. Upper bearings have an oil groove and oil holes; lower bearings do not. (a) Align the bearing claw with the claw groove of the main bearing cap or cylinder block. NOTICE: Install the bearing with the oil hole in the cylinder block. (b) Install the bearings in the cylinder block and main bearing caps. EG90 ENGINE ENGINE MECHANICAL 2. 3. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.4 main journal position of the cylinder block with the oil grooves facing outward. PLACE CRANKSHAFT ON CYLINDER BLOCK 4. INSTALL MAIN BEARING CAP AND LOWER THRUST WASHERS A. Place main bearing cap and lower thrust washers on cylinder block (a) Install the lower thrust washers on the No.4 main bearing with the grooves facing outward. (b) Install the main bearing caps in numerical order with the arrows facing forward. B. Install main bearing cap bolts HINT: The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any of the main bearing bolts break or deform, replace them. (a) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts. (b) Install and uniformly tighten the 14 main bearing cap bolts, in several passes, in the sequence shown. Torque: 44 Nm (450 kgfcm, 33 ftlbf) If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. EG91 ENGINE ENGINE MECHANICAL (c) Mark the front of the main bearing cap bolt head with paint. (d) Retighten the main bearing cap bolts 905 in the numerical order shown above. (e) Check that the painted mark is now at a 905 angle to the front. (f) Check that the crankshaft turns smoothly. 5. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.0200.220 mm (0.00080.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 1.9401.990 mm (0.07640.0783 in.) 6. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. EG92 ENGINE ENGINE MECHANICAL 7. INSTALL CONNECTING ROD CAPS A. Place connecting rod cap on connecting rod (a) Match the numbered connecting rod cap with the connecting rod. (b) Install the connecting rod cap with by aligning the dowel pin to the corresponding hole. B. Install connecting rod cap bolts HINT: The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any of the connecting rod bolts break or deform, replace them. (a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (b) Install and alternately tighten the bolts of the connecting rod cap in several passes. Torque: 29 Nm (300 kgfcm, 22 ftlbf) If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolt. (c) Mark the front of the connecting rod cap bolt with paint. (d) Retighten the connecting rod cap bolts 905 in the numerical order shown. (e) Check that the painted mark is now at a 905 angle to the front. (f) Check that the crankshaft turns smoothly. EG93 ENGINE ENGINE MECHANICAL 8. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rods back and forth. Standard thrust clearance: 0.2500.402 mm (0.00980.0158 in.) Maximum thrust clearance: 0.50 mm (0.0197 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 25.89825.950 mm (1.01961.0217 in.) 9. INSTALL REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all debris. Using a nonresidue solvent, clean both sealing surfaces. (b) Apply seal packing to the retainer as shown in the illustration. Seal packing: Part No.0882600080 or equivalent Install a nozzle that has been cut to a 23 mm (0.080.12 in.) opening. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. (c) Install the retainer with the 6 bolts. Torque: 5.9 Nm (60 kgfcm, 52 in.lbf) EG94 ENGINE ENGINE MECHANICAL POST ASSEMBLY EG4MU01 1. 2. 3. 4. 5. INSTALL OIL PUMP (See steps 1 to 8 in oil pump installation in Lubrication System) INSTALL FUEL PIPE SUPPORT Torque: 14 Nm (145 kgfcm, 10 ftlbf) INSTALL RH ENGINE MOUNTING BRACKET Torque: 58 Nm (590 kgfcm, 43 ftlbf) INSTALL LH ENGINE MOUNTING BRACKET Torque: 58 Nm (590 kgfcm, 43 ftlbf) INSTALL OIL FILTER BRACKET Torque: 88 Nm (900 kgfcm, 65 ftlbf) 6. INSTALL KNOCK SENSORS AND OIL PRESSURE SWITCH (a) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No.0883300080, THREE BOND 1344, LOCTITE 242 or equivalent (b) Using SST, install the 2 knock sensors and oil pressure switch. SST 0981630010 Torque: Knock sensor: Oil pressure switch: 44 Nm (450 kgfcm, 33 ftlbf) 14 Nm (150 kgfcm, 11 ftlbf) 7. INSTALL CYLINDER HEAD (See steps 1 to 20 and, 23 to 32 and, 34 to 37 in cylinder head installation) EG95 ENGINE ENGINE MECHANICAL 8. INSTALL WATER PUMP AND BYPASS PIPE (a) Install the water pump. (See step 1 in water pump installation in Cooling System) (b) Install a new gasket to the water pump. (c) Install the No.2 water bypass pipe with the bolt and 2 nuts. Torque: 21 Nm (210 kgfcm, 15 ftlbf) (d) Connect the No.2 water bypass hose to the engine hanger. 9. INSTALL TIMING PULLEYS AND BELT (See steps 1 to 7 and, 9 to 16 and, 18 in timing belt installation) 10. INSTALL GENERATOR Torque: 37 Nm (380 kgfcm, 27 ftlbf) 11. REMOVE ENGINE STAND FROM ENGINE 12. INSTALL DRIVE PLATE (a) Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part No. 0883300070, THREE BOND 1324 or equivalent (b) Install the front spacer, drive plate and rear plate on the crankshaft. (c) Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown. Torque: 83 Nm (850 kgfcm, 61 ftlbf) EG96 ENGINE ENGINE MECHANICAL EG4MV01 ENGINE & TRANSMISSION ASSEMBLY 1. CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using calipers and straight edge, measure from the installed surface of the torque converter clutch to the front surface of the transmission. Correct distance: Less than 0.1 mm (0.004 in.) If the distance is not as specified, check for an improper installation. 2. ASSEMBLY ENGINE AND TRANSMISSION (a) Align the 2 knock pins on the cylinder block with the pin holes of the converter housing. (b) Temporarily install bolt. (c) Install the transmission with the mounting bolts. Torque: 14 mm head: 39 Nm (400 kgfcm, 29 ftlbf) 17 mm head: 72 Nm (730 kgfcm, 43 ftlbf) 3. INSTALL TORQUE CONVERTER CLUTCH MOUNTING BOLTS (a) First, install the gray bolt. Then install 5 black bolts while turning the crankshaft to gain access. Tighten the bolts evenly. Torque: 33 Nm (340 kgfcm, 25 ftlbf) (b) Install the hole plug. 4. CONNECT THROTTLE CABLE (a) Connect the throttle cable to the cable bracket on the cylinder head. (b) Connect the throttle cable to the throttle body. 5. INSTALL A/T OIL COOLER PIPES FOR TRANSMISSION (a) Temporarily install the 2 oil cooler pipes with the 2 pipe brackets and 3 bolts. (b) Connect the 2 oil cooler pipes to the unions on the transmission. Tighten the union nuts. Torque: 34 Nm (350 kgfcm, 25 ftlbf) (c) Tighten the 3 pipe clamp bolts. Torque: 10 Nm (100 kgfcm, 7 ftlbf) 6. INSTALL STARTER (a) Install the starter and engine wire bracket with the 2 bolts. Torque: 39 Nm (400 kgfcm, 29 ftlbf) (b) 7. (a) (b) Connect the starter connector. CONNECT ENGINE WIRE TO TRANSMISSION Connect the 5 connectors. Install the 5 wire clamps to the brackets. EG97 ENGINE ENGINE MECHANICAL 8. (a) (b) (c) (d) (e) INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION Install a new Oring to the dipstick guide. Apply soapy water to the Oring. Connect the dipstick guide end to the dipstick tube of the oil pan. Install the dipstick guide with the bolt. Install the dipstick. EG4MW01 ENGINE INSTALLATION 1. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE (a) Attach the engine hoist chain to the engine hangers. (b) Lower the engine and transmission assembly into the engine compartment. NOTICE: Install the engine and transmission assembly carefully without damaging the A/C compressor and cooling fan. (c) Insert the stud bolts of the front engine mounting insulators into the stud bolt holes of the front suspension crossmember. (d) Temporarily install the 2 nuts holding the engine front mounting insulators to the front suspension crossmember. (e) Keep the engine level with a jack. (f) Remove the hoist chain. (g) Temporarily install the support member to the engine rear mounting insulator with the 4 nuts with the front mark facing forward. (h) Install the 4 bolts holding the support member to the body. Torque: 25 Nm (260 kgfcm, 19 ftlbf) (i) Tighten the 4 nuts holding the support member to the engine rear mounting insulator. Torque: 13 Nm (135 kgfcm, 10 ftlbf) EG98 ENGINE ENGINE MECHANICAL (j) Tighten the 2 nuts holding the engine front mounting insulators to the front suspension crossmember. Torque: 74 Nm (750 kgfcm, 54 ftlbf) (k) 2. Install the hole plugs. INSTALL PROPELLER SHAFT (See steps 1 and 2 in propeller shaft installation in Propeller Shaft) 3. CONNECT TRANSMISSION CONTROL ROD (a) Shift the shift lever to N position. (b) Fully turn the control shaft lever back and return 2 notches. It is now in neutral position. (c) Connect the control rod to the shift lever with the nut. Torque: 13 Nm (130 kgfcm, 9 ftlbf) 4. INSTALL REAR CENTER FLOOR CROSSMEMBER BRACE Torque: 13 Nm (130 kgfcm, 9 ftlbf) 5. 6. INSTALL EXHAUST PIPE HEAT INSULATOR Install the heat insulator with the 6 bolts with the front mark facing forward. INSTALL NO.2 FRONT EXHAUST PIPE Install 2 new gaskets and No.2 front exhaust pipe with 4 new nuts. Torque: 62 Nm (630 kgfcm, 46 ftlbf) 7. INSTALL EXHAUST PIPE ASSEMBLY (a) Install the 2 hooks of the tailpipes to the 4 rings on the tailpipe brackets. (b) Install the 2 hooks of the exhaust pipe to the rings on the exhaust pipe brackets. (c) Install the pipe support bracket with the 2 bolts. Torque: 43 Nm (440 kgfcm, 32 ftlbf) (d) Install a new gasket and the No.2 front exhaust pipe to the front exhaust pipe with the 2 bolts and nuts. Torque: 43 Nm (440 kgfcm, 32 ftlbf) 8. INSTALL SUB HEATED OXYGEN SENSOR (a) Install the oxygen sensor to the front exhaust pipe. Torque: 44 Nm (450 kgfcm, 33 ftlbf) HINT: Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and a 1/2 turns. After installing the oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the oxygen sensor and reinstall it. (b) Install the sensor cover with the 2 bolts. (c) Connect the wire grommet to the floor. EG99 ENGINE ENGINE MECHANICAL 9. CONNECT ENGINE WIRE TO CABIN (a) Push in the engine wire through the cowl panel. NOTICE: Be careful not to damage the engine wire. (b) (c) (d) (e) (f) (g) (h) Connect the connector to the cowl wire connector. Connect the connector to the ECM. Install the ECM with the nut. Install the ECM protector with the bolt and 2 nuts. Install the floor carpet. Install the air heater guide. Install the instrument panel under cover. Install the step light to the under cover. Install the under cover with the 3 clips. Install the scuff plate. CONNECT HEATER WATER VALVE AND ENGINE WIRE TO COWL PANEL CONNECT HEATER WATER HOSE CONNECT EVAP HOSE CONNECT BRAKE BOOSTER VACUUM HOSE INSTALL A/C COMPRESSOR Temporarily install the compressor with the 2 bolts. Connect the compressor connector. Using a torx socket (E10), install the stud bolt. Torque: 26 Nm (265 kgfcm, 19 ftlbf) (i) 10. 11. 12. 13. 14. (a) (b) (c) (d) Install the nut. Torque: 52 Nm (530 kgfcm, 38 ftlbf) (e) Install the 2 mounting bolts. Torque: 52 Nm (530 kgfcm, 38 ftlbf) 15. INSTALL PS PUMP (a) Install the pump housing and bracket with the 2 bolts. Torque: Bracket x A/C Compressor: 58 Nm (590 kgfcm, 43 ftlbf) Bracket x Cylinder Block: 39 Nm (400 kgfcm, 29 ftlbf) (b) Install the front pump bracket with the 2 bolts. Torque: 58 Nm (590 kgfcm, 43 ftlbf) (c) Install the plate washer and bolt to the oil pump. Torque: 52 Nm (530 kgfcm, 38 ftlbf) (d) Install the pump rear stay with the 2 bolts. Torque: 39 Nm (400 kgfcm, 29 ftlbf) (e) Connect these hoses: (1) Air hose to No.4 timing belt cover (2) Air hose to air intake chamber EG100 ENGINE ENGINE MECHANICAL 16. CONNECT FUEL HOSES (a) Connect the fuel return hose to the intake manifold stay and No.2 fuel pipe. (b) Install the fuel inlet hose with 2 new gaskets and union bolt. Torque: 29 Nm (300 kgfcm, 22 ftlbf) 17. CONNECT WIRES AND CONNECTORS (a) Connect the starter wire with the nut and rubber cap. (b) Connect the ground strap to the LH engine mounting bracket with the bolt. (c) Connect the generator wire with the nut and rubber cap. (d) Connect the generator connector. (e) Connect the wire harness to the wire clamp and coolant reservoir. (f) Connect the ignition coil connector. (g) Connect the igniter connector. 18. INSTALL RADIATOR ASSEMBLY (See steps 4 to 6 in radiator installation in Cooling System) 19. INSTALL DRIVE BELT 20. INSTALL AIR CLEANER, VAF METER AND INTAKE AIR CONNECTOR PIPE 21. INSTALL AIR CLEANER DUCT 22. CONNECT CONTROL CABLES TO THROTTLE BODY (See step 2 in throttle body removal in SFI System) 23. FILL WITH FUEL 24. FILL WITH ENGINE OIL 25. FILL WITH ENGINE COOLANT 26. START ENGINE AND CHECK FOR LEAKS 27. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL 28. CHECK IGNITION TIMING (See ignition timing inspection and adjustment) 29. INSTALL ENGINE UNDER COVER 30. INSTALL HOOD Torque: 13 Nm (130 kgfcm, 9 ftlbf) NOTICE: Be careful not to damage the body or glass with the hood end. 31. CONNECT HOOD SUPPORTS TO HOOD Torque: 22 Nm (225 kgfcm, 16 ftlbf) 32. INSTALL HOOD INSULATOR 33. ROAD TEST VEHICLE Check for abnormal noise, shock slippage, correct shift points and smooth operation. 34. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS EG101 ENGINE ENGINE MECHANICAL EG0FN0D EXHAUST SYSTEM COMPONENTS SERVICE DATA SERVICE SPECIFICATIONS EG102 Cylinder head bushing Valve guide tensioner Timing belt pressure Compression vacuum manifold Intake Idle speed Ignition timing clearance Valve Cylinder head bolt diameter Valve seat Valve guide bore diameter Warpage inside diameter at 250 rpm at idle speed Clearance Contacting width Contacting angle Refacing angle Exhaust manifold side Intake manifold side Cylinder block side Outside diameter (for repair part) Protrusion (from housing side) Difference of pressure between each cylinder Adjusting shim (for repair part) w/ Terminals TE1 and E1 connected of DLC1 10 BTDC @ idle ENGINE ENGINE MECHANICAL Mark 3.300 3.300 mm (0.1299 in.) Mark 3.250 3.250 mm (0.1280 in.) Mark 3.200 3.200 mm (0.1260 in.) Mark 3.150 3.150 mm (0.1240 in.) Mark 3.100 3.100 mm (0.1220 in.) Mark 3.050 3.050 mm (0.1201 in.) Mark 3.000 3.000 mm (0.1181 in.) Mark 2.950 2.950 mm (0.1161 in.) Mark 2.900 2.900 mm (0.1142 in.) Mark 2.850 2.850 mm (0.1122 in.) Mark 2.800 2.800 mm (0.1102 in.) Mark 2.750 2.750 mm (0.1083 in.) Mark 2.700 2.700 mm (0.1063 in.) Mark 2.650 2.650 mm (0.1043 in.) Mark 2.600 2.600 mm (0.1024 in.) Mark 2.550 2.550 mm (0.1004 in.) Mark 2.500 2.500 mm (0.0984 in.) Maximum 0.10 mm (0.0039 in.) Maximum 0.10 mm (0.0039 in.) Maximum 0.10 mm (0.0039 in.) Minimum 10.7 mm (0.421 in.) 45 15, 45, 60 700 50 rpm Minimum 1,079 kPa (11.0 kgf/cm2, 156 psi) O/S 0.05 11.03511.056 mm (0.43440.4353 in.) O/S 0.05 11.08311.094 mm (0.43630.4368 in.) Exhaust 1.21.6 mm (0.0470.063 in.) Intake 1.01.4 mm (0.0390.055 in.) 8.08.8 mm (0.3150.346 in.) Exhaust 0.250.35 mm (0.0100.014 in.) Intake 0.150.25 mm (0.0060.010 in.) STD 10.811.0 mm (0.4250.433 in.) STD 10.98511.006 mm (0.43250.4333 in.) STD 11.03311.044 mm (0.43440.4348 in.) 6.0106.030 mm (0.23660.2374 in.) 98 kPa (1.0 kgf/cm2, 14 psi) or less STD 1,275 kPa (13.0 kgf/cm2, 185 psi) or more 66.7 kPa (500 mmHg, 19.7 in.Hg) or more EG0PW0L Cylinder block Manifold chamber Air intake Camshaft Valve Lifter Valve spring Valve Main bearing bolt diameter Cylinder bore diameter Warpage Warpage Circuit runout Journal oil clearance Journal diameter Cam lobe height Thrust clearance Oil clearance Lifter bore diameter Lifter diameter Free length Deviation Margin thickness Stem oil clearance Stem diameter Valve face angle Valve overall length Main journal bore diameter (Reference) Cylinder head surface warpage Installed tension at 34.5 mm (1.358 in.) ENGINE Yellow painted mark 41.70 mm (1.6417 in.) Blue painted mark 41.74 mm (1.6433 in.) Maximum (Intake) 0.15 mm (0.0059 in.) Maximum (Intake) 0.08 mm (0.0031 in.) Minimum (Intake) 44.42 mm (1.7488 in.) Minimum (Intake) 98.19 mm (3.8657 in.) STD (Intake) 44.57044.670 mm (1.75471.7587 in.) STD (Intake) 0.0250.060 mm (0.00100.0024 in.) STD (Intake) 98.2998.79 mm (3.86973.8894 in.) ENGINE MECHANICAL Maximum 86.02 mm (3.3866 in.) Maximum 0.07 mm (0.0028 in.) Maximum 0.15 mm (0.0059 in.) Maximum 0.08 mm (0.0031 in.) Maximum 0.10 mm (0.0039 in.) Maximum 0.30 mm (0.0118 in.) Maximum 0.07 mm (0.0028 in.) Maximum 2.0 mm (0.079 in.) (Exhaust) 0.50 mm (0.0196 in.) (Exhaust) 44.62 mm (1.7567 in.) (Exhaust) 44.77044.870 mm (1.76261.7665 in.) (Exhaust) 0.10 mm (0.0039 in.) (Exhaust) 0.0300.065 mm (0.00120.0026 in.) (Exhaust) 98.74 mm (3.8874 in.) (Exhaust) 98.8499.34 mm (3.89133.9110 in.) Minimum 9.7 mm (0.382 in.) Minimum 0.5 mm (0.020 in.) 44.5 Exhaust 5.9655.980 mm (0.23480.2354 in.) Mark 7 66.03466.036 mm (2.599762.59984 in.) Mark 6 66.03266.034 mm (2.599682.59976 in.) Mark 5 66.03066.032 mm (2.599602.59968 in.) Mark 4 66.02866.030 mm (2.599522.59960 in.) Mark 3 66.02666.028 mm (2.599442.59952 in.) Mark 2 66.02466.026 mm (2.599362.53344 in.) Mark 1 66.02266.024 mm (2.599292.59936 in.) Mark 0 66.02066.022 mm (2.599222.59929 in.) Intake 5.9705.985 mm (0.23500.2356 in.) STD 86.00086.013 mm (3.38583.3863 in.) STD 0.0350.072 mm (0.00140.0028 in.) STD 0.0800.190 mm (0.00310.0075 in.) STD 0.0240.050 mm (0.00090.0020 in.) STD 0.81.2 mm (0.0310.047 in.) 28.94928.965 mm (1.13971.1404 in.) 31.00031.016 mm (1.22051.2211 in.) 30.96630.976 mm (1.21911.2195 in.) 186206 N (19.021.0 kgf, 41.946.3 lbf) STD 9.969.97 mm (0.39210.3925 in.) EG103 EG104 rod Connecting Piston ring Piston and Rod twist per 100 mm (3.94 in.) Piston pin oil clearance Piston pin diameter Bushing inside diameter Connecting rod oil clearance Connecting bolt diameter Thrust clearance Piston ring end gap Piston ring groove clearance Piston oil clearance Piston diameter (Reference) (Reference) Rod outofalignment per 100 mm (3.94 in.) Connecting rod big end inside diameter Connecting rod bearing center wall thickness ENGINE Maximum (No.1) 1.07 mm (0.0421 in.) Maximum (STD) 0.08 mm (0.0031 in.) STD (Mark 1) 1.4921.495 mm (0.05870.0589 in.) ENGINE MECHANICAL STD (No.1) 0.3000.470 mm (0.01180.0185 in.) STD (STD) 0.0350.053 mm (0.00140.0021 in.) (U/S 0.25) 0.09 mm (0.0035 in.) (U/S 0.25) 0.0400.078 mm (0.00160.0031 in.) Maximum 0.15 mm (0.0059 in.) Maximum 0.05 mm (0.0020 in.) Maximum 0.05 mm (0.0020 in.) Maximum 0.50 mm (0.0197 in.) Maximum 0.10 mm (0.0039 in.) Minimum 8.0 mm (0.315 in.) (No.2) 1.12 mm (0.0441 in.) (Oil) 1.05 mm (0.0413 in.) (Mark 5) 1.5041.507 mm (0.05920.0593 in.) (Mark 4) 1.5011.504 mm (0.05910.0592 in.) (Mark 3) 1.4981.501 mm (0.05900.0591 in.) (Mark 2) 1.4951.498 mm (0.05890.0590 in.) Mark 3 55.03755.043 mm (2.16682.1670 in.) Mark 2 55.03155.037 mm (2.16662.1668 in.) Mark 1 55.02555.031 mm (2.16332.1666 in.) (No.2) 0.3500.520 mm (0.01380.0205 in.) No.2 0.0300.070 mm (0.00120.0028 in.) No.1 0.0110.070 mm (0.00040.0028 in.) STD 0.0050.011 mm (0.00020.0004 in.) STD 8.18.3 mm (0.3190.327 in.) STD 0.2500.402 mm (0.00980.0158 in.) STD 0.0550.078 mm (0.00220.0031 in.) (Oil) 0.1300.450 mm (0.00510.0177 in.) 21.99722.006 mm (0.86600.8664 in.) 22.00522.014 mm (0.86630.8667 in.) 85.93585.945 mm (3.38333.3837 in.) Crankshaft Crank pin taper and outofround Circle runout Crank pin diameter (Reference) Crank pin diameter Main journal diameter Main journal oil clearance Thrust washer thickness Thrust clearance Main journal taper and outofround Main journal diameter (Reference) Main bearing center wall thickness (Reference) Main journal bore diameter (Reference) ENGINE STD (Mark 0) 51.99452.000 mm (2.04702.0472 in.) STD (Mark 0) 61.99862.000 mm (2.440862.44094 in.) STD (STD) 0.0260.040 mm (0.00100.0016 in.) (U/S 0.25) 0.08 mm (0.0031 in.) (U/S 0.25) 0.0250.061 mm (0.00100.0024 in.) Maximum 0.02 mm (0.0008 in.) Maximum 0.02 mm (0.0008 in.) Maximum 0.06 mm (0.0024 in.) Maximum 0.06 mm (0.0024 in.) (STD) Maximum 0.30 mm (0.0118 in.) ENGINE MECHANICAL U/S 0.25 51.74551.755 mm (2.03722.0376 in.) U/S 0.25 61.74561.755 mm (2.43092.4313 in.) (Mark 2) 51.98251.988 mm (2.04652.0468 in.) (Mark 1) 51.98851.994 mm (2.04682.0470 in.) Mark 5 2.0062.009 mm (0.07900.0791 in.) Mark 4 2.0032.006 mm (0.07890.0790 in.) Mark 3 2.0002.003 mm (0.07870.0789 in.) Mark 2 1.9972.000 mm (0.07860.0787 in.) Mark 1 1.9941.997 mm (0.07850.0786 in.) STD 1.9401.990 mm (0.07640.0783 in.) STD 0.0200.220 mm (0.00080.0087 in.) STD 51.98252.000 mm (2.04652.0472 in.) STD 61.98462.000 mm (2.44032.4409 in.) (Mark 7) 61.98461.986 mm (2.440312.44039 in.) (Mark 6) 61.98661.988 mm (2.440392.44047 in.) (Mark 5) 61.98861.990 mm (2.440472.44055 in.) (Mark 4) 61.99061.992 mm (2.440552.44063 in.) (Mark 3) 61.99261.994 mm (2.440632.44070 in.) (Mark 2) 61.99461.996 mm (2.440702.44078 in.) (Mark 1) 61.99661.998 mm (2.440782.44086 in.) Mark 7 66.03466.036 mm (2.599762.59984 in.) Mark 6 66.03266.034 mm (2.599682.59976 in.) Mark 5 66.03066.032 mm (2.599602.59968 in.) Mark 4 66.02866.030 mm (2.599522.59960 in.) Mark 3 66.02666.028 mm (2.599442.59952 in.) Mark 2 66.02466.026 mm (2.599362.59944 in.) Mark 1 66.02266.024 mm (2.599292.59936 in.) Mark 0 66.02066.022 mm (2.599222.59929 in.) EG105 TORQUE SPECIFICATIONS EG106 Fuel pipe support x Cylinder block Main bearing cap x Cylinder block Exhaust manifold x Cylinder head EGR pipe x EGR valve EGR pipe x Cylinder head No.2 fuel pipe x Intake manifold No.1 fuel pipe x Intake manifold No.1 fuel pipe x Delivery pipe Intake manifold x Cylinder head Cylinder head x Cylinder block Engine hanger x Cylinder head ECT sensor x Cylinder head EGR cooler x Cylinder head Timing belt tensioner x Oil pump Crankshaft pulley x Crankshaft PS pump front bracket x Oil pump Idler pulley x Oil pump Spark plug x Cylinder head Rear oil seal retainer x Cylinder block Water bypass outlet x Cylinder head Air intake chamber x Intake manifold Intake manifold stay x Cylinder block ECT sender gauge x Cylinder head Drive belt tensioner x Cylinder head Camshaft timing pulley x Camshaft Connecting rod cap x Connecting rod EGR gas temperature sensor x EGR valve No.2 vacuum pipe x Air intake chamber Intake air connector x Air intake chamber Air intake chamber stay x Cylinder head Air intake chamber stay x Air intake chamber PS pump rear stay x Intake manifold stay PS pump rear stay x PS pump bracket Intake manifold stay x Intake manifold Vacuum control valve set x Intake manifold No.2 fuel pipe x Fuel pressure regulator No.4 timing belt cover x Cylinder head Camshaft bearing cap x Cylinder head No.3 cylinder head cover x Cylinder head No.2 cylinder head cover x Cylinder head PS pump front bracket x Cylinder block No.1 cylinder head cover x Cylinder head Part tightened ENGINE ENGINE MECHANICAL 2nd 2nd 2nd 3rd 1st 1st 1st Turn 90 Turn 90 Turn 90 Turn 90 Nm 324 8.8 8.8 8.8 8.8 8.8 8.3 8.3 8.3 44 29 39 64 27 20 27 27 18 18 27 39 39 39 39 21 27 42 21 34 39 20 20 20 21 26 79 52 58 34 18 5.9 14 kgfcm 3,300 145 450 300 400 650 280 200 280 280 185 185 280 400 400 400 400 210 280 420 210 350 400 200 200 200 210 270 810 530 590 350 180 60 90 90 90 90 90 85 85 85 52 in.lbf 78 in.lbf 78 in.lbf 78 in.lbf 78 in.lbf 78 in.lbf 74 in.lbf 74 in.lbf 74 in.lbf ftlbf 239 33 22 29 47 20 14 20 20 13 13 20 29 29 29 29 15 20 30 15 25 29 14 14 14 15 20 59 38 43 25 13 10 EG0TL0B Hood support x Hood Hood hinge x Hood Fuel inlet hose x Fuel pipe support PS pump bracket x Cylinder block A/C compressor x Cylinder block Rear support member x Body Starter x Transmission Cylinder block x Transmission Drive plate x Crankshaft Generator x Cylinder block Generator x Water pump Knock sensor x Cylinder block Oil filter bracket x Cylinder block PS pump bracket x A/C compressor Sub heated oxygen sensor x Front exhaust pipe No.2 front exhaust pipe x Front exhaust pipe Pipe support bracket x Transmission No.2 front exhaust pipe x Exhaust manifold Rear center floor crossmember brace x Body Transmission control rod x Shift lever Front suspension crossmember x Engine mounting insulator Rear support member x Engine rear mounting insulator A/T oil cooler pipe bracket x Cylinder block A/T oil cooler pipe bracket x Transmission A/T oil cooler pipe x Union (Transmission) Drive plate x Torque converter clutch Water pump x No.2 water bypass pipe Oil pressure switch x Cylinder block RH engine mounting bracket x Cylinder block LH engine mounting bracket x Cylinder block ENGINE for bolt and nut 17 mm head 14 mm head for stud bolt ENGINE MECHANICAL 22 13 29 39 58 52 26 44 43 43 62 13 13 74 13 25 39 10 10 34 33 72 39 83 37 37 21 14 44 88 58 58 225 130 300 400 590 530 265 450 440 440 630 130 130 750 135 260 400 100 100 350 340 730 400 850 380 380 210 150 450 900 590 590 EG107 16 22 29 43 38 19 33 32 32 46 74 10 19 29 25 25 43 29 61 27 27 15 33 65 43 43 11 9 9 7 7 9 EG108 ENGINE EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS SYSTEM PURPOSE EG4JY01 The emission control systems are installed to reduce the amount of HC, CO and NOx exhausted from the engine ((3), (4) and (5)), to prevent the atmospheric release of blowby gascontaining HC (1) and evaporated fuel containing HC being released from the fuel tank (2). The function of each system is shown in the following table. System Abbreviation PCV EVAP EGR SFI TWC Function (1) Positive Crankcase Ventilation (2) Evaporative Emission Control (3) Exhaust Gas Recirculation Reduces HC Reduces evaporated HC Reduces NOx (4) ThreeWay Catalytic Converter Reduces HC, CO and NOx (5) Sequential Multiport Fuel Injection* Regulates all engine conditions for reduction of exhaust emissions. Remark: * For inspection and repair of the SFI system, refer to the SFI section this manual. PREPARATION EG2DF06 RECOMMENDED TOOLS EG2DG07 Tachometer Torque wrench Vacuum gauge EQUIPMENT EG109 ENGINE EMISSION CONTROL SYSTEMS COMPONENT LAYOUT EG2DD0A SCHEMATIC DRAWING EG110 ENGINE EMISSION CONTROL SYSTEMS POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM EG2DL05 PCV VALVE INSPECTION 1. REMOVE PCV VALVE (a) Disconnect the PCV hose from the PCV valve. (b) Remove the PCV valve. 2. INSTALL CLEAN HOSE TO PCV VALVE 3. INSPECT PCV VALVE OPERATION (a) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. (b) Blow air into the intake manifold side, and check that air passes through with difficulty. If operation is not as specified, replace the PCV valve. 4. REMOVE CLEAN HOSE FROM PCV VALVE 5. REINSTALL PCV VALVE EG2DM07 PCV HOSES AND CONNECTORS INSPECTION VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. EG111 ENGINE EMISSION CONTROL SYSTEMS EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EG2DQ0A FUEL VAPOR LINES, FUEL TANK AND TANK CAP INSPECTION 1. 2. VISUALLY INSPECT LINES AND CONNECTIONS Look for loose connections, sharp bends or damage. VISUALLY INSPECT FUEL TANK Look for deformation, cranks or fuel leakage. VISUALLY INSPECT FUEL TANK CAP Check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap. 3. EG4JZ01 CHARCOAL CANISTER INSPECTION 1. 2. REMOVE CHARCOAL CANISTER VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage. 3. CHECK FOR CLOGGED FILTER AND STUCK CHECK VALVE (a) Using low pressure compressed air (4.71 kPa, 48 gf/cm2, 0.68 psi), blow into port A and check that air flows without resistance from the other ports. (b) Blow air (4.71 kPa, 48 gf/cm2, 0.68 psi) into port B and check that air does not flow from the other ports. If a problem is found, replace the charcoal canister. EG112 ENGINE EMISSION CONTROL SYSTEMS 4. CLEAN FILTER IN CANISTER Clean the filter by blowing 294 kPa (3 kgf/cm2, 43 psi) of compressed air into port A while holding port B closed. NOTICE: Do not attempt to wash the canister. No activated carbon should come out. 5. REINSTALL CHARCOAL CANISTER EG4K001 VSV INSPECTION (See VSV for EVAP in SFI System) EG2DU08 CHECK VALVE INSPECTION 1. REMOVE CHECK VALVE 2. INSPECT CHECK VALVE (a) Check that air flows from the blue port to the black port. (b) Check that air does not flow from the black port to the blue port. If operation is not as specified, replace check valve. 3. REINSTALL CHECK VALVE HINT: Reinstall the check valve with the black port facing the purge port side. EG113 ENGINE EMISSION CONTROL SYSTEMS EXHAUST GAS RECIRCULATION (EGR) SYSTEM EG4K101 EGR SYSTEM INSPECTION 1. CHECK AND CLEAN FILTER IN EGR VACUUM MODULATOR (a) Remove the cap and filter. (b) Check the filter for contamination or damage. (c) Using compressed air, clean the filter. (d) Reinstall the filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side outward. 2. INSTALL VACUUM GAUGE Using a 3way connector, connect a vacuum gauge to the hose between the EGR valve and EGR vacuum modulator. 3. INSPECT SEATING OF EGR VALVE Check that the engine starts and runs at idle. 4. INSPECT VSV OPERATION WITH COLD ENGINE (a) The engine coolant temperature should be below 45_C (113_F). (b) Check that the vacuum gauge indicates zero at 2,500 rpm. (c) Check that the EGR pipe is not hot. 5. INSPECT OPERATION OF VSV AND EGR VACUUM MODULATOR WITH HOT ENGINE (a) Warm up the engine to above 50_C (122_F). (b) Check that the vacuum gauge indicates low vacuum at 2,500 rpm. (c) Disconnect the vacuum hose from port R of the EGR vacuum modulator and connect port R directly to the intake manifold with another hose. (d) Check that the vacuum gauge indicates high vacuum at 2,500 rpm. HINT: As exhaust gas is increasingly recirculated, the engine will start to misfire. EG114 ENGINE EMISSION CONTROL SYSTEMS 6. REMOVE VACUUM GAUGE Remove the vacuum gauge, and reconnect the vacuum hoses to their proper locations. 7. INSPECT EGR VALVE (a) Apply vacuum directly to the EGR valve with the engine idling. (b) Check that the engine runs rough or dies. (c) Reconnect the vacuum hoses to their proper locations. IF NO PROBLEM IS FOUND DURING THIS INSPECTION, SYSTEM IS NORMAL; OTHERWISE INSPECT EACH PART VSV INSPECTION EG4K201 (See VSV for EGR in SFI System) EG4K301 EGR VACUUM MODULATOR INSPECTION 1. DISCONNECT VACUUM HOSES FROM EGR VACUUM MODULATOR Disconnect the 3 vacuum hoses from ports P, Q and R of the EGR vacuum modulator. 2. INSPECT EGR VACUUM MODULATOR OPERATION (a) Block ports P and R with your finger. (b) Blow air into port Q, and check that the air passes through to the air filter side freely. (c) Start the engine, and maintain speed at 2,500 rpm. (d) Repeat the above test. Check that there is a strong resistance to air flow. 3. RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Connect the 3 vacuum hoses to the proper locations. EG115 ENGINE EMISSION CONTROL SYSTEMS EG2GF04 EGR VALVE INSPECTION 1. DISCONNECT ENGINE WIRE AND HEATER WATER VALVE FROM COWL PANEL (a) Remove the 2 nuts, and disconnect the engine wire protector and ground strap. (b) Remove the 2 bolts, and disconnect the heater water valve. (c) Pull out the engine wire protector and heater water hose from the cowl panel. 2. (a) (b) 3. REMOVE EGR PIPE Loosen the union nut of the EGR pipe. Remove the 2 bolts, EGR pipe and gasket. REMOVE EGR GAS TEMPERATURE SENSOR 4. REMOVE EGR VALVE (a) Disconnect these hoses: (1) Vacuum hose from EGR valve (2) Pressure hose from EGR valve (b) Remove the 2 nuts, EGR valve and gasket. EG116 ENGINE EMISSION CONTROL SYSTEMS 5. INSPECT EGR VALVE Check for sticking and heavy carbon deposits. If a problem is found, replace the EGR valve. 6. REINSTALL EGR VALVE (a) Place a new gasket on the intake air connector. (b) Install the EGR valve with the 2 nuts. Torque: 18 Nm (185 kgfcm, 13 ftlbf) (c) Connect these hoses: (1) Vacuum hose to EGR valve (2) Pressure hose to EGR valve 7. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 Nm (200 kgfcm, 14 ftlbf) 8. REINSTALL EGR PIPE (a) Temporarily install the union nut of the EGR pipe. (b) Install a new gasket and the EGR pipe with the 2 bolts. Torque: 27 Nm (280 kgfcm, 20 ftlbf) (c) Tighten the union nut of the EGR pipe. Torque: 64 Nm (650 kgfcm, 47 ftlbf) 9. REINSTALL ENGINE WIRE AND HEATER WATER VALVE TO COWL PANEL (a) Install the heater water valve with the 2 bolts. (b) Install the engine wire protector and ground strap with the 2 nuts. EG117 ENGINE EMISSION CONTROL SYSTEMS EG2GJ06 THREEWAY CATALYTIC CONVERTER (TWC) SYSTEM EXHAUST PIPE ASSEMBLY INSPECTION 1. 2. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE EG4K401 THREEWAY CATALYTIC CONVERTER INSPECTION CHECK FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it contacts the threeway catalytic converter, repair or replace it. EG4K501 HEAT INSULATOR INSPECTION 1. 2. CHECK HEAT INSULATOR FOR DAMAGE CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR EG2E60D THREEWAY CATALYTIC CONVERTERS COMPONENTS FOR REPLACEMENT EG118 ENGINE EMISSION CONTROL SYSTEMS EG4K601 CATALYTIC CONVERTERS REPLACEMENT Front Catalytic Converter: 1. REMOVE NO.2 FRONT EXHAUST PIPE (FRONT TWC) (a) Check that the converter is cool. (b) Remove the 2 bolts and nuts holding the No.2 front exhaust pipe to the front exhaust pipe. (c) Remove the 2 bolts and pipe support bracket from the transmission. (d) Disconnect the front exhaust pipe from the No.2 front exhaust pipe, and remove the gasket. (e) Remove the 4 nuts and No.2 front exhaust pipe and 2 gaskets. 2. REINSTALL NO.2 FRONT EXHAUST PIPE (FRONT TWC) (a) Install 2 new gaskets and the No.2 front exhaust pipe to the exhaust manifolds with 4 new nuts. Torque: 62 Nm (630 kgfcm, 46 ftlbf) (b) Install the pipe support bracket to the transmission with the 2 bolts. Torque: 43 Nm (440 kgfcm, 32 ftlbf) (c) Install a new gasket to front end of the front exhaust pipe, and torque the front exhaust pipe to the No.2 front exhaust pipe. Torque: 43 Nm (440 kgfcm, 32 ftlbf) Rear Catalytic Converter: 1. DISCONNECT SUB HEATED OXYGEN SENSOR FROM FRONT EXHAUST PIPE (a) Disconnect the wire grommet from the floor. (b) Remove the 2 bolts and sensor cover. (c) Disconnect the oxygen sensor from the exhaust pipe. EG119 ENGINE EMISSION CONTROL SYSTEMS 2. REMOVE FRONT EXHAUST PIPE (REAR TWC) (a) Remove the 2 bolts holding the front exhaust pipe to the center exhaust pipe. (b) Remove the 2 bolts and nuts holding the front exhaust pipe to the No.2 front exhaust pipe. (c) Remove the front exhaust pipe and 2 gaskets. 3. REINSTALL FRONT EXHAUST PIPE (REAR TWC) Install 2 new gaskets, the front exhaust pipe with the 4 bolts and 2 new nuts. Torque: 43 Nm (440 kgfcm, 32 ftlbf) 4. RECONNECT SUB HEATED OXYGEN SENSOR (a) Install the oxygen sensor to the front exhaust pipe. Torque: 44 Nm (450 kgfcm, 33 ftlbf) HINT: Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and a 1/2 turns. After installing the oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the oxygen sensor and reinstall it. (b) Install the sensor cover with the 2 bolts. (c) Install the wire grommet to the floor. EG06Q12 SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS Part tightened Nm 18 20 27 64 62 43 43 43 44 kgfcm 185 200 280 650 630 440 440 440 450 ftlbf 13 14 20 47 46 32 32 32 33 EGR valve x Intake air connector EGR pipe x Cylinder head EGR valve x EGR pipe EGR gas temperature sensor x EGR valve No.2 front exhaust pipe (front TWC) x Exhaust manifold Pipe support bracket x Transmission No.2 front exhaust pipe (front TWC) x Front exhaust pipe (rear TWC) Front exhaust pipe (rear TWC) x Center exhaust pipe Sub heated oxygen sensor x Front exhaust pipe EG120 ENGINE SFI SYSTEM SFI SYSTEM PREPARATION EG0CF0R SST (SPECIAL SERVICE TOOLS) EQUIPMENT Mirror Soft brush Vacuum gauge Torque wrench Tachometer Sound scope Carburetor cleaner Graduated cylinder Throttle body Injector Injector Throttle body EG0CH0J RECOMMENDED TOOLS ENGINE SFI SYSTEM EG121 EG0CG0L EG122 ENGINE SFI SYSTEM PRECAUTION EG0A20K 1. 2. 3. Before working on the fuel system, disconnect negative () terminal cable from the battery. HINT: Any diagnostic trouble code retained by the computer will be erased when the battery terminal is removed. Therefore, if necessary, read the diagnosis before removing the terminal. Do not smoke or work near an open flame when working on the fuel system. Keep gasoline away from rubber or leather parts. EG11U MAINTENANCE PRECAUTIONS 1. PRECAUTION WHEN CONNECTING GAUGE (a) Use battery as the power source for the timing light, tachometer, etc. (b) Connect the tester probe of a tachometer to the terminal IG of the DLC1. 2. (a) (b) (c) (d) 3. (a) (b) IN EVENT OF ENGINE MISFIRE, THESE PRECAUTIONS SHOULD BE TAKEN Check proper connection of battery terminals, etc. Handle hightension cords carefully. After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely. When cleaning the engine compartment, be especially careful to protect the electrical system from water. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR Do not allow oxygen sensor to drop or hit against an object. Do not allow the sensor to come into contact with water. EG123 ENGINE SFI SYSTEM EG4L801 IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. EG0CM0D AIR INDUCTION SYSTEM 1. 2. Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will cause air suction and cause the engine to run out of tune. EG4L901 ELECTRONIC CONTROL SYSTEM 1. Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the negative () terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the battery terminals. 2. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative () cables. 3. Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM. 4. Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can cause further troubles. 5. Do not open the ECM cover. 6. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. 7. Parts should be replaced as an assembly. 8. Care is required when pulling out and inserting wiring connectors. (a) Release the lock and pull out the connector, pulling on the connectors. (b) Fully insert the connector and check that it is locked. EG124 ENGINE SFI SYSTEM 9. Use SST for inspection or test of the injector or its wiring connector. SST 0984230070 EG4LA01 FUEL SYSTEM 1. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe these procedures: (a) Remove the luggage compartment floor mat and trim cover. (b) Disconnect the fuel pump connector. (c) Start the engine. After the engine has stopped on its own, turn off the ignition switch. (d) (e) (f) (g) (h) (i) Put a container under the connection. Slowly loosen the connection. Disconnect the connection. Plug the connection with a rubber plug. Reconnect the fuel pump connector. Reinstall the luggage compartment trim cover and floor mat. 2. When connecting the flare nut or union bolt on the high pressure pipe union, observe these procedures: Union Bolt Type (a) Always use a new gasket. (b) Tighten the union bolt by hand. (c) Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kgfcm, 22 ftlbf) Flare Nut Type (a) Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. (b) Using SST, tighten the flare nut to specified torque. SST 0963122020 Torque: 30 Nm (310 kgfcm, 22 ftlbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) EG125 ENGINE SFI SYSTEM 3. Observe the following precautions when removing and installing the injectors. (a) Never reuse the Oring. (b) When placing a new Oring on the injector, take care not to damage it in any way. (c) Coat a new Oring with spindle oil or gasoline before installingnever use engine, gear or brake oil. 4. Install the injector to the delivery pipe and intake manifold as shown in the illustration. (a) Using SST, connect terminals +B and FP of the DLC 1. 5. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. SST 0984318020 (b) With engine stopped, turn the ignition switch ON. (c) Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/cm2, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack. (d) Turn the ignition switch to LOCK. (e) Remove the SST from the DLC1. SST 0984318020 EG126 ENGINE SFI SYSTEM EG4LB01 FUEL PUMP ONVEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION (a) Using SST, connect terminals +B and FP of the DLC 1. SST 0984318020 (b) Turn the ignition switch ON. NOTICE: Do not start the engine. (c) Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check these parts: Fuses Fuel pump ECU Fuel pump ECM Wiring connections Turn the ignition switch to LOCK. Remove the SST from the DLC1. SST 0984318020 CHECK FUEL PRESSURE Check the battery voltage above 12 volts. Disconnect the negative () terminals cable from the battery. (d) (e) 2. (a) (b) (c) Remove the 2 nuts and disconnect the No.2 vacuum pipe. (d) Remove the union bolt holding the fuel inlet pipe to the delivery pipe. Remove the 2 gaskets. CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the union bolt. EG127 ENGINE SFI SYSTEMS (e) Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with 3 new gaskets and the union bolt. SST 0926845012 Torque: 42 Nm (420 kgfcm, 30 ftlbf) (f) Wipe off any splattered gasoline. (g) Using SST, connect terminals +B and FP of the DLC 1. SST 0984318020 (h) Reconnect the negative () terminal cable to the battery. (i) Turn the ignition switch ON. (j) Measure the fuel pressure. Fuel pressure: 265304 kPa (2.73.1 kgf/cm2, 3844 psi) (k) (l) If pressure is high, replace the fuel pressure regulator. If pressure is low, check these parts: Fuel hoses and connections Fuel pump Fuel filter Fuel pressure regulator Remove the SST from the DLC1. SST 0984318020 Start the engine. (m) Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. (n) Measure the fuel pressure at idle. Fuel pressure: 265304 kPa (2.73.1 kgf/cm2, 3844 psi) (o) Reconnect the vacuum sensing hose to the fuel pressure regulator. (p) Measure the fuel pressure at idle. Fuel pressure: 196235 kPa (2.02.4 kgf/cm2, 2834 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. (q) Turn the ignition switch to LOCK. EG128 ENGINE SFI SYSTEM (r) Check that the fuel pressure remains as specified for 5 minutes after the engine is has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more (s) If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. After checking fuel pressure, disconnect the nagative () terminal cable from the battery and carefully remove SST to prevent gasoline from splashing. SST 0926845012 Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 42 Nm (420 kgfcm, 30 ftlbf) (t) (u) Install the No.2 vacuum pipe with the 2 nuts. Torque: 27 Nm (280 kgfcm, 20 ftlbf) (v) Check for fuel leaks. (See step 5 in fuel system) EG129 ENGINE SFI SYSTEM EG2FF0A COMPONENTS FOR REMOVAL AND INSTALLATION EG130 ENGINE SFI SYSTEM EG4LC01 FUEL PUMP REMOVAL 1. 2. 3. 4. 5. 6. 7. Installation in is the reverse order of removal. REMOVE LUGGAGE COMPARTMENT FLOOR MAT REMOVE LUGGAGE COMPARTMENT TRIM FRONT COVER DISCONNECT FUEL PUMP CONNECTOR REMOVE REAR SEAT CUSHION REMOVE REAR SEATBACK REMOVE ROOM PARTITION TRIM REMOVE ROOM PARTITION COVER INSTALLATION HINT: Install the partition cover with butyl tape with arrow facing upward. Remove the 6 nuts. HINT: Using a scraper, pry out the partition cover. 8. REMOVE FUEL PUMP (a) Disconnect the wire clip from the fuel tank. (b) Remove the 8 bolts, and disconnect the fuel pump set plate from the fuel tank. Torque: 2.9 Nm (30 kgfcm, 26 in.lbf) (c) Remove the 3 nuts, and disconnect the fuel pump bracket from the fuel tank. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) (d) Disconnect the fuel pump hose from the fuel pump bracket, and remove the fuel pump, bracket and set plate assembly. (e) Remove the gasket from the pump set plate. INSTALLATION HINT: Use a new gasket. EG1LY0H FUEL PUMP INSPECTION 1. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance: At 20C (68F): 0.23.0 W If the resistance is not as specified, replace the fuel pump and/or set plate. EG131 ENGINE SFI SYSTEM 2. INSPECT FUEL PUMP OPERATION Connect a test lead from the terminal 1 of the connector to the positive (+) terminal of the battery; connect another test lead from the terminal 2 of the connector to the negative () terminal of the battery. NOTICE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep the fuel pump as far away from the battery as possible. Always connect or disconnect at the battery. If operation is not as specified, replace the fuel pump and/or set plate. EG132 ENGINE SFI SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY EG0D10T FUEL PUMP DISASSEMBLY EG4LD01 Assembly is in the reverse order of disassembly. 1. REMOVE PUMP SET PLATE FROM FUEL PUMP Disconnect the lead connector from the fuel pump, and remove the set plate. 2. REMOVE FUEL PUMP FROM PUMP BRACKET (a) Pull out the lower side of the fuel pump from the pump bracket. (b) Remove the rubber cushion from the fuel pump. (c) Disconnect the fuel hose from the fuel pump, and remove the fuel pump. 3. REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Using a small screwdriver, remove the clip. ASSEMBLY HINT: Use a new clip. (b) Pull out the pump filter. EG133 ENGINE SFI SYSTEM FUEL PRESSURE REGULATOR COMPONENTS FOR REMOVAL AND INSTALLATION EG1AC0P FUEL PRESSURE REGULATOR REMOVAL EG4LE01 1. 2. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR Remove the union bolt and 2 gaskets, and disconnect the fuel pipe from the pressure regulator. CAUTION: Put a shop rag under the pressure regulator. Slowly loosen the union bolt. 3. REMOVE FUEL PRESSURE REGULATOR (a) Remove the 2 bolts and pressure regulator. (b) Remove the Oring from the pressure regulator. EG134 ENGINE SFI SYSTEM FUEL PRESSURE REGULATOR EG4LF01 INSTALLATION 1. INSTALL FUEL PRESSURE REGULATOR (a) Apply a light coat of gasoline to a new Oring, and install it to the pressure regulator. (b) Attach the pressure regulator to the delivery pipe. (c) Check that the pressure regulator rotates smoothly. NOTICE: If it does not rotate smoothly, the Oring may be pinched, so remove the pressure regulator and do steps (b) and (c) again. (d) Install the pressure regulator with the 2 bolts. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 2. CONNECT FUEL RETURN PIPE TO FUEL PRESSURE REGULATOR Connect the fuel pipe to the pressure regulator with 2 new gaskets and the union bolt. Torque: 27 Nm (280 kgfcm, 20 ftlbf) 3. 4. CONNECT VACUUM SENSING HOSE TO FUEL PRESSURE REGULATOR CHECK FOR FUEL LEAKS (See step 5 in fuel system) EG135 ENGINE SFI SYSTEM INJECTOR ONVEHICLE INSPECTION EG0RD0A 1. INSPECT INJECTOR OPERATION Check operation sound from each injector. (a) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. (b) If you have no sound scope, you can check the injector transmission operation with your finger. If no sound or an unusual sound is heard, check the wiring connector, injector or injection signal from the ECM. 2. INSPECT INJECTOR RESISTANCE (a) Remove the throttle body together with the intake air connector. (See steps 1 to 6 in injectors removal) (b) Disconnect the injector connectors. (c) Using an ohmmeter, measure the resistance between the terminals. Resistance: At 20C (68F): 13.414.2 W If the resistance is not as specified, replace the injector. (d) Reconnect the injector connectors. (e) Reinstall the throttle body together with the intake air connector. (See steps 8 to 14 in injectors installation) EG136 ENGINE SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG2GD0G EG137 ENGINE SFI SYSTEM INJECTORS REMOVAL EG4LQ01 1. 2. DRAIN ENGINE COOLANT DISCONNECT CONTROL CABLES AND INTAKE AIR CONNECTOR PIPE (See steps 2 and 3 in throttle body removal) 3. (a) (b) 4. REMOVE EGR PIPE Loosen the union nut of the EGR pipe. Remove the 2 bolts, EGR pipe and gasket. DISCONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR 5. DISCONNECT THROTTLE BODY BRACKET FROM THROTTLE BODY AND CYLINDER HEAD 6. REMOVE THROTTLE BODY WITH INTAKE AIR CONNECTOR (a) Disconnect these hoses: (1) PCV hose from intake air connector (2) 3 vacuum hoses from No.2 vacuum pipe (b) Disconnect these connectors: (1) w/ TRAC: Subthrottle actuator connector (2) w/ TRAC: Subthrottle position sensor connector (3) IAC valve connector (4) Throttle position sensor connector (5) VSV connector for EGR (c) Remove the nut holding the VSV to the chamber stay. (d) Remove the 4 bolts and 2 nuts holding the intake air connector to the intake chamber. EG138 ENGINE SFI SYSTEM (e) Disconnect the vacuum hose (from the actuator) from the No.1 vacuum pipe. (f) Disconnect the 2 water bypass hoses from the throttle body. (g) Remove the throttle body together with the intake air connector and gasket. 7. DISCONNECT FUEL INLET PIPE FROM DELIVERY PIPE (a) Remove the 2 nuts and disconnect the No.2 vacuum pipe. (b) Remove the union bolt and 2 gaskets, and disconnect the fuel pipe. CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the union bolt. 8. DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR (a) Remove the bolt holding the fuel pipe to the intake manifold. (b) Remove the union bolt and 2 gaskets, and disconnect the fuel pipe from the pressure regulator. CAUTION: Put a shop towel under the pressure regulator. Slowly loosen the union bolt. EG139 ENGINE SFI SYSTEM 9. REMOVE AIR INTAKE CHAMBER STAYS Remove the bolt, nut and intake chamber stay. Remove the No.1 and No.2 stays. 10. DISCONNECT VACUUM SENSING HOSE FROM PRESSURE REGULATOR 11. DISCONNECT INJECTOR CONNECTORS 12. DISCONNECT ACTUATOR FOR ACIS (a) Remove the 2 bolts and disconnect the actuator. (b) Wrap the actuator with adhesive tape and attach it to the intake chamber. NOTICE: Do not apply any force on the actuator rod and prevent the rod clip from detaching. 13. REMOVE DELIVERY PIPE AND INJECTORS (a) Remove the 3 bolts and delivery pipe together with the 6 injectors. NOTICE: Be careful not to drop the injectors when removing the delivery pipe. (b) Pull out the 6 injectors from the delivery pipe. (c) Remove the Orings and grommets from each injector. (d) Remove the 3 spacers from the intake manifold. EG140 ENGINE SFI SYSTEM INJECTORS INSPECTION EG4LM01 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. (a) Disconnect the fuel inlet hose from the fuel tube. (b) Connect SST (hose) to the fuel inlet tube with SST (union). Tighten the flare nut on the fuel tube. SST 0926841045 (9040552010) Torque: 30 Nm (310 kgfcm, 22 ftlbf) HINT: Use SST. (See step 2 in fuel system) SST 0963122020 (c) Disconnect the fuel return hose from the fuel tube. (d) Install a new Oring to the fuel inlet of the pressure regulator. (e) Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 0926841045 (0926841090) (f) Connect the fuel return hose to the fuel outlet of the pressure regulator with SST (union), 2 new gaskets and union bolt. SST 0926841045 (0926841070) (g) Install the grommet and a new Oring to the injector. (h) Connect SST (hose) to the injector with SST (union), and hold the injector and union with SST (clamp). SST 0926841045 (i) Put the injector into the graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. EG141 ENGINE SFI SYSTEM (j) (k) (l) Using SST, connect terminals +B and FP of the DLC 1. SST 0984318020 Reconnect the negative () terminal cable to the battery. Turn the ignition switch ON. NOTICE: Do not start the engine. (m) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 0984230070 Injection volume: 7088 cm3 (4.35.4 cu in.) per 15 sec. Difference between each injector: 9 cm3 (0.5 cu in.) or less If the injection volume is not as specified, replace the injector. 2. INSPECT LEAKAGE (a) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 0984230070 Fuel drop: One drop or less per minute (b) Disconnect the negative () terminal cable from the battery. (c) Remove the SST. SST 0926841045 and 0984318020 (d) Reconnect the fuel return hose to the fuel tube. (e) Reconnect the fuel inlet hose to the fuel tube. SST 0963122020 Torque: 30 Nm (310 kgfcm, 22 ftlbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). INJECTORS INSTALLATION EG4LJ01 1. INSTALL INJECTORS AND DELIVERY PIPE (a) Install 2 new grommets to each injector. (b) Apply a light coat of gasoline to 2 new Orings and install them to each injector. EG142 ENGINE SFI SYSTEM (c) While turning the injector clockwise and counterclockwise, push it to the delivery pipe. Install the 6 injectors. (d) Position the injector connector outward. (e) Place the for and 3 spacers in position on the intake manifold. (f) Place the 6 injectors together with the delivery pipe and 3 bolts in position on the intake manifold. (g) Temporarily install the 3 bolts holding the delivery pipe to the intake manifold. (h) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of Orings. Replace the Orings. (i) Position the injector connector upward. EG143 ENGINE SFI SYSTEM (j) Tighten the 3 bolts holding the delivery pipe to the intake manifold. Torque: 21 Nm (210 kgfcm, 15 ftlbf) 2. INSTALL ACTUATOR FOR ACIS (a) Install the actuator with the 2 bolts. Torque: 6.8 Nm (70 kgfcm, 61 in.lbf) (b) Inspect the intake air control valve. (See step 1 in ACIS inspection) 3. 4. CONNECT INJECTOR CONNECTORS HINT: The No.1, No.3 and No.5 injector connectors are dark gray, and the No.2, No.4 and No.6 injector connectors are gray. CONNECT VACUUM SENSING HOSE 5. INSTALL AIR INTAKE CHAMBER STAYS Install the intake chamber stay with the bolt and nut. Install the No.1 and No.2 stays. Torque: 18 Nm (185 kgfcm, 13 ftlbf) HINT: The No.1 stay is marked with "F" and No.2 stay is marked with "R". 6. CONNECT FUEL RETURN PIPE TO FUEL PRESSURE REGULATOR (a) Connect the fuel pipe with 2 new gaskets and the union bolt. Torque: 27 Nm (280 kgfcm, 20 ftlbf) (b) Install the bolt holding the fuel pipe to the intake manifold. EG144 ENGINE SFI SYSTEM 7. CONNECT FUEL INLET PIPE TO DELIVERY PIPE (a) Connect the fuel pipe with 2 new gaskets and the union bolt. Torque: 42 Nm (420 kgfcm, 30 ftlbf) (b) Install the No.2 vacuum pipe with the 2 nuts. Torque: 27 Nm (280 kgfcm, 20 ftlbf) 8. INSTALL THROTTLE BODY WITH INTAKE AIR CONNECTOR (a) Place the new gasket so the protrusion face the intake chamber, and set the throttle body together with the intake air connector. (b) Connect the 2 water bypass hoses to the throttle body. (c) Connect the vacuum hose (from the actuator) to the No.1 vacuum pipe. (d) Install the intake air connector with the 4 bolts and 2 nuts. Torque: 21 Nm (210 kgfcm, 15 ftlbf) (e) Install the nut holding the VSV to the chamber stay. EG145 ENGINE SFI SYSTEM (f) Connect these connectors: (1) w/ TRAC: Subthrottle actuator connector (2) w/ TRAC: Subthrottle position sensor connector (3) IAC valve connector (4) Throttle position sensor connector (5) VSV connector for EGR (g) Connect these hoses: (1) PCV hose to intake air connector (2) 3 vacuum hoses to No.2 vacuum pipe 9. INSTALL THROTTLE BODY BRACKET Install the throttle body bracket with the 4 nuts. Torque: 21 Nm (210 kgfcm, 15 ftlbf) 10. CONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR 11. INSTALL EGR PIPE (a) Temporarily install the union nut of the EGR pipe. (b) Install a new gasket and the EGR pipe with the 2 bolts. Torque: 27 Nm (280 kgfcm, 20 ftlbf) (c) Tighten the union nut of the EGR pipe. Torque: 64 Nm (650 kgfcm, 47 ftlbf) 12. INSTALL INTAKE AIR CONNECTOR PIPE AND CONNECT CONTROL CABLES (See steps 2 and 3 in throttle body removal) 13. FILL WITH ENGINE COOLANT 14. CHECK FOR FUEL LEAKS (See step 5 in fuel system) EG146 ENGINE SFI SYSTEM FUEL PRESSURE PULSATION DAMPER COMPONENTS FOR REMOVAL AND INSTALLATION EG1MF0E FUEL PRESSURE PULSATION DAMPER REMOVAL EG4LK01 1. REMOVE STARTER (See starter removal in Starting System) 2. REMOVE FUEL PRESSURE PULSATION DAMPER (a) Remove the pulsation damper and upper gasket. (b) Disconnect the fuel inlet pipe from the fuel pipe support, and remove the lower gasket. FUEL PRESSURE PULSATION DAMPER INSTALLATION EG4LL01 1. INSTALL FUEL PRESSURE PULSATION DAMPER (a) Install the fuel inlet pipe and pulsation damper with 2 new gaskets. HINT: Different gaskets are used for the upper (large size) and lower (small size). EG147 ENGINE SFI SYSTEM (b) Using SST, tighten the pulsation damper. SST 0961224014 (0961724011) Torque: 41 Nm (420 kgfcm, 30 ftlbf) 35 Nm (350 kgfcm, 25 ftlbf) for SST HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). 2. 3. INSTALL STARTER (See starter removal in Starting System) CHECK FOR FUEL LEAKS (See step 5 in fuel system) EG148 ENGINE SFI SYSTEM FUEL TANK AND LINE COMPONENTS EG0DC0H EG149 ENGINE SFI SYSTEM PRECAUTIONS EG0DD04 1. 2. Always use new gaskets when replacing the fuel tank or component parts. Apply the proper torque to all parts tightened. FUEL LINES AND CONNECTIONS INSPECTION EG0DE04 (a) Check the fuel lines for cracks or leakage, and all connections for deformation. (b) Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. (c) Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. (d) Check the filler neck for damage or fuel leakage. (e) Hose and tube connections are as shown in the illustration. If a problem is found, repair or replace the part as necessary. EG150 ENGINE SFI SYSTEM VOLUME AIR FLOW (VAF) METER ONVEHICLE INSPECTION EG0YH09 INSPECT RESISTANCE OF VAF METER (a) Disconnect the VAF meter connector. (b) Using an ohmmeter, measure the resistance between terminals THA and E2. (c) COMPONENTS FOR REMOVAL AND INSTALLATION EG0YJ0G Between terminals THAE2 THAE2 THAE2 THAE2 THAE2 Resistance Temperature 1020 kW 47 kW 23 kW 0.91.3 kW 0.40.7 kW 20C (4F) 0C (32F) 20C (68F) 40C (104F) 60C (140F) If the resistance is not as specified, replace the VAF meter. Reconnect the VAF meter connector. EG151 ENGINE SFI SYSTEM VAF METER REMOVAL EG4LM01 Installation is in the reverse order of removal. 1. REMOVE AIR CLEANER HOSE (a) Disconnect the PS air hose to the air cleaner hose. (b) Loosen the 2 hose clamps, and remove the air cleaner hose. 2. (a) (b) (c) REMOVE VAF METER FROM AIR CLEANER Disconnect the hightension cord from the cord clamp. Disconnect the VAF meter connector. Disconnect the wire clamp from the bracket. (d) Remove the 4 nuts, bolt, VAF meter and gasket. Torque: 10 Nm (100 kgfcm, 7 ftlbf) INSTALLATION HINT: Use a new gasket. VAF METER INSPECTION EG0H20B INSPECT VAF METER Check that the honeycomb is neither deformed nor damaged. If necessary, replace the VAF meter. EG152 ENGINE SFI SYSTEM THROTTLE BODY ONVEHICLE INSPECTION EG4LN01 1. INSPECT THROTTLE BODY (a) Check that the throttle linkage moves smoothly. (b) Check the vacuum at each port. Start the engine. Check the vacuum with your finger. (f) Reconnect the throttle position sensor connector. (g) Reconnect the throttle opener vacuum hose to the throttle body. 2. (a) (b) (c) (d) INSPECT THROTTLE POSITION SENSOR Disconnect the vacuum hose from the throttle opener. Apply vacuum to the throttle opener. Disconnect the sensor connector. Insert a feeler gauge between the throttle stop screw and stop lever. (e) Using an ohmmeter, measure the resistance between each terminal. Clearance between lever and stop screw 0 mm (0 in.) 0.40 mm (0.016 in.) 0.60 mm (0.024 in.) Throttle valve fully open Between terminals VTA1E2 IDL1E2 IDL1E2 VTA1E2 VCE2 Resistance 0.346.3 kW 0.5 kW or less Infinity 2.411.2 kW 3.17.2 kW Port name P E R At idle No vacuum No vacuum No vacuum At 3,000 rpm Vacuum Vacuum Vacuum EG153 ENGINE SFI SYSTEM 3. A. B. INSPECT AND ADJUST DASHPOT Warm up engine Allow the engine to warm up to normal operating temperature. Check idle speed Idle speed (Transmission in neutral): 700 50 rpm C. Check and adjust dashpot setting speed Push the dashpot rod all the way with a screwdriver, and confirm the dashpot setting. Dashpot setting speed: 1,800 400 rpm If not as specified, adjust with the dashpot adjusting screw. D. Check VTV operation (a) Maintain the engine at 3,500 rpm. (b) Release the throttle valve, and check that the engine returns to idle in a few seconds. 4. INSPECT THROTTLE OPENER A. Warm up engine Allow the engine to warm up to normal operating temperature. B. Check idle speed Idle speed (Transmission in neutral): 700 50 rpm C. Check throttle opener setting speed (a) Disconnect the vacuum hose from the throttle opener, and plug the hose end. (b) Maintain the engine speed at 2,500 rpm. (c) Release the throttle valve. (d) Check that the throttle opener is set. Throttle opener setting speed: 1,500 400 rpm If the throttle opener setting is not as specified, replace the throttle body. (e) Reconnect the vacuum hose to the throttle opener. EG154 ENGINE SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG13G0V EG155 ENGINE SFI SYSTEM THROTTLE BODY REMOVAL EG4LP01 1. 2. Installation is in the reverse order of removal. DRAIN ENGINE COOLANT DISCONNECT CONTROL CABLES FROM THROTTLE BODY Disconnect these cables: (1) Accelerator cable (2) A/T throttle control cable (3) Cruise control actuator cable 3. REMOVE INTAKE AIR CONNECTOR PIPE (a) Disconnect these hoses: (1) PS air hose from air connector pipe (2) PCV hose from No.2 cylinder head cover (b) Loosen the 2 hose clamps, and remove the air connector pipe with the hoses. 4. DISCONNECT THROTTLE BODY BRACKET FROM THROTTLE BODY AND CYLINDER HEAD Remove the 4 nuts, and disconnect the throttle body bracket from the throttle body and cylinder head. Torque: 21 Nm (210 kgfcm, 15 ftlbf) 5. REMOVE THROTTLE BODY (a) Disconnect these connectors: (1) Throttle position sensor connector (2) w/ TRAC: Subthrottle position sensor connector (3) w/ TRAC: Subthrottle actuator connector (4) IAC valve connector (b) Disconnect these hoses: (1) 4 vacuum hoses (2) Air hose (from intake manifold) (c) Remove the 2 bolts and 2 nuts. Torque: 21 Nm (210 kgfcm, 15 ftlbf) EG156 ENGINE SFI SYSTEM (d) Disconnect the water bypass hose (from the No.2 water bypass pipe) from the clamp on the engine hanger. (e) Slightly slide the throttle body away from the intake air connector. (f) Disconnect these hoses: (1) Water bypass hose (from water outlet) (2) Water bypass hose (from No.2 water bypass pipe) (g) Remove the throttle body and gasket. INSTALLATION HINT: Use a new gasket. THROTTLE BODY INSPECTION EG2GA05 1. CLEAN THROTTLE BODY (a) Using a soft brush and carburetor cleaner, clean the cast parts. (b) Using compressed air, clean all the passages and apertures. NOTICE: To prevent deterioration, do not clean the throttle position sensor and dashpot. 2. INSPECT THROTTLE VALVE AND THROTTLE POSITION SENSOR A. Inspect throttle valve (a) Disconnect the vacuum hose from the throttle opener. (b) Apply vacuum to the throttle opener. (c) Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. (d) Reconnect the vacuum hose to the throttle opener. B. Inspect throttle position sensor (See step 2 in onvehicle inspection) EG157 ENGINE SFI SYSTEM C. If necessary, adjust throttle position sensor (a) Loosen the 2 set screws of the sensor. (b) Insert a 0.50 mm (0.020 in.) feeler gauge between the throttle stop screw and stop lever. (c) Connect the test probe of an ohmmeter to the terminals IDL1 and E2 of the sensor. (d) Gradually turn the sensor clockwise until the ohmmeter deflects, and secure it with the 2 set screws. (e) Recheck the continuity between terminals IDL1 and E2. 3. A. w/ TRAC: INSPECT SUBTHROTTLE ACTUATOR, SUB THROTTLE VALVE AND SUBTHROTTLE POSITION SENSOR Inspect subthrottle actuator Using an ohmmeter, measure the resistance between the terminals (ACM A and A, BCM B and B). Resistance: 0.51.0 W Clearance between lever and stop screw 0.40 mm (0.016 in.) 0.60 mm (0.024 in.) Continuity (IDL1E2) Continuity No continuity EG158 ENGINE SFI SYSTEM If the resistance is not as specified, replace the actuator. B. Inspect subthrottle actuator Remove the 4 screws and subthrottle actuator. C. Inspect subthrottle valve Check that there is no clearance between the throttle stop screw and throttle valve gear when the subthrottle valve is fully closed. D. Inspect subthrottle position sensor (a) Insert a 0.30 mm (0.012 in.) or 0.50 mm (0.020 in.) feeler gauge between the throttle stop screw and throttle valve gear. (b) Using an ohmmeter, measure the resistance between terminals. Clearance between lever and stop screw 0 mm (0 in.) 0.30 mm (0.012 in.) 0.50 mm (0.020 in.) Throttle valve fully open Between terminals VTA2E2 IDL2E2 IDL2E2 VTA2E2 VCE2 Resistance 0.346.3 kW 0.5 kW or less Infinity 2.411.2 2 411 2 kW 3.17.2 kW E. If necessary, adjust subthrottle position sensor (a) Loosen the 2 set screws of the sensor. EG159 ENGINE SFI SYSTEM (b) Insert a 0.40 mm (0.016 in.) feeler gauge, between the throttle stop screw and throttle valve gear. (c) Connect the test probe of an ohmmeter to the terminals IDL2 and E2 of the sensor. (d) Set that the subthrottle valve is fully closed. (e) Gradually turn the sensor clockwise until the ohmmeter deflects, and secure it with the 2 set screws. Clearance between lever and stop screw 0.30 mm (0.012 in.) 0.50 mm (0.020 in.) Continuity (IDL2E2) Continuity No continuity (f) Recheck the continuity between terminals IDL2 and E2. F. Reinstall subthrottle actuator Install the subthrottle actuator with the 4 screws. EG160 ENGINE SFI SYSTEM IDLE AIR CONTROL (IAC) VALVE ONVEHICLE INSPECTION EG4LQ01 1. 2. A. B. INSPECT IAC VALVE FOR OPERATING SOUND Check that there is a clicking sound immediately after stopping the engine. If operation is not as specified, check the IAC valve, wiring and ECM. INSPECT AIR ASSIST SYSTEM Warm up engine Allow the engine to warm up to normal operating temperature. Check idle speed Idle speed (Transmission in neutral): 700 50 rpm C. Check IAC valve operation With engine idling, pinch the air hose and check that engine speed drops, and then returns back up to idle speed. If operation is not as specified, check the IAC valve, wiring and ECM. IAC VALVE REMOVAL EG4LR01 1. 2. Installation is in the reverse order of removal. REMOVE THROTTLE BODY (See throttle body removal) REMOVE IAC VALVE Remove the 2 screws, IAC valve and Oring. INSTALLATION HINT: Use a new Oring. IAC VALVE INSPECTION EG1SM05 1. INSPECT IAC VALVE RESISTANCE Using an ohmmeter, measure the resistance between the terminals (B1S1 and S3, B2S2 and S4). Resistance: 1030 If resistance is not as specified, replace the IAC valve. EG161 ENGINE SFI SYSTEM 2. INSPECT IAC VALVE OPERATION (a) Apply battery voltage to terminals B1 and B2, and while repeatedly grounding S1S2S3S4S1 in sequence, and check that the valve moves toward the closed position. (b) Apply battery voltage to terminals B1 and B2, and while repeatedly grounding S4S3S2S1S4 in sequence, check that the valve moves toward the open position. If operation is not as specified, replace the IAC valve. EG162 ENGINE SFI SYSTEM ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) ONVEHICLE INSPECTION EG2GL07 1. 2. CONNECT VACUUM GAUGE Using a 3way connector, connect vacuum gauge to the hose between the actuator and VSV. START ENGINE 3. INSPECT INTAKE AIR CONTROL VALVE (a) While the engine is idling, check that the vacuum gauge needle does not move. (b) Rapidly depress the accelerator pedal to fully open position and check that the vacuum gauge needle momentarily fluctuates approx. 33.3 kPa (250 mmHg, 9.84 in.Hg) or more. (The actuator rod is pulled down.) 4. REMOVE VACUUM GAUGE Remove the vacuum gauge, and reconnect the vacuum hoses to their proper locations. IF NO PROBLEM IS FOUND DURING THIS INSPECTION, SYSTEM IS NORMAL; OTHERWISE INSPECT EACH PART EG163 ENGINE SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG26K0A ACIS REMOVAL EG4LS01 Installation is in the reverse order of removal. 1. REMOVE DATA LINK CONNECTOR 1 (DLC1) BRACKET (a) Disconnect the DLC1 from the bracket. (b) Disconnect the VSV connector. (c) Disconnect these hoses: (1) PS air hose from air intake chamber (2) Vacuum sensing hose from air intake chamber (3) Vacuum sensing hose from fuel pressure regulator (d) Remove the bolt, DLC1 bracket and VSV assembly. 2. REMOVE EGR PIPE (See step 3 in injectors removal and step 11 in injectors installation) EG164 ENGINE SFI SYSTEM 3. REMOVE DIPSTICK GUIDE FOR TRANSMISSION (a) Remove the mounting bolt. (b) Pull out the dipstick guide together with the dipstick. INSTALLATION HINT: Apply soapy water on the Oring. (c) Remove the Oring from the dipstick guide. INSTALLATION HINT: Use a new Oring. 4. DISCONNECT VACUUM HOSES Disconnect these vacuum hoses: (1) Vacuum hose (from actuator) from No.1 vacuum pipe (2) Vacuum hose from air intake chamber (3) Vacuum hose from hose clamp (4) Brake booster vacuum hose from union 5. DISCONNECT NO.2 VACUUM PIPE FROM AIR INTAKE CHAMBER (a) Disconnect the 2 vacuum hoses from the vacuum control valve set. (b) Remove the 2 nuts and disconnect the No.2 vacuum pipe. Torque: 27 Nm (280 kgfcm, 20 ftlbf) 6. REMOVE AIR INTAKE CHAMBER (a) Disconnect the accelerator cable from the bracket. (b) Remove the union bolt, brake booster union and 2 gaskets. INSTALLATION HINT: Use 2 new gaskets. Torque: 29 Nm (300 kgfcm, 22 ftlbf) (c) Remove the 2 bolts, accelerator cable bracket and hose clamp. (d) Remove the 2 bolts holding the chamber stays to the air intake chamber. Torque: 18 Nm (185 kgfcm, 13 ftlbf) (e) Remove the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber. Torque: 27 Nm (280 kgfcm, 20 ftlbf) (f) Remove the 2 nuts holding the throttle body bracket to the cylinder head. Torque: 21 Nm (210 kgfcm, 15 ftlbf) EG165 ENGINE SFI SYSTEM (g) Remove the 5 bolts, nut, air intake chamber and 2 gaskets. Torque: 27 Nm (280 kgfcm, 20 ftlbf) INSTALLATION HINT: Place the new gasket so the protrusion faces the intake chamber. 7. REMOVE VACUUM CONTROL VALVE SET (a) Disconnect the VSV connector. (b) Remove the 2 nuts and vacuum control valve set. Torque: 21 Nm (210 kgfcm, 15 ftlbf) 8. REMOVE VACUUM TANK AND VSV Remove the vacuum hose, screw and VSV from the vacuum tank. ACIS INSPECTION EG4LT01 1. INSPECT INTAKE AIR CONTROL VALVE (a) With 53.3 kPa (400 mmHg, 15.75 in.Hg) of vacuum applied to the actuator, check that the actuator rod moves. If operation is not as specified, turn the adjusting screw. (b) One minute after applying the vacuum in (a), check that the actuator rod does not return. EG166 ENGINE SFI SYSTEM 2. INSPECT VACUUM TANK (a) Check that air flows from port A to B. (b) Check that air does not flow port B to A. (c) 3. Plug port B with your finger, and apply 53.3 kPa (400 mmHg, 15.75 in.Hg) of vacuum to port A, and check that there is no change in vacuum after 1 minute. If operation is not as specified, replace the vacuum tank. INSPECT VSV (See VSV for EVAP) EFI MAIN RELAY EFI MAIN RELAY INSPECTION EG13W0G 1. REMOVE EFI MAIN RELAY LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. If continuity is not as specified, replace the relay. B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY EG167 ENGINE SFI SYSTEM IGNITION MAIN RELAY IGNITION MAIN RELAY INSPECTION EG2GQ01 1. REMOVE IGNITION MAIN RELAY LOCATION: In the engine compartment relay box. 2. INSPECT IGNITION MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. If continuity is not as specified, replace the relay. B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL IGNITION MAIN RELAY EG168 ENGINE SFI SYSTEM VSV FOR ACIS COMPONENTS FOR REMOVAL AND INSTALLATION EG0U00Z VSV INSPECTION EG4LU01 1. 2. 3. A. REMOVE VACUUM CONTROL VALVE SET (See steps 3 and 7 in ACIS removal) REMOVE VSV Remove the screw, vacuum hose and VSV. INSPECT VSV Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 20C (68F): 38.544.5 W If there is no continuity, replace the VSV. EG169 ENGINE SFI SYSTEM B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air flows from port E to the filter. (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 4. INSTALL VSV (a) Install the VSV with the screw to the vacuum tank. (b) Install the vacuum hose. 5. REINSTALL VACUUM CONTROL VALVE SET (See steps 3 and 7 in ACIS removal) EG170 ENGINE SFI SYSTEM EG0E22L VSV FOR FUEL PRESSURE CONTROL COMPONENTS FOR REMOVAL AND INSTALLATION VSV INSPECTION EG4LV01 1. 2. A. REMOVE VSV INSPECT VSV Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 20C (68F): 3339 W If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. EG171 ENGINE SFI SYSTEM C. Inspect VSV operation (a) Check that air flows from pipe E to pipe G. (b) Apply battery voltage across the terminals. (c) Check that air flows from pipe E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV EG172 ENGINE SFI SYSTEM VSV FOR EVAP COMPONENTS FOR REMOVAL AND INSTALLATION EG0U010 VSV INSPECTION EG4LW01 1. REMOVE VSV 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 20C (68F): 2733 W If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. EG173 ENGINE SFI SYSTEM C. Inspect VSV operation (a) Check that air does not flows from port E to F. (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV EG174 ENGINE SFI SYSTEM VSV FOR EGR COMPONENTS FOR REMOVAL AND INSTALLATION EG0U011 VSV INSPECTION EG4LX01 1. 2. A. REMOVE VSV INSPECT VSV Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 20C (68F): 38.544.5 W If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. EG175 ENGINE SFI SYSTEM C. Inspect VSV operation (a) Check that air does not flows from port E to G. (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to G. If operation is not as specified, replace the VSV. 3. REINSTALL VSV EG176 ENGINE SFI SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR COMPONENTS FOR REMOVAL AND INSTALLATION EG26D0H ECT SENSOR INSPECTION EG4LY01 1. 2. (a) (b) 3. DRAIN ENGINE COOLANT REMOVE ECT SENSOR Disconnect the ECT sensor connector. Using a 19 mm dia deep socket wrench, remove the ECT sensor and gasket. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph above If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm dia deep socket wrench, install the ECT sensor. Torque: 20 Nm (200 kgfcm, 14 ftlbf) (c) 5. Connect the ECT sensor connector. REFILL WITH ENGINE COOLANT EG177 ENGINE SFI SYSTEM KNOCK SENSOR COMPONENTS FOR REMOVAL AND INSTALLATION EG0TU0D KNOCK SENSORS INSPECTION EG4LZ01 1. REMOVE STARTER (See starter removal in Starting System) 2. REMOVE PS PUMP REAR STAY 3. REMOVE KNOCK SENSORS (a) Disconnect the knock sensor connector. (b) Using SST, remove the knock sensor. SST 0981630010 4. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. EG178 ENGINE SFI SYSTEM 5. REINSTALL KNOCK SENSORS (a) Using SST, install the knock sensor. SST 0981630010 Torque: 44 Nm (450 kgfcm, 33 ftlbf) (b) Connect the knock sensor connector. 6. 7. REINSTALL PS PUMP REAR STAY Torque: 39 Nm (400 kgfcm, 29 ftlbf) REINSTALL STARTER (See starter removal in Starting System) EG179 ENGINE SFI SYSTEM EGR GAS TEMPERATURE SENSOR COMPONENTS FOR REMOVAL AND INSTALLATION EG0E40C EGR GAS TEMPERATURE SENSOR INSPECTION EG4M001 1. 2. REMOVE EGR GAS TEMPERATURE SENSOR INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: At 50C (112F): 6497 kW At 100C (212F): 1116 kW At 150C (302F): 24 kW 3. If the resistance is not as specified, replace the sensor. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 Nm (200 kgfcm, 14 ftlbf) EG180 ENGINE SFI SYSTEM OXYGEN SENSOR Main Heated Oxygen Sensors COMPONENTS FOR REMOVAL AND INSTALLATION EG4M101 OXYGEN SENSORS INSPECTION EG4M201 1. 2. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. INSPECT FEEDBACK VOLTAGE Connect the positive (+) probe of a voltmeter to terminal VF1 (for No.1) or VF2 (for No.2) of the DLC1, and negative () probe to terminal E1. Do the test as described on the next page. HINT: Use SST when connecting between terminals TE1 and E1 of the DLC1. SST 0984318020 EG181 ENGINE SFI SYSTEM EG182 ENGINE SFI SYSTEM 3. INSPECT HEATER RESISTANCE OF MAIN HEATED OXYGEN SENSORS (a) Disconnect the oxygen sensor connectors. (b) Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: At 20C (68F): 11.714.3 W (c) 4. Reconnect the oxygen sensor connectors. IF NECESSARY, REPLACE OXYGEN SENSORS Torque: 44 Nm (450 kgfcm, 33 ftlbf) Sub Heated Oxygen Sensor EG1LW0F COMPONENTS FOR REMOVAL AND INSTALLATION OXYGEN SENSOR INSPECTION EG4M301 1. INSPECT OPERATION OF SUB HEATED OXYGEN SENSOR (See sub heated oxygen sensor circuit in Engine Troubleshooting) EG183 ENGINE SFI SYSTEM 2. INSPECT HEATER RESISTANCE OF SUB HEATED OXYGEN SENSOR (a) Remove the scuff plate. (b) Remove the instrument panel under cover. (c) Take out the front side of the floor carpet. (d) Disconnect the oxygen sensor connector. Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: At 20C (68F): 11.714.3 W If the resistance is not as specified, replace the sensor. Torque: 44 Nm (450 kgfcm, 33 ftlbf) (e) (f) (g) (h) Reconnect the oxygen sensor connector. Reinstall the floor carpet. Reinstall the instrument panel under cover. Reinstall the scuff plate. EG184 ENGINE SFI SYSTEM FUEL PUMP ECU COMPONENTS FOR REMOVAL AND INSTALLATION EG1Q00B FUEL PUMP ECU INSPECTION EG2PZ03 1. 2. 3. REMOVE FUEL PUMP ECU INSPECT FUEL PUMP ECU (See fuel pump control circuit in Engine Troubleshooting) REINSTALL FUEL PUMP ECU EG185 ENGINE SFI SYSTEM ENGINE CONTROL MODULE (ECM) COMPONENTS FOR REMOVAL AND INSTALLATION EG1Q20G ECM INSPECTION EG2HE03 1. 2. 3. REMOVE ECM INSPECT ECM (See standard value of ECM terminals in Engine Troubleshooting) HINT: Use SST. SST 0999001000 REINSTALL ECM EG186 ENGINE SFI SYSTEM FUEL CUT RPM FUEL CUTOFF INSPECTION EG4M501 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER TO ENGINE Connect the tester probe of a tachometer to terminal IG the DLC1. of NOTICE: Never allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use. 3. (a) (b) (c) INSPECT FUEL CUTOFF OPERATION Increase the engine speed to at least 3,000 rpm. Check for injector operating noise. Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. HINT: Measure with the A/C OFF. Fuel return rpm: 1,400 rpm 4. DISCONNECT TACHOMETER SERVICE DATA SERVICE SPECIFICATIONS d EGR gas tem . Resistance temp. sensor VSV for ACIS VSV for EGR VSV for Fuel pressure control t l ECT sensor IAC valve Subthrottle actuator (w/TRAC) Subthrottle position sensor (w/TRAC) Throttle position osition sensor (Main) Throttle body VAF meter Injector Fuel pump Fuel pressure regulator VSV for EVAP Resistance Resistance Resistance Resistance Resistance Resistance Resistance (B1 S1 and S3, B2 S2 and S4) Resistance (ACM A and A, BCM B and B) Clearance between stop screw and lever 0 mm (0 in.) 0.30 mm (0.012 in.) 0.50 mm (0.020) in. Throttle valve fully open Clearance between stop screw and lever sto 0 mm (0 in.) 0.40 mm (0.016 in.) 0.60 mm (0.024 in.) Throttle valve fully open y Throttle body fully closed angle Dashpot setting speed Throttle opener setting speed Resistance (THAE2) Resistance Injection volume Difference between each cylinder y Fuel leakage F ll k Fuel pressure ENGINE SFI SYSTEM at 50C (122F) 64 97 kW 50 C (122 F) at 100C ( (212F) 11 16 kW ) at 150C (302F) 2 4 kW t at 20C (4F) 20 C (4 F) at 0 C (32F) 0C (32 F) at 20C (68F) 20 C (68 F) at 40C (104 F) 40 C (104F) at 60C 140F) ) at 80C (176F) at 20C (4F) at 0C (32F) at 20C (68F) at 40C (104F) at 60C (140F) at 20C (68F) 33 39 W 20 C (68 F) at 20C (68F) 27 33 W at 20C (68F) 0.23.0 W VTA2 E2 IDL2 E2 IDL2 E2 VTA2 E2 VC E2 VTA1 E2 IDL1 E2 IDL1 E2 VTA1 E2 VC E2 10 30 W 1020 kW 47 kW 23 kW 0.91.3 kW 0.40.7 kW at 20C (68F) 38.5 44.5 W at 20C (68F) 38.5 44.5 W 10 20 kW 4 7 kW 2 3 kW 0.9 1.3 kW 0.4 0.7 kW 0.2 0.4 kW 0.5 1.0 W at no vacuum 265304 kPa (2.73.1 kgf/cm2, 3844 psi) 0.34 6.3 kW 0.5 kW or less Infinity 2.4 11.2 kW 3.1 7.2 kW 0.34 6.3 kW 0.5 kW or less Infinity 2.4 11.2 kW 3.1 7.2 kW 6 1,800 1 800 $ 400 rpm 1,500 $ 400 rpm 13.414.2 W 70 88 7088 cm3 (4.3 5.4 cu in.) per 15 sec. (4.35.4 er 9 cm3 (0.5 cu in.) or less ( ) One drop or l O d less per minute i t EG187 EG0ZA0K VAF meter X Air cleaner case Vacuum control valve X Intake manifold Air intake chaqmber X Intake manifold Throttle body X Intake air connector ECT sensor X Cylinder head EGR gas temperature sensor X EGR valve Knock sensor X Cylinder block PS pump rear stay X PS pump brackekt PS pump rear stay X Intake manifold stay Main heated oxygen sensor X Exhaust manifold Sub heated oxygen sensor X Front exhaust pipe Fuel line No.1 fuel pipe X Delivery pipe No. 2 vacuum pipe X Air intake chamber No. 2 vacuum pipe X Intake manifold Fuel pump X Fuel tank Fuel pump set plate X Fuel tank Fuel tank X Body Fuel sender gauge X Fuel tank Fuel sender gauge X Fuel tank Fuel tank main tube X Fuel tank Fuel tank return tube X Fuel tank Fuel tank evaporation vent tube X Fuel tank No. 2 fuel pipe X Fuel pressure regulator Fuel pressure regulator X Delivery pipe Delivery pipe X Intake manifold Actuator for ACIS X Air intake chamber Intake air connector X Air intake chamber Throttle body bracket X Throttle body Throttle body bracket X Cylinder head EGR pipe X Cylinder head EGR pipe X Cylinder head Air intake chamber stay X Cylinder head Brake booster union X Air intake chamber Air intake chamber stay X Air intake chamber Fuel pressure pulsation damper X Fuel pipe support TORQUE SPECIFICATIONS EG188 Fuel cut rpm Sub heated oxygen sensor Main heated oxygen sensor Fuel return rpm Heater coil resistance Heater coil resistance Part tightened for union bolt for flare nut ENGINE for SST at 20C (68F) at 20C (68F) SFI SYSTEM Nm 29 30 42 27 27 5.4 3.9 25 2.9 2.9 29 29 2.9 27 8.8 21 6.8 27 21 21 27 64 18 29 18 41 35 10 21 27 21 20 20 44 39 39 44 44 1,400 rpm 11.714.3 W 11.714.3 W kgfcm 300 310 420 280 280 55 40 250 30 30 300 300 30 280 90 210 70 280 210 210 280 650 185 300 185 420 350 100 210 280 210 200 200 450 400 400 450 450 ftlbf 22 22 30 20 20 48 in.lbf 35 in.lbf 18 26 in.lbf 26 in.lbf 22 22 26 in.lbf 20 78 in.lbf 15 61 in.lbf 20 15 15 20 47 13 22 13 30 25 7 15 20 15 14 14 33 29 29 33 33 EG0EE11 Engine coolant (w/ Heater) Torque wrench Thermometer Heater Radiator cap tester SSM (SPECIAL SERVICE MATERIALS) COOLANT EQUIPMENT RECOMMENDED TOOLS SST (SPECIAL SERVICE TOOLS) PREPARATION COOLING SYSTEM Item 0883300080 Adhesive 1344, , THREE BOND 1344, LOCTITE 242 or equivalent ENGINE 7.5 liters (7.9 US qts, 6.6 lmp. qts) Capacity Thermostat ECT switch Thermostat ECT switch SFI SYSTEM Idler pulley pivot bolt y Ethyleneglycol base Classification EG189 EG0S60G EG0S50A EG0S704 EG0S409 EG0S305 EG190 ENGINE COOLING SYSTEM COOLANT CHECK AND REPLACEMENT EG4KD01 1. 2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the "LOW" and "FULL" lines. If low, check for leaks and add engine coolant up to the "FULL" line. CHECK ENGINE COOLANT QUALITY There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. 3. REPLACE ENGINE COOLANT (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Loosen the 2 drain plugs (for the engine and radiator), and drain the coolant. (c) Close the drain plugs. Torque: 29 Nm (300 kgfcm, 22 ftlbf) for engine (d) Slowly fill the system with coolant. Use a good brand of ethyleneglycol base coolant and mix it according to the manufacturer's directions. Using coolant which includes more than 50 % ethyleneglycol (but not more than 70 %) is recommended. NOTICE: Do not use an alcohol type coolant. The coolant should be mixed with demineralized water or distilled water. Capacity (w/ Heater): 7.5 liters (7.9 US qts, 6.6 lmp. qts) (e) Install the radiator cap. (f) Start the engine, and bleed the cooling system. (g) Refill the reservoir tank with coolant until it reaches the "FULL" line. EG191 ENGINE COOLING SYSTEM WATER PUMP COMPONENTS FOR REMOVAL AND INSTALLATION EG2GX07 EG192 ENGINE COOLING SYSTEM WATER PUMP REMOVAL EG4KE01 1. 2. 3. 4. DRAIN ENGINE COOLANT REMOVE ENGINE UNDER COVER REMOVE AIR CLEANER DUCT REMOVE AIR CLEANER, VAF METER AND INTAKE AIR CONNECTOR PIPE 5. REMOVE DRIVE BELT, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY (a) Loosen the 4 nuts holding the fluid coupling to the water pump. EG193 ENGINE COOLING SYSTEM (b) Loosen the drive belt tension by turning the drive belt tensioner clockwise, and remove the drive belt. (c) Remove the 4 nuts, fluid coupling and water pump pulley. 6. REMOVE RADIATOR ASSEMBLY (See steps 5 and 6 in radiator removal) 7. REMOVE WATER INLET AND THERMOSTAT (a) Remove the 2 nuts holding the water inlet to the water pump, and disconnect the water inlet from the water pump. (b) Remove the thermostat. (c) Remove the gasket from the thermostat. 8. REMOVE DISTRIBUTOR (See distributor removal in Ignition System) 9. (a) (b) 10. 11. REMOVE WATER BYPASS OUTLET AND NO.1 WATER BYPASS PIPE Remove the 2 bolts, water bypass outlet and No.1 water bypass pipe. Remove the 3 Orings from the water bypass outlet and No.1 water bypass pipe. REMOVE TIMING BELT (See steps 6 to 10 and 12 to 16 in timing belt removal in Engine Mechanical) REMOVE IDLER PULLEY (See step 17 in timing belt removal in Engine Mechanical) 12. REMOVE WATER PUMP (a) Remove the mounting bolt, and disconnect the engine wire bracket. (b) Loosen the generator mounting nut. (c) Remove the generator mounting bolt, and disconnect the generator from the water pump. EG194 ENGINE COOLING SYSTEM (d) Remove the 2 nuts, and disconnect the No.2 water bypass pipe from the water pump. (e) Remove the 6 bolts, water pump and gasket. (f) Remove the Oring from the cylinder block. WATER PUMP COMPONENTS INSPECTION EG2GZ06 1. INSPECT WATER PUMP Turn the pulley seat, and check that the water pump bearing is not rough or noisy. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING (a) Remove the 4 nuts and fan from the fluid coupling. (b) Check that the fluid coupling is not damaged and that no silicon oil leaks. If necessary, replace the fluid coupling. (c) Reinstall the fan to the fluid coupling with the 4 nuts. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf) EG195 ENGINE COOLING SYSTEM WATER PUMP INSTALLATION EG4KF01 1. INSTALL WATER PUMP (a) Install a new Oring to the cylinder block. (b) Install a new gasket to the water pump. (c) Connect the water pump to the water bypass pipe. Do not install the nut yet. (d) Install the water pump with the 2 bolts (A) and 4 bolts (B). Torque: 21 Nm (210 kgfcm, 15 ftlbf) HINT: Hand tighten the (A) bolts first. (e) Install the 2 nuts holding the No.2 water bypass pipe to the water pump. Torque: 21 Nm (210 kgfcm, 15 ftlbf) (f) Install the generator mounting bolt. Torque: 37 Nm (380 kgfcm, 27 ftlbf) (g) Tighten the generator mounting nut. Torque: 37 Nm (380 kgfcm, 27 ftlbf) (h) Install the engine wire bracket with the bolt. 2. INSTALL IDLER PULLEY (See step 2 in timing belt installation in Engine Mechanical) EG196 ENGINE COOLING SYSTEM 3. INSTALL TIMING BELT (See steps 3 to 7 and 9 to 16 in timing belt installation in Engine Mechanical) 4. INSTALL WATER BYPASS OUTLET AND NO.1 WATER BYPASS PIPE (a) Install 2 new Orings to the No.1 water bypass pipe. (b) Install a new Oring and the water bypass outlet with the 2 bolts. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 5. INSTALL DISTRIBUTOR (See steps 3 and 5 to 6 distributor installation in Ignition System) 6. PLACE THERMOSTAT IN WATER INLET (a) Install a new gasket to the thermostat. (b) Align the jiggle valve of the thermostat with the protrusion of the water inlet. 7. INSTALL WATER INLET Install the water inlet with the 2 nuts. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 8. INSTALL RADIATOR ASSEMBLY (See steps 4 and 5 in radiator installation) EG197 ENGINE COOLING SYSTEM 9. INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND DRIVE BELT (a) Align the matchmarks, and install the water pump pulley and fan fluid coupling with the 4 nuts. (b) Install the drive belt by turning the drive belt tensioner clockwise. (c) Stretch the belt tight and tighten the 4 nuts. Torque: 16 Nm (165 kgfcm, 12 ftlbf) 10. INSTALL AIR CLEANER, VAF METER AND INTAKE AIR CONNECTOR PIPE 11. INSTALL AIR CLEANER DUCT 12. FILL WITH ENGINE COOLANT 13. START ENGINE AND CHECK FOR LEAKS 14. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL 15. CHECK IGNITION TIMING (See ignition timing inspection and adjustment in Engine Mechanical) 16. INSTALL ENGINE UNDER COVER 17. ROAD TEST VEHICLE Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 18. RECHECK ENGINE COOLANT LEVEL EG198 ENGINE COOLING SYSTEM THERMOSTAT COMPONENTS FOR REMOVAL AND INSTALLATION EG2H20A THERMOSTAT REMOVAL EG1L406 1. 2. Installation is in reverse order of removal. HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. DRAIN ENGINE COOLANT DISCONNECT WATER INLET FROM WATER PUMP, AND REMOVE THERMOSTAT (a) Remove the 2 nuts holding the water inlet to the water pump, and disconnect the water inlet from the water pump. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) (b) Remove the thermostat. (c) Remove the gasket from the thermostat. INSTALLATION HINT: See water pump installation. EG199 ENGINE COOLING SYSTEM THERMOSTAT INSPECTION EG0SE07 INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 8084C (176183F) If the valve opening temperature is not as specified, replace the thermostat. (c) Check the valve lift. Valve lift: 8.5 mm (0.335 in.) or more at 95C (203F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve spring is tight when the thermostat is fully closed. If not closed, replace the thermostat. EG200 ENGINE COOLING SYSTEM RADIATOR RADIATOR CLEANING EG2H706 Using water or a steam cleaner, remove any mud and dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. If the cleaner nozzle pressure is 2,9423,432 kPa (3035 kgf/cm2, 427498 psi), keep a distance of at least 40 cm (15.75 in.) between the radiator core and cleaner nozzle. RADIATOR INSPECTION 1. INSPECT RADIATOR CAP NOTICE: When doing steps (a) and (b) below, keep the radiator pump tester at an angle of over 30 above the horizontal. (a) Using a radiator cap tester, slowly pump the tester and check that air is coming from the relief valve. Pump speed: 1 push/3 seconds or more NOTICE: Push the pump at a constant speed. If air is not coming from the relief valve, replace the radiator cap. (b) Pump the tester several times and measure the relief valve opening pressure. Pump speed: 1st time 1 push/1 second or less 2nd time or more Any speed Standard opening pressure: 74103 kPa (0.751.05 kgf/cm2, 10.714.9 psi) Minimum opening pressure: 59 kPa (0.6 kgf/cm2, 8.5 psi) 2. If the opening pressure is less than minimum, replace the radiator cap. INSPECT COOLING SYSTEM FOR LEAKS (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head. EG201 ENGINE COOLING SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG0SJ09 EG202 ENGINE COOLING SYSTEM RADIATOR REMOVAL EG4KG01 1. 2. 3. 4. (a) (b) REMOVE ENGINE UNDER COVER DRAIN ENGINE COOLANT REMOVE AIR CLEANER DUCT REMOVE NO.2 FAN SHROUD Remove the 2 clips. Disconnect the claw of the No.2 fan shroud from the hook of the No.1 fan shroud, and remove the No.2 fan shroud. DISCONNECT HOSES FROM RADIATOR Disconnect these hoses from the radiator: (1) Reservoir tank inlet hose (2) Upper radiator hose 5. (3) Lower radiator hose (4) 2 A/T oil cooler hoses Plug the hose ends. 6. REMOVE RADIATOR ASSEMBLY (a) Disconnect the ECT switch for electric cooling fan connector and wire. (b) Disconnect the electric cooling fan connector and wire. (c) Remove the nut and upper radiator support. Remove the 2 upper radiator supports. (d) Lift out the radiator assembly. (e) Remove the 2 lower radiator supports. 7. REMOVE ELECTRIC COOLING FAN FROM RADIATOR EG203 ENGINE COOLING SYSTEM 8. REMOVE NO.1 FAN SHROUD FROM RADIATOR (a) Remove the 2 bolts. (b) Disconnect the lower sides of the No.1 fan shroud from the 2 hooks of the radiator, and remove the radiator. (c) Remove the 2 cushions from the No.1 fan shroud. 9. REMOVE ENGINE COOLANT TEMPERATURE (ECT) SWITCH FROM RADIATOR (a) Remove the ECT switch. (b) Remove the Oring from the ECT switch. COMPONENTS FOR DISASSEMBLY AND ASSEMBLY EG1LB0C EG204 ENGINE COOLING SYSTEM RADIATOR DISASSEMBLY EG4KH01 1. 2. REMOVE RESERVOIR TANK INLET PIPE FROM RADIATOR REMOVE DRAIN HOSE FROM RADIATOR 3. ASSEMBLE SST SST 0923001010 (a) Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension "B" shown in the diagram is 0.20.5 mm (0.0080.020 in.). NOTICE: If this adjustment is not performed, the claw may be damaged. 4. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 0923001010 5. REMOVE TANKS AND ORINGS (a) Lightly tap the radiator hose inlet (or outlet) with a softfaced hammer and remove the tank. (b) Remove the Oring. 6. REMOVE OIL COOLER FROM LOWER TANK (a) Remove the inlet pipes. HINT: Make a note of the direction to face the pipes. (b) Remove the nuts, spring washers, plate washers and oil cooler. (c) Remove the Orings from the oil cooler. EG205 ENGINE COOLING SYSTEM RADIATOR ASSEMBLY EG4KJ01 1. INSTALL OIL COOLER TO LOWER TANK (a) Clean the Oring contact surface of the lower tank and oil cooler. (b) Install new Orings (1) to the oil cooler (2). (c) Install the oil cooler (2) to the lower tank (3). (d) Install the plate washers (4), spring washers (5) and nuts (6). Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) (e) Install the inlet pipes (7). Torque: 15 Nm (150 kgfcm, 11 ftlbf) HINT: Face the inlet pipes in the same direction they were before disassembly. 2. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented. Therefore, repair or replace if necessary. 3. INSTALL NEW ORINGS AND TANKS (a) After checking that there are no foreign objects in the lock plate groove, install the new Oring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. (b) Install the tank without damaging the Oring. (c) Tap the lock plate with a softfaced hammer so that there is no gap between it and the tank. EG206 ENGINE COOLING SYSTEM 4. ASSEMBLE SST SST 0923001010 (a) Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" as shown in the illustration. (b) While gripping the handle, adjust the stopper bolt so that dimension "B" shown in the diagram is 7.7 mm (0.03 in.). 5. CAULK LOCK PLATE (a) Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. SST 0923001010 HINT: Do not stake the areas protruding around the pipes, brackets or tank ribs. The points shown in the illustration and oil cooler near here cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates. EG207 ENGINE COOLING SYSTEM (b) Check the lock plate height (H) after completing the caulking. Plate height: 7.758.25 mm (0.30510.3248 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 6. INSPECT FOR WATER LEAKS (a) Tighten the drain plug. (b) Plug the inlet and outlet pipes of the radiator with SST. SST 0923001010 (c) Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) (d) Inspect for water leaks. HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, move the radiator around in the water until all air bubbles disappear. 7. PAINT LOCK PLATES HINT: If the water leak test checks out okay, allow the radiator to completely dry and then paint the lock plates. 8. INSTALL DRAIN HOSE TO RADIATOR 9. INSTALL RESERVOIR TANK INLET PIPE TO RADIATOR EG208 ENGINE COOLING SYSTEM RADIATOR INSTALLATION EG4KK01 1. INSTALL ENGINE COOLANT TEMPERATURE (ECT) SWITCH TO RADIATOR (a) Install a new Oring to the ECT switch. (b) Apply soapy water to the Oring. (c) Install the ECT switch. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf) 2. INSTALL NO.1 FAN SHROUD TO RADIATOR (a) Install the 2 cushions to the radiator. (b) Connect the lower sides of the No.1 fan shroud to the 2 hooks of the radiator. (c) Install the No.1 fan shroud with the 2 bolts. 3. INSTALL ELECTRIC COOLING FAN TO RADIATOR 4. INSTALL RADIATOR ASSEMBLY (a) Install the 2 lower radiator supports to the radiator. (b) Place the radiator assembly on the body bracket. (c) Install the radiator with the 2 upper radiator supports and 2 nuts. Torque: 12 Nm (120 kgfcm, 9 ftlbf) HINT: After installation, check that the rubber cushion (A) of the support is not depressed. (d) Connect the electric cooling fan connector and wire. (e) Connect the ECT switch (for electric cooling fan) connector and wire. 5. CONNECT HOSES TO RADIATOR 6. INSTALL NO.2 FAN SHROUD (a) Connect the claw of the No.2 fan shroud from the hook of the No.1 fan shroud. (b) Install the No.2 fan shroud with the 2 clips. 7. INSTALL AIR CLEANER DUCT 8. FILL WITH ENGINE COOLANT 9. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL 10. START ENGINE AND CHECK FOR LEAKS 11. INSTALL ENGINE UNDER COVER EG209 ENGINE COOLING SYSTEM ELECTRIC COOLING FAN OnVehicle Inspection EG2HF06 CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 88_C (190_F) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT switch, and check for a separated connector or severed wire between the cooling fan relay and ECT switch. (c) Disconnect the ECT switch connector. (d) Check that the cooling fan rotates. If not, check the fan main relay, cooling fan relay, cooling fan, fuses, and check for short circuit between the cooling fan relay and ECT switch. (e) Reconnect the ECT switch connector. 1. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 97_C (207_F) (a) Start the engine, and raise coolant temperature to above 97_C (207_F). (b) Check that the cooling fan rotates. If not, replace the ECT switch. 2. EG210 ENGINE COOLING SYSTEM Cooling Fan COMPONENTS FOR REMOVAL AND INSTALLATION EG14908 COOLING FAN INSPECTION EG4KL01 INSPECT COOLING FAN (a) Disconnect the fan connector. (b) Connect battery and ammeter to the cooling fan connector. (c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 6.07.4 A (d) Reconnect the fan connector. EG211 ENGINE COOLING SYSTEM COOLING FAN REMOVAL EG4KM01 Installation is in the reverse order of removal. 1. REMOVE ENGINE UNDER COVER 2. REMOVE AIR CLEANER DUCT 3. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 4. REMOVE COOLING FAN (a) Disconnect the cooling fan connector. (b) Disconnect the ECT switch wire from the wire clamp. (c) Remove the 3 bolts and cooling fan. COMPONENTS FOR DISASSEMBLY AND ASSEMBLY EG4KM01 COOLING FAN DISASSEMBLY EG4KN01 Assembly is in the reverse order of disassembly. 1. REMOVE FAN 2. REMOVE FAN MOTOR (a) Disconnect the wire and connector from the fan shroud. (b) Remove the 3 screws and fan motor. EG212 ENGINE COOLING SYSTEM Engine Coolant Temperature (ECT) Switch ECT SWITCH INSPECTION EG4KP01 1. 2. 3. (a) (b) (c) REMOVE ENGINE UNDER COVER DRAIN ENGINE COOLANT REMOVE ECT SWITCH Disconnect the ECT switch connector. Remove the ECT switch. Remove the Oring the ECT switch. 4. INSPECT ECT SWITCH (a) Using an ohmmeter, check that there is no continuity between the terminals when the coolant temperature is above 101_C (214_F). (b) Using an ohmmeter, check that there is continuity between the terminals when the coolant temperature is below 91_C (196_F). If continuity is not as specified, replace the switch. 5. (a) (b) (c) (d) 6. 7. 8. REINSTALL ECT SWITCH Install a new Oring to the ECT switch. Apply soapy water on the Oring. Install the ECT switch. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf) Connect the ECT switch connector. REFILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS REINSTALL ENGINE UNDER COVER Fan Main Relay ("RDI FAN MAIN") FAN MAIN RELAY INSPECTION EG4KQ01 1. 2. REMOVE RELAY BOX COVER REMOVE FAN MAIN RELAY 3. INSPECT FAN MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 3 and 5. (b) Check that there is continuity between terminals 2 and 4. (c) Check that there is no continuity between terminals 1 and 4. If continuity is not as specified, replace the relay. EG213 ENGINE COOLING SYSTEM B. Inspect relay operation (a) Apply battery voltage across terminals 3 and 5. (b) Using an ohmmeter, check that there is no continuity between terminals 2 and 4. (c) Check that there is continuity between terminals 1 and 2. If operation is not as specified, replace the relay. 4. REINSTALL FAN MAIN RELAY 5. REINSTALL RELAY BOX COVER Cooling Fan Relay ("RDI FAN") COOLING FAN RELAY INSPECTION EG4KR01 1. 2. REMOVE RELAY BOX COVER REMOVE COOLING FAN RELAY 3. INSPECT COOLING FAN RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is continuity between terminals 3 and 4. If continuity is not as specified, replace the relay. B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If operation is not as specified, replace the relay. 4. REINSTALL COOLING FAN RELAY 5. REINSTALL RELAY BOX COVER TORQUE SPECIFICATIONS Upper radiator support X Body ECT switch X Radiator Fan X Fluid coupling Electric cooling fan Radiator cap Thermostat Oil cooler X Oil cooler pipe Fluid coupling X Water pump Water inlet X Water pump Generator X Cylinder block Generator X Water pump Water pump X Cylinder block Oil cooler X Radiator lower tank Water bypass outlet X Cylinder head Water pump X No. 2 water bypass pipe Engine drain plug X Cylinder block Rotating amperage Part tightened 8084C (176183F) at 95C (203F) 8.5 mm (0.335 in.) or more STD 74103 kPa (0.751.05 kgf/cm2, 10.714.9 psi) Minimum 59 kPa (0.6 kgf/cm2, 8.5 psi) 6.07.4 A Nm 7.4 8.3 8.8 8.8 7.4 15 16 37 37 21 21 29 12 kgfcm 120 150 165 380 380 210 210 300 75 85 90 90 75 65 in.lbf 74 in.lbf 78 in.lbf 78 in.lbf 65 in.lbf ftlbf 12 27 27 15 15 22 11 9 EG0SY0A SERVICE DATA SERVICE SPECIFICATIONS EG214 ENGINE COOLING SYSTEM Valve opening temperature Valve lift Relief valve opening pressure EG0SX08 EG215 ENGINE LUBRICATION SYSTEM LUBRICATION SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) EG04X07 Item Engine oil Dry fill Drain and refill w/ Oil filter change w/o Oil filter change LUBRICANT EQUIPMENT Torque wrench Precision straight edge Oil pressure gauge Oil pump SSM (SPECIAL SERVICE MATERIALS) RECOMMENDED TOOLS EG216 0883300080 Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent ENGINE 8882600080 Seal Packing Black or equivalent (FIPG) 5.4 liters (5.7 US qts, 4.8 Imp. qts) 5.1 liters (5.4 US qts, 4.5 Imp. qts) 6.5 liters (6.9 US qts, 5.7 lmp. qts) Capacity LUBRICATION SYSTEM Classification API grade SH, EnergyConserving II or ILSAC multigrade and recommended viscosity oil with SAE 5W30 being the preferred engine oil Oil pressure switch Idler pulley pivot bolt Oil pump No.1 oil pan No.2 oil pan EG0T40D EG0T505 EG0T305 EG0T206 EG217 ENGINE LUBRICATION SYSTEM OIL PRESSURE CHECK EG4KA01 1. 2. 3. CHECK OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If oil quality is visibly poor, replace the oil. CHECK ENGINE OIL LEVEL The oil level should be between the "L" and "F" marks on the dipstick. If low, check for the leakage and add oil up to "F" mark. REMOVE ENGINE UNDER COVER 4. REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner clockwise, and remove the drive belt. 5. DISCONNECT A/C COMPRESSOR WITHOUT DISCONNECTING HOSES (a) Remove the 4 bolts and nut. (b) Using a torx socket (E10), remove the stud bolt. (c) Disconnect the compressor connector. (d) Remove 4 bolts and pull the compressor downward. 6. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL PRESSURE GAUGE (a) Disconnect the oil pressure switch connector. (b) Using SST, remove the oil pressure switch. SST 0981630010 (c) Install an oil pressure gauge. EG218 ENGINE LUBRICATION SYSTEM 7. 8. 9. REINSTALL A/C COMPRESSOR REINSTALL DRIVE BELT WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 10. CHECK OIL PRESSURE Oil pressure: At idle 49 kPa (0.5 kgf/cm2, 7.1 psi) or more At 3,000 rpm 324579 kPa (3.35.9 kgf/cm2, 4784 psi) 11. REMOVE DRIVE BELT 12. DISCONNECT A/C COMPRESSOR FROM ENGINE 13. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH (a) Remove the oil pressure gauge. (b) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No.0883300080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Using SST, install the oil pressure switch. SST 0981630010 Torque: 14 Nm (150 kgfcm, 11 ftlbf) (d) 14. 15. 16. 17. Connect the compressor connector. REINSTALL A/C COMPRESSOR REINSTALL DRIVE BELT START ENGINE AND CHECK FOR LEAKS REINSTALL ENGINE UNDER COVER EG219 ENGINE LUBRICATION SYSTEM OIL AND FILTER REPLACEMENT EG2HP04 CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug, and drain the oil into a container. 2. REPLACE OIL FILTER (a) Using SST, remove the oil filter. SST 0922807500 (b) Check and clean the oil filter installation surface. (c) Apply clean engine oil to the gasket of a new oil filter. EG220 ENGINE LUBRICATION SYSTEM (d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (e) Using SST, tighten it an additional 3/4 turn. SST 0922807500 3. REFILL WITH ENGINE OIL (a) Clean and install the oil drain plug with a new gasket. Torque: 25 Nm (250 kgfcm, 18 ftlbf) (b) Fill with fresh engine oil. Oil grade: API grade SH, EnergyConserving II or ILSAC multigrade and recommended viscosity oil, with SAE 5 W30 being the preferred engine oil. Capacity: Drain and refill w/ Oil filter change 5.4 liters (5.7 US qts, 4.8 Imp. qts) w/o Oil filter change 5.1 liters (5.4 US qts, 4.5 Imp. qts) Dry fill 6.5 liters (6.9 US qts, 5.7 Imp. qts) (c) 4. 5. Reinstall the oil filler cap. START ENGINE AND CHECK FOR OIL LEAKS RECHECK ENGINE OIL LEVEL EG221 ENGINE LUBRICATION SYSTEM OIL PUMP COMPONENTS FOR REMOVAL AND INSTALLATION EG2HQ02 EG222 ENGINE LUBRICATION SYSTEM OIL PUMP REMOVAL EG4KB01 1. 2. 3. 4. 5. 6. HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. REMOVE ENGINE WITH TRANSMISSION (See engine removal in Engine Mechanical) SEPARATE ENGINE AND TRANSMISSION (See engine & transmission separation in Engine Mechanical) INSTALL ENGINE TO ENGINE STAND FOR REMOVAL REMOVE TIMING BELT (See steps 4 and, 6 to 10 and, 12 to 16 in timing belt removal in Engine Mechanical) REMOVE IDLER PULLEY (See step 17 in timing belt removal in Engine Mechanical) REMOVE CRANKSHAFT TIMING PULLEY (See step 18 in timing belt removal in Engine Mechanical) 7. (a) (b) (c) REMOVE OIL DIPSTICK AND GUIDE Remove the mounting bolt. Pull out the dipstick guide together with dipstick. Remove the Oring from the dipstick guide. 8. (a) (b) (c) REMOVE OIL LEVEL SENSOR Disconnect the level sensor connector. Remove the 4 mounting bolts and level sensor. Remove the gasket from the level sensor. NOTICE: Be careful not to drop the oil level sensor when removing it. 9. REMOVE NO.2 OIL PAN (a) Remove the 16 mounting bolts and 2 nuts. EG223 ENGINE LUBRICATION SYSTEM (b) Insert the blade of SST between the No.1 and No.2 oil pan, break the seal of the applied sealer and remove the No.2 oil pan. SST 0903200100 NOTICE: Be careful not to damage the No.2 oil pan contact surface of the No.1 oil pan. Be careful not to damage the oil pan flange. 10. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. 11. REMOVE OIL PAN BAFFLE PLATE Remove the 6 bolts and baffle plate. 12. REMOVE NO.1 OIL PAN (a) Remove the 22 mounting bolts. (b) Remove the No.1 oil pan by prying the portions between the cylinder block and No.1 oil pan with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and No.1 oil pan. (c) Remove the Oring from the cylinder block. EG224 ENGINE LUBRICATION SYSTEM 13. REMOVE CRANKSHAFT FRONT OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip 14. REMOVE OIL PUMP (a) Remove the 9 mounting bolts. (b) Using a hammer and a brass bar, remove the oil pump by carefully tapping the oil pump body. (c) Remove the 2 Orings from the cylinder block. EG225 ENGINE LUBRICATION SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY EG2HS05 OIL PUMP DISASSEMBLY EG2HT04 1. REMOVE RELIEF VALVE (a) Carefully mount the pump body in a soft jaw vise. (b) Remove the plug, gasket, compression spring and relief valve. NOTICE: Be careful not to damage the pump body. 2. REMOVE DRIVE AND DRIVEN ROTORS Remove the 10 screws, pump body cover, the drive and driven rotors. EG226 ENGINE LUBRICATION SYSTEM OIL PUMP INSPECTION EG0TA09 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole under its own weight. If it doesn't, replace the relief valve. If necessary, replace the oil pump assembly. 2. A. INSPECT DRIVE AND DRIVEN ROTORS Place drive and driven rotors into oil pump body The marks on the rotors must face up. B. Inspect rotor tip clearance Using a feeler gauge, measure the clearance between the drive and driven rotors. Standard tip clearance: 0.3100.490 mm (0.01220.0193 in.) Maximum tip clearance: .53 mm (0.0209 in.) If the tip clearance is greater than maximum, replace the rotors as a set. C. Inspect rotor body clearance Using a feeler gauge, measure the clearance between the driven rotor and pump body. Standard body clearance: 0.1000.175 mm (0.00390.0069 in.) Maximum body clearance: 0.20 mm (0.0079 in.) If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. EG227 ENGINE LUBRICATION SYSTEM D. Inspect rotor side clearance Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: 0.0300.090 mm (0.00120.0035 in.) Maximum side clearance: 0.12 mm (0.0047 in.) E. If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. Remove drive and driven rotors OIL PUMP ASSEMBLY EG0TC08 1. INSTALL DRIVE AND DRIVEN ROTORS (a) Place the drive and driven rotors into oil pump body with the mark facing upward. (b) Install the pump body cover with the 10 screws. Torque: 10 Nm (105 kgfcm, 8 ftlbf) 2. INSTALL RELIEF VALVE (a) Carefully mount the pump body in a soft jaw vise. NOTICE: Be careful not to damage the pump body. (b) Insert the relief valve and compression spring into the oil pump body hole. (c) Install the plug with a new gasket. Torque: 49 Nm (500 kgfcm, 36 ftlbf) EG228 ENGINE LUBRICATION SYSTEM OIL PUMP INSTALLATION EG4KC01 1. INSTALL OIL PUMP (a) Place 2 new Orings in position on the cylinder block. (b) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block. Using a razor blade gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the debris. Using a nonresidue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. (c) Apply seal packing to the oil pump as shown in the illustration. Seal packing: Part No.0882600080 or equivalent Install a nozzle that has been cut to a 23 mm (0.080.12 in.) opening. HINT: Avoid applying an excessive amount to the surface. Be particularly careful near oil passages. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. (d) Install the oil pump with the 9 bolts. Torque: 21 Nm (210 kgfcm, 15 ftlbf) EG229 ENGINE LUBRICATION SYSTEM 2. INSTALL CRANKSHAFT FRONT OIL SEAL (a) Apply MP grease to a new oil seal lip. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 0931660010 (0931600010) 3. INSTALL NO.1 OIL PAN (a) Place a new Oring in the position on the cylinder block. (b) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No.1 oil pan and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the debris. Using a nonresidue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. Apply seal packing to the No.1 oil pan as shown in the illustration. Seal packing: Parts No.0882600080 or equivalent (c) Install a nozzle that has been cut to a 34 mm (0.120.16 in.) opening. HINT: Avoid applying an excessive amount to the surface. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. (d) Install the No.1 oil pan with the 22 bolts. Torque: 12 mm head: 21 Nm (210 kgfcm, 15 ftlbf) 4 mm head: 39 Nm (400 kgfcm, 29 ftlbf) 4. 5. INSTALL OIL PAN BAFFLE PLATE Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) EG230 ENGINE LUBRICATION SYSTEM 6. INSTALL NO.2 OIL PAN (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No.1 and No.2 oil pans. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the debris. Using a nonresidue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. (b) Apply seal packing to the No.2 oil pan as shown in the illustration. Seal packing: Part No.0882600080 or equivalent (c) Install a nozzle that has been cut to a 34 mm (0.120.16 in.) opening. HINT: Avoid applying an excessive amount to the surface. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the No.2 oil pan with the 16 bolts and 2 nuts. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 7. INSTALL OIL LEVEL SENSOR (a) Install a new gasket to the level sensor. (b) Install the level sensor with the 4 bolts. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) (c) Connect the level sensor connector. 8. (a) (b) (c) INSTALL OIL DIPSTICK GUIDE AND DIPSTICK Install a new Oring on the dipstick guide. Apply soapy water on the Oring. Push in the dipstick guide into the guide hole of the No.1 oil pan. (d) Install the guide with the mounting bolt. 9. INSTALL CRANKSHAFT TIMING PULLEY (See step 1 in timing belt installation in Engine Mechanical) TORQUE SPECIFICATIONS Oil level sensor X No.1 oil pan No.2 oil pan X No.1 oil pan Oil strainer X No.1 oil pan Oil pump X Cylinder Block Plug X Oil pump body Part tightened Oil pump Oil pressure No. 2 oil pan X Cylinder Block Oil drain plug X No. 2 oil pan Oil pan baffle plate X No.1 oil pan Oil pump body cover X Oil pump body Oil pressure switch X Cylinder block Side clearance 12 mm head 14 mm head Maximum 0.12 mm (0.0047 in.) Nm 5.4 8.8 8.8 8.8 21 39 21 49 10 25 14 STD 0.0300.090 mm (0.00120.0035 in.) kgfcm 210 400 210 500 105 250 150 55 90 90 90 48 in.lbf 78 in.lbf 78 in.lbf 78 in.lbf ftlbf 15 29 15 36 18 11 8 EG0TJ0B SERVICE DATA SERVICE SPECIFICATIONS Body clearance Tip clearance 10. INSTALL IDLER PULLEY (See step 2 in timing belt installation in Engine Mechanical) 11. INSTALL TIMING BELT (See steps 3 to 7 and, 9 to 16 and, 18 in timing belt installation in Engine Mechanical) 12. REMOVE ENGINE STAND FROM ENGINE 13. ASSEMBLY ENGINE AND TRANSMISSION (See engine & transmission assembly in Engine Mechanical) 14. INSTALL ENGINE WITH TRANSMISSION (See engine installation in Engine Mechanical) ENGINE at idle speed 49 kPa (0.5 kgf/cm2, 5.9 psi) or more at 3,000 rpm 324579 kPa Maximum 0.20 mm (0.0079 in.) Maximum 0.53 mm (0.0209 in.) LUBRICATION SYSTEM STD 0.1000.175 mm (0.00390.0069 in.) STD 0.3100.490 mm (0.01220.0193 in.) (3.35.9 kgf/cm2, 4784 psi) EG231 EG0TH06 EG232 ENGINE LUBRICATION SYSTEM MEMO EG233 ENGINE TROUBLESHOOTING EG234 ENGINE TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. P. EG235 P. EG237, EG339 P. EG238 P. IN23 P. EG238 P. EG252 P. EG240 P. EG261 P. EG251 EG235 ENGINE TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS CHECK SHEET CUSTOMER PROBLEM ANALYSIS CHECK SHEET EG236 ENGINE TROUBLESHOOTING DIAGNOSIS SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The ECM contains a builtin selfdiagnosis system by which troubles with the engine signal network are detected and a Malfunction Indicator Lamp in the instrument panel lights up. By analyzing various signals as shown in a later table (See page EG240) the Engine Control Module (ECM) detects system malfunctions relating to the sensors or actuators. In the normal mode, the selfdiagnosis system monitors 18 (with TRAC control) items, indicated by code No. as shown in EG240. A Malfunction Indicator Lamp informs the driver that a malfunction has been detected. The lamp goes off automatically when the malfunction has been repaired, but the diagnostic trouble code(s) remains stored in the ECM memory (except for code Nos. 16 and 53). The ECM stores the code(s) until it is cleared by removing the EFI fuse with the ignition switch OFF. The diagnostic trouble code can be read by the number of blinks of the Malfunction Indicator Lamp when TE1 and E1 terminals on the data link connector 1 or 2 are connected. When 2 or more codes are indicated, the lowest number (code) will appear first. In the test mode, 13 (with TRAC control) items, indicated by code No. as shown in EG240 are monitored. If a malfunction is detected in any one of the systems indicated by code Nos. 13, 21, 22, 24, 25, 26, 27, 28, 35, 41, 47, 71 and 78 the ECM lights the Malfunction Indicator Lamp to warn the technician that a malfunction has been detected. In this case, TE2 and E1 terminals on the data link connector 1 or 2 should be connected as shown later. (See page EG238). In the test mode, even if the malfunction is corrected, the malfunction code is stored in the ECM memory even when the ignition switch is OFF (except code Nos. 43 and 51). This also applies in the normal mode. The diagnostic trouble mode (normal or test) and the output of the Malfunction Indicator Lamp can be selected by connecting TE1, TE2 and E1 terminals of data link connector 1 or 2, as shown later. A test mode function has been added to the functions of the selfdiagnosis system of the normal mode for the purpose of detecting malfunctions such as poor contact, which are difficult to detect in the normal mode. This function fills up the selfdiagnosis system. The test mode can be implemented by the technician following the appropriate procedures of check terminal connection and operation described later. (See page EG238) EG237 ENGINE TROUBLESHOOTING DIAGNOSIS SYSTEM Diagnosis Inspection (Normal Mode) MALFUNCTION INDICATOR LAMP CHECK 1. The Malfunction Indicator Lamp will light up when the ignition switch is turned ON and the engine is not running. HINT: If the Malfunction Indicator Lamp does not light up, proceed to troubleshooting of the combination meter (See page BE75). When the engine is started, the Malfunction Indicator Lamp should go off. If the light remains on, the diagnostic system has detected a malfunction or abnormality in the system. 2. DIAGNOSTIC TROUBLE CODE CHECK 1. 2. Turn ignition switch ON. Using SST, connect terminals between TE1 and E1 of data link connector 1 or 2. SST 0984318020 3. Read the diagnostic trouble code from Malfunction Indicator Lamp. HINT: If a diagnostic trouble code is not output, check the TE1 terminal circuit (See page EG337). 4. 5. As an example, the blinking patterns for codes; normal, 12 and 31 are as shown on the illustration. Check the details of the malfunction using the diagnostic trouble code chart on page EG240. After completing the check, disconnect terminals TE1 and E1, and turn OFF the display. HINT: In the event of 2 or more malfunction codes, indication will begin from the smaller numbered code and continue in order to the larger. EG238 ENGINE TROUBLESHOOTING DIAGNOSIS SYSTEM Diagnosis Inspection (Test Mode) Compared to the normal mode, the test mode has an increased sensing ability to detect malfunctions. It can also detect malfunctions in the starter signal circuit, the IDL contact signal of the throttle position sensor, air conditioning signal and park/neutral position switch signal. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the test mode. DIAGNOSTIC TROUBLE CODE CHECK 1. Initial conditions. (a) Battery voltage 11 V or more (b) Throttle valve fully closed (c) Transmission in neutral position (d) Air conditioning switch OFF Turn ignition switch OFF. Using SST, connect terminals TE2 and E1 of data link connector 1 or 2. SST 0984318020 Turn ignition switch ON HINT: To confirm that the test mode is operating, check that the Malfunction Indicator Lamp flashes when the ignition switch is turned to ON. If the Malfunction Indicator Lamp does not flash, proceed to troubleshooting of the TE2 terminal circuit on page EG337. Start the engine. Simulate the conditions of the malfunction described by the customer. After the road test, using SST, connect terminals TE1 and E1 of data link connector 1 or 2. SST 0984318020 Read the diagnostic trouble code on Malfunction Indicator Lamp in the combination meter (See page EG237). After completing the check, disconnect the SST from terminals TE1, TE2 and E1, and turn off the display. HINT: The test mode will not start if terminals TE2 and E1 are connected after the ignition switch is turned ON. When the engine is not cranked, diagnostic trouble code "43" (Starter signal) is output, but this is not abnormal. When the automatic transmission shift lever is in the "D", "2", "L" or "R" shift position, or when the air conditioning is ON or when the accelerator pedal is depressed, code "51" (Switch condition signal) is output, but this is not abnormal. 2. 3. 4. 5. 6. 7. 8. 9. EG239 ENGINE TROUBLESHOOTING DIAGNOSIS SYSTEM DIAGNOSTIC TROUBLE CODE CHECK USING LEXUS HANDHELD TESTER 1. 2. Hook up the LEXUS handheld tester to the DLC2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the LEXUS handheld tester operator's manual for further details. After repairing the trouble arears, the diagnostic trouble code retained in the ECM memory must be cleared out by removing the EFI fuse (20 A) from R/B No.2 for 10 seconds or more, with the ignition switch OFF. HINT: Cancellation can also be done by removing the negative () terminal cable from the battery, but in this case, other memory systems (clock, etc.) will also be cancelled out. If it is necessary to work on engine components requiring removal of the negative () terminal cable from the battery, a check must first be made to see if a diagnostic trouble code has been recorded. After cancellation, road test the vehicle to check that a normal code is now read on the malfunction indicator lamp. If the same diagnostic trouble code(s) appears, it indicates that the trouble area has not been repaired thoroughly. DIAGNOSTIC TROUBLE CODE CLEARANCE 1. 2. ECM DATA MONITOR USING LEXUS HANDHELD TESTER 1. 2. Hook up the LEXUS handheld tester to the DLC2. Monitor the ECM data by following the prompts on the tester screen. HINT: LEXUS handheld tester has a "Snapshot" function which records the monitored data. Please refer to the LEXUS hand held tester operator's manual for further details. ECM TERMINAL VALUES MEASUREMENT USING LEXUS BREAKOUTBOX AND LEXUS HANDHELD TESTER 1. 2. Hook up the LEXUS breakoutbox and LEXUS handheld tester to the vehicle. Read the ECM input/output values by following the prompts on the tester screen. HINT: LEXUS handheld tester has a "Snapshot" function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the LEXUS handheld tester/LEXUS breakoutbox operator's manual for further details. EG240 ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly same as your reading due to type of the instruments or other factors. *4: See page EG248 *1, 2: See page EG248 S ECM S ECM S ECM S ECM S ECM S ECM S ECM S ECM S Intake air temp. sensor S Igniter S Distributor S Distributor S Di t ib t Distributor S Open or short in intake air temp. sensor circuit S Engine coolant temp. sensor S Main heated oxygen sensor (Fr) S Main heated oxygen sensor (Fr) circuit S Main heated oxygen sensor (Fr) heater S Open or short in NE circuit S Open or short in NE circuit S Open or short in STA circuit O en S Open or short in NE, G circuit Trouble Area S Open or short in engine coolant temp. sensor circuit S Open or short in heater circuit of main heated oxygen sensor (Fr) S Open or short in IGF or IGT circuit from igniter to ECM If a malfunction code is displayed during the diagnostic code check in test mode, check the circuit for that code listed in the table below (Proceed to the page given for that circuit). ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART Malfunction Indicator Lamp*1 Normal Test Mode Mode N.A. ON ON ON ON ON ON ON ON N.A. N.A. N.A. N.A. N.A ON ON ON ON Memory Memory*2 O O O O O O X EG276 See page EG264 EG 265 EG278 EG271 EG270 EG261 EG241 EG242 ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART *4: See page EG248 S Open or short in injector circuit S Fuel line pressure (injector leak, blockage) S Mechanical system malfunction (skipping teeth of timing belt) S Ignition system S Compression pressure (foreign object caught in valve) S Volume air flow meter (air intake) S ECM S Open or short in injector circuit S Fuel line pressure (injector leak, blockage) S Mechanical system malfunction (skipping teeth of timing belt) S Ignition system S Compression pressure (foreign object caught in valve) S Volume air flow meter (air intake) S ECM S Open or short in injector circuit S Fuel line pressure (injector leak, blockage) S Mechanical system malfunction (skipping teeth of timing belt) S Ignition system S Compression pressure (foreign object caught in valve) S Volume air flow meter (air intake) S ECM S Open or short in injector circuit S Fuel line pressure (injector leak, blockage) S Mechanical system malfunction (skipping teeth of timing belt) S Ignition system S Compression pressure (foreign object caught in valve) S Volume air flow meter (air intake) S ECM S S S S Open or short in main heated oxygen sensor circuit Main heated oxygen sensor Ignition system ECM. Trouble Area *1, 2: See page EG248 ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART Malfunction Indicator Lamp*1 Normal Test Mode Mode ON ON ON ON Memory*2 y O O See p g page EG280 EG280 EG243 EG244 ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART *4: See page EG248 *1, 2: See page EG248 S ECM S ECM S ECM S ECM S ECM S ECM S ECM S Combination meter S Throttle position sensor S Volume air flow meter S Open or short in No.1 vehicle speed sensor circuit S No.1 vehicle speed sensor S Open or short in throttle position sensor circuit S Open or short in volume air flow meter circuit S Main heated oxygen sensor (Rr) S Main heated oxygen sensor (Rr) circuit S Main heated oxygen sensor (Rr) heater S Sub heated oxygen sensor S Open or short in sub heated oxygen sensor circuit S Sub heated oxygen sensor Trouble Area S Open or short in heater circuit of main heated oxygen sensor (Rr) S Open or short in heater circuit of sub heated oxygen sensor ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART Normal Mode OFF ON ON ON ON ON ON ON Malfunction Indicator Lamp*1 Test Mode OFF N.A. N.A. N.A. ON ON ON ON Memory Memory*2 O O O O O O See page EG298 EG294 EG293 EG290 EG271 EG286 EG245 EG246 ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART *3, 4: See page EG248 *1, 2: See page EG248 S ECM S ECM S ECM S ECM S ECM S ECM S ECM S Fuel pump S Fuel pump ECU S ECM power source circuit S Open or short in fuel pump ECU circuit S Clogged EGR gas passage S EGR hose disconnected, valve stuck S Short in VSV circuit for EGR S Open in EGR gas temp. sensor circuit S No.2 knock sensor (looseness) S Open or short in No.2 knock sensor circuit S No.1 knock sensor (looseness) S Open or short in No. 1 knock sensor circuit S Subthrottle position sensor S Open or short in subthrottle position sensor circuit S Open or short in ignition switch or starter relay circuit S Open or short in starter signal circuit Trouble Area ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART Normal Mode OFF OFF N.A. ON ON ON ON Malfunction Indicator Lamp*1 Test Mode N.A. N.A. OFF N.A. ON ON ON Memory Memory*2 O O O O O O X See page EG296 EG306 EG302 EG294 EG300 EG247 EG248 ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART *1: "ON" displayed in the diagnostic mode column indicates that the Malfunction Indicator Lamp is lit up when a malfunction is detected. "OFF" indicates that the "CHECK" does not light up during malfunction diagnosis, even if a malfunction is detected. "N.A." indicates that the item is not included in malfunction diagnosis. *2: "O" in the memory column indicates that a diagnostic trouble code is recorded in the ECM memory when a malfunction occurs. "X" indicates that a diagnostic trouble code is not recorded in the ECM memory even if a malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is done with the IG switch ON. *3: Only vehicles with TRAC. *4: This indicates items for which "2 trip detection logic" is used. With this logic, when a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same case is detected again during the second drive test, this second detection causes the Malfunction Indicator Lamp to light up. The 2 trip repeats the same mode a 2nd time. (However, the IG switch must be turned OFF between the 1st trip and 2nd trip). In the Test Mode, the Malfunction Indicator Lamp lights up the 1st trip a malfunction is detected. S ECM S Accelerator pedal and cable S A/C switch circuit S Park neutral position switch circuit S Throttle position sensor IDL circuit Trouble Area ENGINE TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART Normal Mode N.A. Malfunction Indicator Lamp*1 Test Mode OFF Memory Memory*2 x See page EG313 EG249 EG250 ENGINE TROUBLESHOOTING FAILSAFE CHART FAILSAFE CHART If any of the following codes is detected, the ECM enters failsafe mode. BackUp Function If there is trouble with the program in the ECM and the ignition signals (IGT) are not output from the microcomputer, the ECM controls fuel injection and ignition timing at predetermined levels as a backup function to make it possible to continue to operate the vehicle. Furthermore, the injection duration is calculated from the starting signal (STA) and the throttle position signal (IDL). Also, the ignition timing is fixed at the initial ignition timing, 10BTDC, without relation to the engine speed. HINT: If the engine is controlled by the backup function, the malfunction indicator lamp lights up to warn the driver of the malfunction but the diagnostic trouble code is not output. EG251 ENGINE TROUBLESHOOTING CHECK FOR INTERMITTENT PROBLEMS CHECK FOR INTERMITTENT PROBLEMS As described in the preceding paragraph, abnormality detection ability in the test mode is increased compared to that in the normal mode, so that when intermittent problems intermittent shorts occur in the ECM signal circuits (G1, G2, NE, THW, THA, VTA1, VTA2) shown in the table opposite, the appropriate diagnostic trouble code is output. DTC 13 22 24 41 47 Circuit G, NE signal circuit (No.2) Engine coolant temp. sensor circuit Intake air temp. sensor circuit Throttle position sensor circuit Subthrottle position sensor circuit Accordingly, when the diagnostic trouble codes shown in the table opposite (13, 22, 24, 41, 47) are output during the diagnostic trouble code check, and inspection of the appropriate circuits reveals no abnormality, check for intermittent problems as described below. By checking for intermittent problems, the place where intermittent problems intermittent shorts are occurring due to poor contacts can be isolated. CLEAR DIAGNOSTIC TROUBLE CODES See page EG239. SET TEST MODE 1. With the ignition switch OFF, using SST, connect the terminals TE2 and E1 of the data link connector 1 or 2. SST 0984318020 Start the engine and check to see the Malfunction Indicator Lamp goes OFF. 2. PERFORM A SIMULATION TEST Using the symptom simulation (See page IN23), apply vibration to and pull lightly on the wire harness, connector or terminals in the circuit indicated by the malfunction code. In this test, if the Malfunction Indicator Lamp lights up, it indicates that the place where the wire harness, connector or terminals being pulled or vibrated has faulty contact. Check that point for loose connections, dirt on the terminals, poor fit or other problems and repair as necessary. HINT: After cancelling out the diagnostic trouble code in memory, set the test mode. If the Malfunction Indicator Lamp does not go OFF after the engine is started, check thoroughly for faulty contact, etc., then try the check again. If the Malfunction Indicator Lamp still does not go OFF, check and replace ECM. EG252 ENGINE TROUBLESHOOTING BASIC INSPECTION BASIC INSPECTION In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. If there is a problem, and a normal code is displayed, proceed to the matrix chart of problem symptoms on page EG260. Make sure that every likely cause of the problem is checked. 1 YES Is battery positive voltage 11 V or more when engine is stopped? Charge or replace battery. NO Does engine crank? 2 YES NO Does engine start? Proceed to matrix chart of problem symptoms on page EG260. 3 YES NO Check air filter. Go to step 7. 4 P C Remove air filter. Visually check that the air filter is not excessively dirty or oily. Hint If necessary, clean the air filter with compressed air. First blow from inside thoroughly, then blow from outside of the air filter. OK NG Repair or replace. EG253 ENGINE TROUBLESHOOTING BASIC INSPECTION 5 Check idle speed. P (1) (2) (3) (4) (5) C OK Shift transmission into "N" position. Warm up the engine to normal operating temperature. Switch OFF all accessories. Switch OFF air conditioning. Connect tachometer test probe to terminal IG of data link connector 1. Check idle speed. Idle speed: 700 $ 50 rpm Caution: S Never allow tachometer test prove to touch ground as it could result in damage to igniter and/or ignition coil. S As some tachometers are not compatible with this ignition system, confirm the compatability of your until before use. OK NG Proceed to matrix chart of problem symptoms on page EG260. 6 Check ignition timing. P (1) (2) (3) (4) Shift transmission into "N" position. Warm up the engine to normal operating temperature. Keep the engine speed at idle. Using SST, connect terminals TE1 and E1 of data link connector 1. SST 0984318020 Connect a timing light probe to No.1 high-tension cord. (5) C Check ignition timing. 10 BTDC @ idle OK Ignition timing: OK NG Proceed to page EG16 and continue to troubleshoot. Proceed to matrix chart of problem symptoms on page EG260. EG254 ENGINE TROUBLESHOOTING BASIC INSPECTION 7 Check fuel pressure. P (1) (2) (3) Be sure there is enough fuel in the tank. Turn ignition switch ON. Using SST, connect terminals FP and +B of data link connector 1. SST 0984318020 C Check that there is pressure in the hose from the fuel filter. Hint At this time, you will hear fuel return noise. Notice: Never make a mistake with the terminal connecting position as this will cause a malfunction. OK NG Check for spark. Proceed to page EG126 and continue to troubleshoot. 8 C Disconnect the hightension cord from the distributor and hold the end about 12.5 mm (1/2") from the ground. See if spark occurs while the engine is being cranked. Notice: To prevent excess fuel being injected from the injectors during this test, don't crank the engine for more than 12 seconds at a time. OK NG Proceed to page IG4 and continue to troubleshoot. Proceed to matrix chart of problem symptoms on page EG260. EG255 ENGINE TROUBLESHOOTING PARTS LOCATION PARTS LOCATION EG256 ENGINE TROUBLESHOOTING STANDARD VALUE OF ECM TERMINALS Connectors of the ECM are water proof and are the bolt type. For waterproof type connectors, in order to measure the voltage of ECM terminals and the resistance of connected parts, connect the inspection sub wire harness between the ECM and vehicle wire harness, then do the inspection. The inspection method of inserting a tester probe from the other side of connector significantly reduces the waterproof performance. STANDARD VALUE OF ECM TERMINALS Disconnect the connector by fully loosening the bolt. PREPARATION 1. 2. 3. 4. Turn the ignition switch OFF position. Lift up the passenger side floor carpet. Remove the ECM protector. Disconnect the connector from the ECM. After completely loosening the bolt, the 2 parts of the connector can be separated. NOTICE: Do not pull the wire harness when disconnecting the connector. When disconnecting the connector, the ECM's backup power source is cut off, so the malfunction codes, etc. recorded in the ECM memory are cancelled. Never insert a tester probe or male terminal used for inspection purposes into the female terminal of the vehicle wire harness. Otherwise, the female terminal may be widened, which can result in faulty connection. 5. 6. 7. 8. Connect the SST (check harness "A") between the ECM and connector of the vehicle wire harness. SST 0999001000 HINT: The arrangement of the check connector terminals are the same as those of the ECM. Disconnect the SST. SST 0999001000 Reconnect the connector to the ECM. (a) Match the male connector correctly with the female connector, then press them together. (b) Tighten the bolt. Make sure the connector is completely connected by tightening the bolt until there is a clearance of less than 1 mm (0.04 in.) between the bottom of the male connector and the end of the female connector. Install the ECM protector and floor carpet. EG257 ENGINE TROUBLESHOOTING STANDARD VALUE OF ECM TERMINALS STANDARD VALUE OF ECM TERMINALS EG258 ELS (A15) E1 (B69) VT01 (A40) VT02 (A39) TR (A37) E1 (B69) A/C (A34) E1 (B69) W (A6) E1 (B69) TE1 (A20) E1 (B69) TE2 (A19) E1 (B69) SP1 (A2) E1 (B69) FPU (B36) E01 (B80) NEO (A38) E1 (B69) OD1 (A12) E1 (B69) FPC (A22) E1 (B69) NSW (B76) E1 (B69) OX1 (B48), OX2 (B47) OX3 (A30) HT1 (B73), HT2 (B72) HT3 (A36) ACMG (A23) E1 (B69) KNK1 (B50), KNK2 (B49) E1 (B69) VF1 (B29), VF2 (B28) E1 (B69) ISC1 (B35), ISC2 (B34) ISC3 (B33), ISC4 (B32) EGR (B75) E01 (B80) DI (A21) E1 (B69) ACIS (B39) E01 (B80) EVAP (B74) E01 (B80) Symbols (Terminal Nos.) - E2 (B65) EO1 (B80) E1 (B69)) EO1 (B80) ENGINE TROUBLESHOOTING Pulse generation (See page EG299) 914 914 914 03.0 914 7.514 01.5 03.0 914 914 914 Pulse generation (See page EG305) 914 Pulse generation (See page EG275) STD Voltage (V) Below 1.5 Pulse generation (4.55.5) 7.0 or more 914 914 Below 2.0 1014 Pulse generation (See page EG328) 4.55.5 914 Below 2.0 7.514 01.5 Below 3.0 3.24.9 0.30.8 1.83.2 03.0 STANDARD VALUE OF ECM TERMINALS IG switch ON Other shift position in "P", "N" position IG switch ON Shift position in "P", "N" position IG switch ON Rotate driving wheel slowly IG switch ON IG switch ON Idling IG switch ON IG switch ON A/C switch ON (At idling) A/C switch OFF A/C switch ON (At idling) A/C switch OFF IG switch ON IG switch ON Main or sub throttle valve fully closed IG switch ON Main or sub throttle valve fully open IG switch ON IG switch ON Restarting at high engine coolant temp Defogger switch and taillight switch ON Defogger switch and taillight switch OFF Idling Idling Idling IG switch ON IG switch ON Idling, when A/C switch ON or OFF Idling IG switch ON IG switch ON Idling Engine speed at 3,500 rpm Condition Maintain engine speed at 2,500 rpm for 2 minutes after warming up then return to u idling Maintain engine speed at 2,500 rpm for 2 minutes after warming up ( :A = E7, B = E8) TARGET A/F R*5 TARGET A/F ENGINE SPEED A/F FB RIGHT*5 A/F FB LEFT*4 VEHICLE SPD PNP SIGNAL CTP SIGNAL STA SIGNAL A/C SIGNAL THROTTLE KNOCK FB INJECTOR IAC STEP IGNITION Ox Ox L*4 ECT Item VAF R*5 L*4 RPM stable at 2,500 rpm with normal operating temp. RPM stable at 2,500 rpm with normal operating temp. other than "P" or "N" When shifting from "P" or "N" position into a position A/C switch ON Closed throttle position During cranking Depress throttle pedal suddenly during idling RPM stable at 2,500 rpm with normal operating temp. RPM stable at 2,500 rpm with normal operating temp. Engine idling at normal operating temp. Engine idling at normal operating temp. (Comparison with speedometer) During driving Closed throttle position Wide open throttle From closed throttle position to wide open throttle Engine normal operating temp. Increase engine speed Engine idling at normal operating RPM kept stable (Comparison with tachometer) Ignition switch ON (Do not start engine) A/T shifting in "D" position A/C switch ON Engine idling at normal operating Increase engine speed Engine idling at normal operating temp.*1 Engine cold to hot ENGINE TROUBLESHOOTING *1: All accessories and A/C switched OFF *2: If the engine coolant temp. sensor circuit is open or shorted, the ECM assumes an engine coolant temp. value of 80C (176F). *3: When feedback control is forbidden, 0 V is desplayed. *4: Oxygen sensor (Front) *5: Oxygen sensor (Rear) Inspection Condition REFERENCE VALUE OF ECM DATA REFERENCE VALUE HINT: ECM data can be monitored by LEXUS handheld tester. 1. Hook up the LEXUS handheld tester to DLC2. 2. Monitor ECM data by following the prompts on the tester screen. Please refer to the LEXUS handheld tester operator's manual for further details. temp.*1 temp.*1 REFERENCE VALUE OF ECM DATA RICH LEAN is repeated RICH LEAN is repeated 2.50 1.85 V 2.50 1.85 V No large differences 7595C (185203F)*2 Gradually decreases Approx. 35 ms No great changes Approx. 125 steps Step increases Step increases 20 25 steps Gradually increases Approx. 2.0 msecs GEAR ON ON ON ON ON ON Below 5 Above 70Gradually increases Gradually increases Reference Value Gradually decreases EG259 *3 *3 EG260 ENGINE TROUBLESHOOTING MATRIX CHART OF PROBLEM SYMPTOMS MATRIX CHART OF PROBLEM SYMPTOMS When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still can not be confirmed in the basic inspection, proceed to this matrix chart and troubleshoot according to the numbered order given below. EG334 AC38 ST3, 13 IG4 IG5 IG7 EG290 EG300 EG306 EG313 EG316 EG318 EG323 EG325 EG328 EG310 IG8 EG8 AT56 BE261 IN34 EG261 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION CIRCUIT INSPECTION DTC 12 G, NE Signal Circuit (No. 1) CIRCUIT DESCRIPTION The distributor in the Engine Control System contains 3 pickup coils (G1, G2 and NE). The G1, G2 signals inform the ECM of the standard crankshaft position. The NE signal informs the ECM of the crankshaft position and the engine speed. DTC No. DTC Detection Condition No "NE" or "G1" and "G2" signal to ECM for 2 sec. or more after cranking Open in "G " circuit Trouble Area S Open or short in NE, G circuit S Distributor S Open or short in STA circuit Open S ECM 12 WIRING DIAGRAM EG262 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check air gap. P C OK Disconnect distributor connector. Measure resistance between each terminals shown in table below. "Cold" is from 10C (14F) to 50C (122F) and "Hot" is from 50C (122F) to 100C (212F) Reference INSPECTION USING OSCILLOSCOPE S During cranking or idling, check waveforms between terminals G1, G2, NE and G of engine control module. HINT: The correct waveforms are as shown. OK NG Replace distributor. 2 OK Check for open and short in harness and connector between engine control module and distributor (See page IN29). NG Repair or replace harness or connector. EG263 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 3 Check air gap. P C Remove distributor cap and rotor. Using SST (G1 and G2 pickups) and a thickness guage (NE pickup), measure the air gap between the signal rotor and pickup coil projection. Air gap: 0.2 0.5 mm (0.008 0.020 in.) OK OK NG Replace distributor. Check and replace engine control module. EG264 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 13 G, NE Signal Circuit (No. 2) CIRCUIT DESCRIPTION Refer to G, NE signal circuit (No.1) on page EG261. DTC No. 13 DTC Detection Condition No NE signal to ECM for 0.1 sec. or more at 1,000 rpm or more NE signal does not pulse 12 times to ECM during the interval between G1 and G2 pulses Trouble Area S Open or short in NE circuit S Distributor S ECM This code indicates that a intermittent problem of the G, NE signal from the distributor to the ECM has occurred, but that it has returned to normal. Note that although this problem may not necessarily appear at the time of inspection, it cannot be ignored because this diagnostic trouble code is output, indicating that there is or was a malfunction in the G, NE signal circuit; this "malfunction" is usually a loose connector. The distributor connector and the NE terminal of the ECM connector must therefore be checked for the following: 1. Loose connectors 2. Dirty connector terminals 3. Loose connector terminals EG265 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 14 Ignition Signal Circuit CIRCUIT DESCRIPTION The ECM determines the ignition timing, turns ON Tr1 at a predetermined angle (CA) before the desired ignition timing and outputs an ignition signal (IGT) "1" to the igniter. Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time the control circuit starts primary current flow to the ignition coil based on the engine speed and ignition timing one revolution ago, that is, the time the Tr2 turns ON. When it reaches the ignition timing, the ECM turns Tr1 OFF and outputs the IGT signal "O". This turns Tr2 OFF, interrupting the primary current flow and generating a high voltage in the secondary coil which causes the spark plug to spark. Also, by the counter electromotive force generated when the primary current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECM. The ECM stops fuel injection as a fail safe function when the IGF signal is not input to the ECM. DTC No. 14 DTC Detection Condition No IGF signal ECM for 6 consecutive IGT signals Trouble Area S Open or short in IGF or IGT circuit from igniter to ECM S Igniter S ECM WIRING DIAGRAM EG266 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 C OK Check for spark. Disconnect the hightension cord from the distributor, hold its end about 12.5 mm (1/2") from the ground, see if spark occurs while the engine is being cranked. Spark should be generated. Notice: To preven texcess fuel being injected from the injectors during this check, don't crank the engine for more than 12 seconds at a time. OK NG Go to Step 4. 2 OK Check for open and short in harness and connector in IGF signal circuit between engine control module and igniter (See page IN29). NG Repair or replace harness or connector. 3 Disconnect igniter connector and check voltage between terminal IGF of engine control module connector and body ground. P (1) Disconnect igniter connector. (2) Connect SST (check harness "A"). (See page EG256) SST 0999001000 (3) Turn ignition switch ON. C OK Measure voltage between terminal IGF of engine control module connector and body ground. Voltage: 4.5 5.5 V NG OK Replace igniter. Check and replace engine control module. EG267 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 4 Check voltage between terminal IGT of engine control module connector and body ground. P Connect SST (check harness "A"). (See page EG256) SST 0999001000 Measure voltage between terminal IGT of engine control module connector and body ground when engine is cranked. Voltage: 0.5 1.0 V (Neither 0 V nor 5 V) C OK Reference INSPECTION USING OSCILLOSCOPE S During cranking or idling, check waveform between terminals IGT and E1 of engine control module. HINT: The correct waveforms are as shown. OK NG Go to step 8. 5 Check voltage between terminal 3 of igniter connector and body ground. P C Disconnect igniter connector. Measure voltage between terminal 3 of igniter connector and body ground, when ignition switch is turned to "ON" and "START" position. Voltage: 9 14 V OK OK NG Check and repair igniter power source circuit. EG268 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 6 OK Check for open and short in harness and connector between ignition switch and ignition coil, ignition coil and igniter (See page IN29). NG Check ignition coils. Repair or replace harness or connector. 7 P C Disconnect ignition coil connector. (1) Check primary coil. Measure resistance between terminals of ignition coil connector. Check secondary coil. Measure resistance between terminal of ignition coil connector and hightension terminal. (2) OK "Cold" is from 10C (14F) to 50C (122F) and "Hot" is from 50C (122F) to 100C (212F) OK Replace igniter. NG Replace ignition coil. EG269 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 8 Disconnect igniter connector and check voltage between terminal IGT of engine control module connector and body ground. P Disconnect igniter connector. C Measure voltage between terminal IGT of engine control module connector and body ground when engine is cranked. Voltage: 0.5 1.0 V (Neither 0 V nor 5 V) OK Reference INSPECTION USING OSCILLOSCOPE S During cranking or idling, check waveform between terminals IGT and E1 of engine control module. HINT: The correct waveforms are as shown. NG OK Replace igniter. 9 OK Check for open and short in harness and connector between ignition switch and ignition coil, ignition coil and igniter (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG270 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 16 A/T Control Signal Malfunction CIRCUIT DESCRIPTION The signal from the A/T CPU retards the ignition timing of the engine during A/T gear shifting, thus momentarily reducing torque output of the engine for smooth clutch operation inside the transmission and reduced shift shock. DTC No. 16 DTC Detection Condition Fault in communications between the engine CPU and A/T CPU in the ECM Trouble Area S ECM If the ECM detects the diagnostic trouble code "16" in memory, it prohibits the torque control of the A/T which performs smooth gear shifting. INSPECTION PROCEDURE 1 NO Are there any codes (besides Code 16) being output? YES Go to relevant diagnostic trouble code chart. Replace engine control module. EG271 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 21, 28 Main Heated Oxygen Sensor Circuit CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three way catalytic converter is used, but for the most efficient use of the three way catalytic converter, the airfuel ration must be precisely controlled so that it is always close to the stoichometric airfuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichometric airfuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the airfuel ratio. When the airfuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: 0 V). When the airfuel ratio is richer than the stoichiometric airfuel ratio the oxygen concentration in the exhaust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1 V). The ECM judges by the electromotive force from the oxygen sensor whether the airfuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes an output of abnormal electromotive force, the ECM is unable to perform accurate airfuel ratio control. (The main heated oxygen sensors include a heater which heats the Zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection.) DTC No. DTC Detection Condition (1) Open or short in heater circuit of main oxygen sensor for 0.5 sec. or more (2) Main heated oxygen sensor signal voltage is reduced to between 0.35 V and 0.70 V for 60 sec. under conditions (a) (d). (2 trip detection logic)*1: (a) Engine coolant temp.: Between 80C (176F) and 95C (203F) (b) Engine speed: 1,500 rpm or more (c) Load driving (Example A/T in 4th speed, A/C ON, Flat road, 80 km/h (50 mph)) (d) Main heated oxygen sensor signal voltage: Alternating above and below 0.45 V Trouble Area S Open or short in heater circuit of main heated oxygen sensor S Main heated oxygen sensor heater S ECM 21 S 28 S Main heated oxygen sensor circuit S Main heated oxygen sensor HINT: Diagnostic trouble code "21" is for the main heated oxygen sensor (Fr) circuit. Diagnostic trouble code "28" is for the main heated oxygen sensor (Rr) circuit. *1: See page EG253 EG272 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont'd) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Main Heated Oxygen Sensor Deterioration It is vital that this test routine is adhered to detect the malfunction: Disconnect the EFI fuse (20 A) for 10 sec. or more, with IG switched OFF. Initiate test mode (Connect terminal TE2 and E1 of data link connector 1 or 2 with IG switched OFF). Start the engine and warm it up with all accessories switches OFF. Idle the engine idle for 3 min. Accelerate gradually with in the range 1,300 1,700 rpm (centered around 1,500 rpm) with the A/C switch ON and D position for A/T. HINT: S Ensure engine rpm does not fall below 1,200 rpm. S Gradually depress the accelerator pedal at a suitable rate to comply with the test requirements on the above graph. S Never allow engine rpm to drop at any time during the test. Maintain the vehicle speed at 6480 km/h (40 50 mph). Keep the vehicle running for 1 2 min. after starting acceleration. HINT: If a malfunction exists, the malfunction indicator lamp will light up during step . NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. EG273 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION WIRING DIAGRAM EG274 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE (Only for California specification vehicles) HINT: If diagnostic trouble code "21" is output, check the main heated oxygen sensor (Fr) circuit. If diagnostic trouble code "28" is output, check the main heated oxygen sensor (Rr) circuit. 1 Check voltage between terminals HT1, HT2 of engine control module connector and body ground. P Connect SST (check harness "A") (See page EG256) SST 0999001000 C OK Measure voltage between terminals HT1, HT2 of engine control module connector and body ground. Voltage: 9 14 V NG OK Go to step 3. 2 Check main heated oxygen sensor heater. P C OK Disconnect main heated oxygen sensor connector. Measure resistance between terminals 1 and 2 of main heated oxygen sensor connector. Resistance: At 20C (68F): 11.7 14.3 W OK NG Replace main heated oxygen sensor. Check and repair harness or connector between main relay and main heated oxygen sensor, main heated oxygen sensor and engine control module. EG275 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 3 Check voltage between terminals HT1, HT2 of engine control module connector and body ground. P Warm up engine to normal operating temperature. C Measure voltage between terminals HT1, HT2 of engine control module connector and body ground, when engine is idling and racing at 4,000 rpm. OK Hint In the 4,000 rpm racing check, continue engine racing at 4,000 rpm for approx. 20 seconds or more. NG OK Replace main heated oxygen sensor.* *: It is probable the oxygen sensor has deteriorated. Usually, this can't be confirmed by visual inspection. Check and replace engine control module. Reference INSPECTION USING OSCILLOSCOPE S With the engine racing (4,000 rpm) measure waveforms between terminals OX1, OX2 and E1 of engine control module. HINT: The correct waveform is as shown, oscillating between approx. 0.1 V and 0.9 V S If the oxygen sensor has deteriorated, the amplitude of the voltage will be reduced as shown. EG276 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 22 Engine Coolant Temp. Sensor Circuit CIRCUIT DESCRIPTION The engine coolant temperature sensor senses the coolant temperature. A thermistor built in the sensor changes its resistance value according to the coolant temperature. The lower the coolant temperature, the greater the thermistor resistance value, and the higher the coolant temperature, the lower the thermistor resistance value (See Fig 1.) The engine coolant temperature sensor is connected to the ECM (See wiring diagram). The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THW via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant sensor changes in accordance with changes in the coolant temperature, the potential at terminal THW also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the diagnostic trouble code 22, it operates the fail safe function in which the engine coolant temperature is assumed to be 80C (176F). DTC No. 22 DTC Detection Condition Open or short in engine coolant temp. sensor circuit for 0.5 sec. or more. Trouble Area S Open or short in engine coolant temp. sensor circuit S Engine coolant temp. sensor S ECM WIRING DIAGRAM EG277 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: If diagnostic trouble codes "22" (engine coolant temperature sensor circuit), "24" (intake air temperature sensor circuit) and "41" (throttle position sensor circuit) are output simultaneously, E2 (sensor ground) may be open. 1 Check voltage between terminals THW and E2 of engine control module connector. P (1) Connect SST (check harness "A"). (See page EG256) SST 0999001000 (2) Turn ignition switch ON. Measure voltage between terminals THW and E2HT1, HT2 of engine control module connector. C OK NG OK Check for intermittent problems (See page EG251). 2 Check engine coolant temp. sensor. P C OK Disconnect the engine coolant temp. sensor connector. Measure resistance between terminals. Resistance is within acceptable zone on chart. OK NG Replace engine coolant temp. sensor. 3 OK Check for open and short in harness and connector between engine control module and engine coolant temp. sensor (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG278 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 24 Intake Air Temp. Sensor Circuit CIRCUIT DESCRIPTION The intake air temp. sensor is built into the volume air flow meter and senses the intake air temperature. The structure of the sensor and connection to the ECM is the same as in the engine coolant temp. sensor shown on page EG276. If the ECM detects the diagnostic trouble code "24", it operates the fail safe function in which the intake air temperature is assumed to be 20C (68F). DTC No. 24 DTC Detection Condition Open or short in intake air temp. sensor circuit for 0.5 sec. or more Trouble Area S Open or short in intake air temp. sensor circuit S Intake air temp. sensor S ECM WIRING DIAGRAM INSPECTION PROCEDURE HINT: If diagnostic trouble codes "22" (engine coolant temperature sensor circuit), "24" (intake air temperature sensor circuit) and "41" (throttle position sensor circuit) are output simultaneously, E2 (sensor ground) may be open. 1 Check voltage between terminals THA and E2 of engine control module connector. P (1) Connect SST (check harness "A"). (See page EG256) SST 0999001000 (2) Turn ignition switch ON. Measure voltage between terminals THA and E2HT1, HT2 of engine control module connector. C OK NG OK Check for intermittent problems (See page EG251). EG279 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 2 Check intake air temp. sensor. P C OK Disconnect the volume air flow meter connector. Measure resistance between terminals 1 and 2 of volume air flow meter connector. Resistance is with acceptable zone on graph. OK NG Replace intake air temp. sensor (Replace volume air flow meter). 3 OK Check for open and short in harness and connector between engine control module and engine coolant temp. sensor (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG280 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 25 26 AirFuel Ratio Lean Malfunction AirFuel Ratio Rich Malfunction Trouble Area Open or short in main heated oxygen sensor circuit Main heated oxygen sensor Ignition system ECM Open and short in injector circuit. Fuel line pressure (injector leak, blockage) Mechanical system malfunction (skipping teeth of timing belt) Ignition system Compression pressure (foreign object caught in valve) Volume air flow meter (air intake) ECM Open and short in injector circuit. Fuel line pressure (injector leak, blockage) Mechanical system malfunction (skipping teeth of timing belt) Ignition system Compression pressure (foreign object caught in valve) Volume air flow meter (air intake) ECM Open and short in injector circuit Fuel line pressure (injector leak, blockage) Mechanical system malfunction (skipping teeth of timing belt) Ignition system Compression pressure (foreign object caught in valve) Volume air flow meter (air intake) ECM Open and short in injector circuit Fuel line pressure (injector leak, blockage) Mechanical system malfunction (skipping teeth of timing belt) Ignition system Compression pressure (foreign object caught in valve) Volume air flow meter (air intake) ECM CIRCUIT DESCRIPTION See page EG271 for the circuit description. DTC No. DTC Detection Condition (1) Main heated oxygen sensor voltage is 0.45 V or less (lean) for 90 sec. under conditions (a) and (b): (2) trip detection logic)*1 (a) Engine coolant temp.: 70C (158F) or more (b) Engine speed: 1,500 rpm or more (2) Difference of airfuel ratio feedback compensation value between fron (No.13 cylinders) and rear (No.46 cylinders) is more than 15 percentage for 20 sec. or more under conditions (a) and (b): (2 trip detection logic)*1 (a) Engine speed: 2,000 rpm or more (b) Engine coolant temp.: Between 60C (140F) and 95C (203F) (3) Engine speed varies by more than 15 rpm over the preceding crank angle period during a period of 20 sec. or more under conditions (a) and (b): (2) trip detection logic) *1 (a) Engine speed: Idling (b) Engine coolant temp.: Between 60C (140F) and 95C (203F) (1) Difference of airfuel ratio feedback compensation value between front (No.13 cylinders) and rear (No.46 cylinders) is more than 15 percent for 20 sec. or more under conditions (a) and (b): (2 trip detection logic)*1 (a) Engine speed: 2,000 rpm or more (b) Engine coolant temp.: Between 60C (140F) and 95C (203F) (2) Engine speed varies by more than 15 rpm over the preceding crank angle period during a period of 20 sec. or more under conditions (a) and (b): (2 trip detection logic)*1 (a) Engine speed: Idling (b) Engine coolant temp.: Between 60C (140F) and 95C (203F) 25 26 *1: See page EG248. EG281 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont'd) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Open or Short in Main Heated Oxygen Sensor Hint: Before this test, check the feedback voltage for oxygen sensor. Disconnect the EFI fuse (20 A) for 10 sec. or more, with IG switched OFF. Initiate test mode (Connect terminal TE2 and E1 of data link connector 1 or 2 with IG switched OFF). Start engine and warm up. Idle the engine for 3 min. Quickly race the engine to 4,000 rpm 3 times by accelerator pedal. Race the engine at 2,000 rpm for 90 sec. HINT: If a malfunction exists, the malfunction indicator lamp will light up during step . NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. EG282 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont'd) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Open or Short in Injector Circuit, Injector Leak or Blockage Disconnect the EFI fuse (20 A) for 10 sec. or more, with IG switched OFF. Initiate test mode (Connect terminal TE2 and E1 of data link connector 1 or 2 with IG switched OFF). Start the engine and warm it up with all accessories switched OFF. Let the engine idle for 5 min. (After engine is started, do not depress the accelerator pedal.) If the malfunction is not detected during idling, race the engine without any load at approx. 2,000 rpm for 60 sec. of starting racing. HINT: If a malfunction exists, the malfunction indicator lamp will light up during the 5 min. idling period or within 60 sec. of starting racing. NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. WIRING DIAGRAM See Page EG273 for the WIRING DIAGRAM. EG283 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check voltage between terminals VF1, VF2 and E1 of data link connector 1. P (1) (2) Warm up the engine to normal operating temperature. Using SST, connect terminals TE1 and E1 of data link connector 1. SST 0984318020 Connect positive probe to terminals VF1, VF2 and negative probe to terminal E1 of data link connector 1. (3) C (1) Warm up the oxygen sensor by racing engine at 2,500 rpm for about 2 minutes. (2) Then, still maintaining engine at 2,500 rpm, count how many times voltmeter fluctuates needle between 0 and 5 V. Result: NG Type I NG TYPE II Go to step 7. 2 Check voltage between terminals OX1, OX2 and E1 of data link connector 1. P C Warm up engine to normal operating temperature. Measure voltage between terminals OX1, OX2 and E1 of data link connector 1 when engine is suddenly raced to full throttle. The voltage should be 0.5 V or higher at least once. OK Hint Inspection should not take longer than 1 second. NG OK Go to step 7. EG284 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 3 OK Check for open and short in harness and connector between engine control module and main heated oxygen sensor, engine control module and data link connector 1 (See page IN29). NG Repair or replace harness or connector. 4 Check each item found to be a possible cause of problem. Check each circuit found to be a possible cause of trouble according to the results of the check in or . The numbers in the table below show the order in which the checks should be done. EG325 IG4 EG26 EG123 EG310 EG290 EG276 EG278 OK NG Check compression (See page EG8). Repair or replace. 5 OK NG Repair or replace. 6 NG Does malfunction disappear when a good main heated oxygen sensor is installed? Replace main heated oxygen sensor. YES Check and replace engine control module. EG285 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 7 Check each item found to be a possible cause of problem. Check each circuit found to be a possible cause of trouble according to the results of the check in . The numbers in the table below show the order in which the checks should be done. EG325 IG4 EG26 EG123 EG310 EG290 EG276 EG278 OK NG Check compression (See page EG8). Repair or replace. 8 OK NG Repair or replace. 9 NG Does malfunction disappear when a good main heated oxygen sensor is installed? YES Replace main heated oxygen sensor. Check and replace engine control module. EG286 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 27 Sub Heated Oxygen Sensor Circuit CIRCUIT DESCRIPTION The sub heated oxygen sensor is installed on the exhaust pipe. Its construction and operation is the same as the main heated oxygen sensor on page EG271. DTC No. DTC Detection Condition (1) Open or short in heater circuit of sub heated oxygen sensor for 0.5 sec. or more (2) Main heated oxygen sensor signal is 0.45 V or more and sub heated oxygen sensor signal is 0.45 V or less under conditions (a) (c): (2 trip detection logic)* (a) Engine coolant temp.: (b) Engine speed: (c) Accel. pedal: 80C (176F) or more S Open or short in sub heated oxygen sensor circuit S Sub heated oxygen sensor S ECM Trouble Area S Open or short in heater circuit of sub heated oxygen sensor S Sub heated oxygen sensor heater S ECM 27 1,500 rpm or more Fully depressed for 2 sec. or more *: See page EG248. EG287 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont'd) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Open or Short in Injector Circuit, Injector Leak or Blockage Disconnect the EFI fuse (20 A) for 10 sec. or more, with IG switched OFF. Initiate test mode (Connect terminal TE2 and E1 of data link connector 1 or 2 with IG switched OFF). Start the engine and warm it up with all accessories switched OFF. Drive vehicle at 80 88 km/h (50 55 mph) for 10 min. or more. Stop the vehicle at a safe place and idle the engine for 2 min. or less. Accelerate to 96 km/h (60 mph) with the throttle valve fully open. HINT: If a malfunction exists, the Malfunction Indicator Lamp will light up during step . NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. EG288 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION WIRING DIAGRAM INSPECTION PROCEDURE HINT: When other codes are output in addition to 27 at the same time, check the circuits for other codes first. 1 Check voltage between terminal HT3 of engine control module connector and body ground. P Connect the SST (check harness "A"). (See page EG256) SST 0999001000 (2) Turn ignition switch ON. Measure voltage between terminal HT3 of the engine control module connector and body ground. Voltage: 9 14 V (1) C OK NG OK Go to step 4. EG289 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 2 Check sub heated oxygen sensor heater. P Disconnect sub heated oxygen sensor connector. (See page EG183) Measure resistance between terminals 1 and 2 of sub heated oxygen sensor connector. Resistance: At 20C (68F): 11.7 14.3 W C OK OK NG Replace sub heated oxygen sensor. 3 OK Check for open and short in harness and connector between EFI main relay and engine control module (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. 4 Check voltage between terminal HT3 of engine control module connector and body ground. P C Warm up the engine to normal operating temperature. Measure voltage between terminal HT3 of the engine control module connector and body ground, when engine is idling and racing at 3,500 rpm.. OK NG OK Replace sub heated oxygen sensor.* *: It is probable the oxygen sensor has deteriorated. Usually, this cannot be confirmed by visual inspection. Check and replace engine control module. EG290 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 31 Volume Air Flow Meter Circuit CIRCUIT DESCRIPTION As shown in the figure at right, when a pillar (Vortex generating body) is placed in the path of a uniform flow, vortices called KarmanVortex are generated downstream of the object. Using this principle, a vortex generator is placed inside the volume air flow meter. By measuring the frequencies of the vortices generated, the ECM can determine the volume of air flowing through the volume air flow meter. The vortices are detected by their exerting pressure on thin metal foil (mirror) surfaces and a light emitting element and light receptor (LED and photo transistor) positioned opposite the mirror which optically senses the vibrations in the mirror. The ECM uses these signals mainly for calculation of the basic injection volume and the basic ignition advance angle. DTC No. DTC Detection Condition All conditions below are detected. (a) No volume air flow meter signal to ECM for 2 sec. when engine speed is above 300rpm (b) Engine stall Trouble Area S Open or short in volume air flow meter circuit S Volume air flow meter S ECM 31 If the ECM detects diagnostic trouble code "31", it operates the fail safe function, keeping the ignition timing and fuel injection volume constant and making it possible to drive the vehicle. WIRING DIAGRAM EG291 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check voltage between terminals KS and E1 of engine control module connector. P Connect SST (check harness "A") (See page EG256) SST 0999001000 Measure voltage between terminals KS and E1 of engine control module connector while engine is cranked. Voltage: 2.0 4.0 V (Neither 0 V nor 5 V) C OK Reference INSPECTION USING OSCILLOSCOPE S During cranking or idling, measure waveform between terminals KS and E1 of engine control module. HINT: The correct rectangular waveform is as shown. NG OK When diagnostic trouble code 31 is displayed, check and replace engine control module. 2 OK Check for open and short in harness and connector between engine control module and volume air flow meter (See page IN29). NG Repair or replace harness or connector. EG292 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 3 Disconnect volume air flow meter connector and check voltage between terminals KS and E1 of engine control module connector. P (1) Disconnect the volume air flow meter connector. (2) Turn ignition switch ON. C OK Measure voltage between terminals KS and E1 of engine control module connector. Voltage: 4.5 5.5 V OK NG Check and replace engine control module. 4 Disconnect volume air flow meter connector and check voltage between terminals VCC and E1 of engine control module connector. P (1) Disconnect the volume air flow meter connector. (2) Turn ignition switch ON. C OK Measure resistance between terminals VCC and E1 of engine control module connector. Voltage: 4.5 5.5 V NG OK Replace volume air flow meter. Check and replace engine control module. EG293 ENGINE TRUBLESHOOTING CIRCUIT INSPECTION DTC 35 Barometric Pressure Sensor Circuit CIRCUIT DESCRIPTION The BARO sensor is built into the ECM. This is a semiconductor pressure sensor with properties which cause its electrical resistance to change when stress is applied to the sensor's crystal (silicon) (piezoelectric effect). This sensor is used to detect the atmospheric (absolute) pressure and outputs corresponding electrical signals. Fluctuations in the air pressure cause changes in the intake air density, which can cause deviations in the airfuel ratio. The signals from BARO sensor are used to make corrections for these fluctuations. If the ECM records diagnostic trouble code "35", the fail safe function operates and the atmospheric pressure is set at a constant 101.3 kPa (760 mmHg, 29.92 in.Hg). DTC No. 35 DTC Detection Condition Open or short in BARO sensor circuit for 0.5 sec. or more. Trouble Area S ECM INSPECTION PROCEDURE 1 NO Are there any other codes (besides Code 35) being output? Go to relevant diagnostic trouble code chart. YES Replace engine control module. EG294 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 41, 47 Throttle Position Sensor(s) Circuit CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening position. When the throttle valve is fully closed, the IDL contacts in the throttle position sensor are on, so the voltage at the terminal IDL of the ECM becomes 0 V. At this time, a voltage of approximately 0.7 V is applied to the terminal VTA of the ECM. When the throttle valve is opened, the IDL contacts go off and thus the power source voltage of approximately 12 V in the ECM is applied to the terminal IDL of the ECM. The voltage applied to the terminal VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from the terminals VTA and IDL, and uses them as one of the conditions for deciding the airfuel ratio correction, power increase correction and fuelcut control etc. The sub throttle position sensor is built and operates in the same way as the main throttle position sensor. This sensor is used for traction control. The subthrottle valve is opened and closed by the subthrottle actuator according to signals from the TRAC ECU to control the engine output. DTC No. DTC Detection Condition (1) Open or short in throttle position sensor circuit (VTA1) for 0.5 sec. or more (2) IDL1 contact is ON and VTA1 output exceeds 1.5 V for 0.5 sec. or more (1) Open or short in subthrottle position sensor circuit (VTA2) for 0.5 sec. or more (2) IDL2 contact is ON and VTA2 output exceeds 1.5 V for 0.5 sec. or more Trouble Area S Open or short in throttle position sensor circuit S Throttle position sensor S ECM S Open or short in subthrottle position sensor circuit S Subthrottle position sensor S ECM 41 47 HINT: Diagnostic trouble code 41 is for the throttle position sensor circuit. Diagnostic trouble code 47 is for the subthrottle position sensor circuit. S When the connector for the throttle position sensor(s) is disconnected, diagnostic trouble code 41 or 47 is not displayed. Diagnostic trouble code 41 or 47 is displayed only when there is an open or short in the VTA signal circuit of the throttle position sensor(s). S Signals from the throttle position sensor(s) are also input to the TRAC ECU. So when a malfunction occurs on the TRAC side, code 41 or 47 may be displayed. EG295 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION WIRING DIAGRAM EG296 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: S If diagnostic trouble code 41 is displayed, check throttle position sensor circuit. If diagnostic trouble code 47 is displayed, check subthrottle position sensor circuit. S If diagnostic trouble codes "22" (engine coolant temperature sensor circuit), "24" (intake air temperature sensor circuit) and "41" (throttle position sensor circuit) are output simultaneously, E2 (sensor ground) may be open. 1 Check voltage between terminals VTA1, 2, IDL1, 2 and E2 of engine control module connector. P Connect SST (check harness "A") (See page EG256) SST 0999001000 (2) Turn ignition switch ON. (3) For subthrottle position sensor, remove intake air duct and disconnect subthrottle valve step motor connector. Measure voltage between terminals VTA1, 2, IDL1, 2 and E2 of engine control module connector when the (sub) throttle valve is opened gradually from the closed position. (1) C OK Hint The voltage should increase steadily in proportion to the throttle valve opening angle. NG OK Check for intermittent problems (See page EG251). EG297 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 2 Check throttle position sensor(s). P (1) (2) Remove intake air duct. Disconnect throttle position sensor(s) connector. C Measure resistance between terminals 3, 2 and 1 of throttle position sensor(s) connector when the throttle valve is opened gradually from the closed condition. OK Hint Resistance between terminals 3 and 1 should increase gradually in accordance with the throttle valve opening angle. OK NG Adjust or replace throttle position sensor(s) (See page EG157). 3 OK Check for open and short in harness and connector between engine control module and throttle position sensor(s) (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG298 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 42 No. 1 Vehicle Speed Sensor Signal Circuit CIRCUIT DESCRIPTION The No. 1 vehicle speed sensor outputs a 4 pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping, circuit inside the combination meter, it is then transmitted to the engine control module. The ECM determines the vehicle speed based on the frequency of these pulse signals. DTC No. DTC Detection Condition All conditions below are detected continuously for 8 sec. or more: (c) No. 1 vehicle speed signal: 0 km/h Trouble Area S No. 1 vehicle speed sensor S Combination meter S Open or short in No. 1 vehicle speed sensor circuit S ECM 42 (0 mph) (d) Engine speed: 2,800 rmp or more (e) Park/neutral position switch: OFF (f) Stop light switch: OFF WIRING DIAGRAM EG299 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 C Check operation of speedometer. Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. Hint The No.1 vehicle speed sensor is operating normally if the speedometer display is normal. OK NG Check speedometer circuit. See combination meter troubleshooting on page BE75. 2 Check voltage between terminal SP1 of engine control module connector and body ground. P (1) (2) (3) (4) (5) C Shift the shift lever to N position. Jack up one of the rear wheels. Connect SST (check harness "A"). (See page EG256) Disconnect power steering ECU connector and cruise control ECU connector. Turn ignition switch ON. Measure voltage between terminal SP1 of engine control module connector and body ground when the wheel is turning slowly. Voltage is generated intermittently. OK OK NG Check speedometer circuit. See combination meter troubleshooting on page BE75. Check and replace engine control module. EG300 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 43 Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is being cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and afterstart injection control. DTC No. 43 DTC Detection Condition No starter signal to ECM Trouble Area S Open or short in starter signal circuit S Open or short in ignition switch or starter relay circuit S ECM WIRING DIAGRAM EG301 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is being cranked under normal conditions. If the engine does not crank, proceed to the matrix chart of problem symptoms on page EG260. 1 Check output condition of diagnostic trouble code 43. P Setting the test mode. (1) Turn ignition switch OFF. (2) Using SST, connect terminals TE2 and E1 of DLC1 or 2. SST 0984318020 (3) Turn ignition switch ON. (Don't start engine) (4) Using SST, connect terminals TE1 and E1 of DLC1 or 2. SST 0984318020 Check if code "43" is output by the malfunction indicator lamp. Code "43" is output. Start the engine. Check if the code "43" disappear. Code "43" is not output. C OK C OK NG OK Proceed to next circuit inspection shown on matrix chart (See page EG260). 2 OK Check for open in harness and connector between engine control module and starter relay (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG302 ENGINE TRUBLESHOOTING CIRCUIT INSPECTION DTC 52, 53, Knock Sensor Circuit 55 CIRCUIT DESCRIPTION Knock sensors are fitted one each to the front and rear of the left side of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. 52 DTC Detection Condition No No. 1 knock sensor signal to ECM for 4 crankshaft revolutions with engine speed between 1,600 rpm and 5,200 rpm Engine control computer (for knock control) malfunction at engine speed between 650 rpm and 5,200 rpm No No.2 knock sensor signal to ECM for 4 crankshaft revolutions with engine speed between 1,600 rpm and 5,200 rpm Trouble Area S Open or short in No. 1 knock sensor circuit S No.1 knock sensor (looseness) S ECM S ECM S Open or short in No.2 knock sensor circuit S No.2 knock sensor (looseness) S ECM 53 55 If the ECM detects the above diagnosis conditions, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. EG303 ENGINE TRUBLESHOOTING CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont'd) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Open or Short in Knock Sensor Start the engine and warm it up. Let the engine idle for 3 min. With the A/C ON, quickly race the engine to 5,000 rpm 3 times. (Repidly depress the accelerator pedal and suddenly release it.) HINT: If a malfunction exists, the malfunction indicator lamp will light up when the engine quickly raced. NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. EG304 ENGINE TRUBLESHOOTING CIRCUIT INSPECTION WIRING DIAGRAM INSPECTION PROCEDURE HINT: If diagnostic trouble code 52 is displayed, check No. 1 knock sensor (for front side) circuit. If diagnostic trouble code 53 is displayed, replace engine control module. If diagnostic trouble code 55 is displayed, check No.2 knock sensor (for rear side) circuit. 1 Check continuity between terminals KNK, KNK2 of engine control module connector and body ground. P (1) Connect the SST (check harness "A"). (See page EG256) SST 0999001000 (2) Disconnect the engine control module connectors. C OK Measure resistance between terminals KNK1, KNK2 of engine control module connector and body ground. Resistance: 1 MW or higher NG OK Go to step 3. EG305 ENGINE TRUBLESHOOTING CIRCUIT INSPECTION 2 Check knock sensor. P C OK Disconnect knock sensor connector. Measure resistance between the knock sensor terminal and body. Resistance: 1 MW or higher OK NG Replace knock sensor (See page EG177) 3 OK Check for open and short in harness and connector between engine control module and knock sensor (See page IN29). NG Repair or replace harness or connector. 4 NO Does malfunction disappear when a good knock sensor is installed? Replace knock sensor (See page EG177). YES Check and replace engine control module. Reference INSPECTION USING OSCILLOSCOPE S With the engine racing (4,000 rpm) measure waveform between terminals KNK1, KNK2 of engine control module and body ground. HINT: The correct waveform is as shown. S Spread the time on the horizontal axis, and confirm that the period of the wave is 123 sec. (Normal mode vibration frequency of knock sensor: 8.1 KHz). HINT: If normal mode vibration frequency is not 8.1 KHz, the sensor is malfunctioning EG306 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 71 EGR System Malfunction CIRCUIT DESCRIPTION The EGR system is designed to recirculate the exhaust gas properly controlled according to the driving condition back into the intake airfuel mixture. It helps to slow down combustion in the cylinder and thus lower the combustion temperature which, in turn, reduces the amount of NOx emission. The amount of EGR is regulated by the EGR vacuum modulator according to the engine load. If even one of the following conditions is fulfilled, the VSV is turned ON by a signal from the ECM. This results in atmospheric air acting on the EGR valve, closing the EGR valve and shutting off the exhaust gas (EGR cutOFF). S Engine coolant temp. below 50C (122F) S During deceleration (throttle valve closed) S Light engine load (amount of intake air very small). S Engine speed over 5,200 rpm. S Traction control is operating. DTC No. DTC Detection Condition EGR gas temp. is 70C (158F) or below for 14 min. under conditions (a) and (b): (2 trip detection logic)* (a) Engine coolant temp.: 63C (145F) (b) EGR operation possible (Example A/T in 3rd speed, A/C ON, 96 km/h (60 mph), flat road) Trouble Area S Open in EGR gas temp. sensor circuit S Short in VSV circuit for EGR S EGR hose disconnected, valve stuck S Clogged EGR gas passage S ECM 71 *: See page EG248. DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. EG307 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont'd) Malfunction: Open in EGR gas temp. sensor circuit Disconnect the EFI fuse (20 A) for 10 sec. or more, with IG switched OFF. Initiate test mode (Connect terminal TE2 and E1 of data link connector 1 or 2 with IG switched OFF). Start the engine and warm it up. Let the engine idle for 3 min. With the A/C ON and transmission in 3rd speed drive at 88 96 km/h (55 60 mph) for 4 min. or less. HINT: If a malfunction exists, the malfunction indicator lamp will light up during step . NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. WIRING DIAGRAM EG308 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check voltage between terminal EGR of engine control module connector and body ground. P (1) Connect SST (check harness "A"). (See page EG256) SST 0999001000 (2) Warm up engine to normal operating temperature. Measure voltage between terminal EGR of engine control module connector and body ground. Voltage: 9 14 V C OK NG OK Go to step 4. 2 Check resistance between terminals of VSV for EGR. P C OK Remove VSV for EGR. (See page EG174) Measure resistance between terminals of VSV for EGR. Resistance: At 20C (68F): 38.5 44.5 W OK NG Replace VSV for EGR. 3 OK Check for open and short in harness and connector between EFI main relay and VSV for EGR, VSV for EGR and engine control module. (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG309 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 4 OK Check EGR system (See page EG113). Repair EGR system. NG 5 Check resistance of EGR gas temp. sensor. P C OK Remove EGR gas temp. sensor. Measure resistance between terminals of EGR gas temp. sensor connector. Resistance: At 50C (122F): 69 89 kW At 100C (212F): 12 15 kW At 150C (302F): 2 4 kW OK NG Replace EGR gas temp sensor. 6 OK Check for open in harness and connector between EGR gas temp. sensor and engine control module. (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG310 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 78 Fuel Pump Control Circuit CIRCUIT DESCRIPTION The fuel pump speed is controlled at 2 steps (high speed, low speed) by the condition of the engine (starting, light load, heavy load), when the engine starts (STA ON), the engine control module sends a Hi signal (battery positive voltage) to the fuel pump ECU (FPU terminal). The fuel pump ECU then outputs Hi voltage (battery voltage) to the fuel pump so that the fuel pump operates at high speed. After the engine starts, during idling or light loads, the engine control module outputs a Low signal (about 9 V) to the fuel pump ECU, the fuel pump ECU outputs Low voltage (about 9 V) to the fuel pump and causes the fuel pump to operate at low speed. If the intake air volume increases (high engine load), the engine control module sends a Hi signal to the fuel pump ECU and causes the fuel pump to operate at high speed. DTC No. (1) DTC Detection Condition Open or short in fuel pump circuit for 1 sec. or more with engine speed 1,000 rpm or less (2 trip detection logic)* Open in input circuit of fuel pump ECU (FPC) with engine speed 1,000 rpm or less (2 trip detection logic)* Open or short in diagnostic signal line (DI) of fuel pump ECU with engine speed 1,000 rpm or less (2 trip detection logic)* Trouble Area S Open or short in fuel pump ECU circuit S Fuel pump ECU S Engine control module power source circuit S Fuel pump S Engine control module (2) 78 (3) *: See page EG248. WIRING DIAGRAM EG311 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 1 Check fuel pump operation. P (1) (2) Turn ignition switch ON. Using SST, connect terminals +B and FP of data link connector 1. SST 0984318020 C OK Check that there is pressure in the hose from the fuel filter. Fuel pressure can be felt. OK NG Go to step 3. 2 NG Check for open and short in harness and connector between terminals +B and +B, FP and FP of the data link connector 1 and fuel pump ECU (See page IN29). OK Go to step 5. Repair or replace harness or connector. 3 Check voltage of terminal +B of data link connector 1. P C OK Turn ignition switch ON. Measure voltage between terminals +B of data link connector 1 and body ground. Voltage: 9 14 V OK NG Check for ECM power source circuit (See page EG318), and check for open in harness and connector between terminal +B of data link connector and main relay. EG312 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 4 NG Check for open and short in harness and connector between terminal FP of data link connector 1, fuel pump and body ground (See page IN29). OK Repair or replace fuel pump. Repair or replace harness or connector. 5 Check voltage between terminals 3 (FPC) and 1 (E) of fuel pump ECU connector. P (1) (2) C Remove the LH quarter trim panel. (See page EG184) Disconnect fuel pump ECU connector. Measure voltage between terminals 3 (FPC) and 1 (E) of fuel pump ECU connector when ignition switch is turned to start. Voltage: 4.5 5.5 V OK NG OK Replace fuel pump ECU. 6 OK Check for open and short in harness and connector between terminal FPC of engine control module and terminal 3 (FPC) of fuel pump ECU, terminal 1 (E) of fuel pump ECU and body ground (See page IN29). NG Repair or replace harness or connector. 7 OK Check for open and short in harness and connector between terminal DI of engine control module and terminal 2 (DI) of fuel pump ECU (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG313 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION DTC 51 Switch Condition Signal Circuit CIRCUIT DESCRIPTION Park/Neutral Position Switch The ECM uses the signals from the park/neutral position switch to determine whether the transmission is in park or neutral, or in some other positions. Air Conditioning Switch Signal The ECM uses the output from the air conditioning switch to determine whether or not the air conditioning is operating so that it can increase the idling speed of the engine if necessary. Throttle Position Sensor IDL Signal The IDL contacts are mounted in the throttle position sensor, and detects the idle condition. DTC No. DTC Detection Condition (1) 3 sec. or more after engine starts idle switch OFF (IDL1) (2) Park/neutral position switch: OFF (Shift position in "R", "D", "2" or "L" position) (3) A/C switch ON Trouble Area S Throttle position sensor IDL circuit S Accelerator pedal and cable S Park/neutral position switch S A/C switch circuit S ECM 51 HINT: In this circuit, diagnoses can only be made in the test mode. WIRING DIAGRAM EG314 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check output condition of diagnostic trouble code 51. P Setting the test mode. (1) Turn ignition switch OFF. (2) Using SST, connect terminals TE2 and E1 of DLC1 or 2. SST 0984218020 (3) Turn ignition switch ON. (For checking terminal A/C, start the engine.) (4) Using SST, connect terminals TE1 and E1 of DLC1 or 2. Check if code "51" is output by the malfunction indicator lamp. C OK *: Before the STA signal is input (Do not start engine), diagnostic trouble code 43 is also output. Hint Diagnostic trouble code 42 is output with vehicle speed 5 km/h (3 mph) or below. OK NG IDL 1... Go to step 2 PNP... Go to page EG316. A/C.... Go to step 3 Proceed to next circuit inspection shown on matrix chart (See page EG260). EG315 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 2 Check throttle position sensor. P C Disconnect throttle position sensor connector. Measure resistance between terminals 2 and 1 of throttle position sensor connector. OK OK NG Adjust or replace throttle position sensor (See page EG157) Check and repair harness or connector between engine control module and throttle position sensor. 3 Check voltage between terminal A/C of engine control module connector and body ground. P Connect SST (check harness "A"). (See page EG256) SST 0999001000 (2) Start the engine. Measure voltage between terminal A/C of engine control module and body ground. (1) C OK OK NG Check A/C compressor circuit (See page AC38). Check and replace engine control module. EG316 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION Park/Neutral Position Switch Circuit CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on the terminal NSW of the ECM is grounded to body ground via the starter relay and theft deterrent and door lock control ECU, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM terminal NSW becomes battery positive voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for airfuel ratio correction and for idle speed control (estimated control), etc. When the park/neutral position switch is off, code "51" is output in the test mode diagnosis. (This is not abnormal.) WIRING DIAGRAM EG317 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: This diagnosis chart is based on the premise that the engine is being cranked under normal conditions. If the engine does not crank, proceed to the matrix chart of problem symptoms on page EG260. 1 Check output condition of diagnostic trouble code 51. P (1) Using SST connect terminals TE2 and TE1 of DLC 1 or 2. SST0984318020 Turn ignition switch ON. Crank the engine. Using SST, connect terminals TE1 and E1 of DLC1 or 2. SST 0984318020 (2) (3) (4) C OK Check if diagnostic trouble code "51" is output when the shift lever is in the P and D shift positions. Result: OK NG Type I NG Type II Go to step 2. Go to step 3. Proceed to next circuit inspection shown on matrix chart (See page EG260). 2 NG Check for open in harness and connector between engine control module and park/neutral position switch (See page IN29). OK Check and replace engine control module. Repair or replace harness or connector. 3 OK Check park/neutral position switch (See page AT82). Replace park/neutral position switch. NG Check and replace engine control module. EG323 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION Back Up Power Source Circuit CIRCUIT DESCRIPTION Battery voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the diagnostic trouble code memory, airfuel ratio adaptive control value memory, etc. WIRING DIAGRAM INSPECTION PROCEDURE 1 Check EFI fuse. P C OK Remove EFI fuse from R/B No. 2. Check continuity of EFI fuse. Continuity OK NG Check for short in the harness and all the components connected to EFI fuse (See Electrical Wiring Diagram). EG324 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 2 Check voltage between terminal BATT of engine control module connector and body ground. P Connect the SST (check harness "A"). (See page EG256) SST 0999001000 Measure voltage between terminal BATT of engine control module connector and body ground. Voltage: 9 14 V C OK OK NG Check and repair harness or connector between engine control module and EFI fuse, EFI fuse and battery. 3 YES Are the diagnostic trouble codes still in the memory when the ignition switch is turned OFF? Check and replace engine control module. NO Proceed to next circuit inspection shown on matrix chart (See page EG260). EG325 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION Injector Circuit CIRCUIT DESCRIPTION The injectors are located in the intake manifold. They inject fuel into the cylinders based on the signals from the engine control module. Reference INSPECTION USING OSCILLOSCOPE S With the engine idling measure waveform between terminals #10 60 and EO1 of engine control module. HINT: The correct waveforms are as shown in. WIRING DIAGRAM EG326 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check voltage between terminals #10 60 of engine control module connector and body ground. P (1) Connect the SST (check harness "A"). (See page EG256) SST 0999001000 (2) Turn ignition switch ON. C OK Measure voltage between terminals #10 60 of engine control module connector and body ground. Voltage: 9 14 V NG OK Check IG2 relay. Go to step 3. 2 P C OK Remove IG2 relay from R/B No. 2. Check continuity between terminals IG2 relay shown below. C (1) (2) Apply battery positive voltage between terminals 1 and 2. Check continuity between terminals 3 and 5. OK OK NG Replace IG2 main relay. Check and repair harness or connector between IG2 fuse and battery. EG327 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 3 OK Check for open in harness and connector between engine terminal EO1, EO2 of ECM connector and body ground (See page IN29). NG Repair or replace harness or connector. 4 OK Check for open in harness and connector between ignition relay and injector, injector and ECM (See page IN29). NG Check injectors. Repair or replace harness or connector. 5 P Disconnect injector connectors (See page EG135). Measure resistance of injectors. Resistance: At 20C (68F): 13.4 14.2 W Check injection volume of injectors (See page EG140). S Injector volume 70 88 cc/15 sec. (4.3 5.4 cu in./15 sec) Difference between each injector: Less than 9 cc (0.5 cu in) S Leakage Fuel drop: One drop or less per minute. C OK C OK OK NG Replace injector. Check and replace engine control module. EG328 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION IAC Valve Circuit CIRCUIT DESCRIPTION The IAC valve is situated on the intake air chamber. Intake air bypassing the throttle valve is directed to the IAC valve through a passage. A step motor is built into the IAC valve. It consists of four coils, a magnetic rotor, valve shaft and valve. When current flows to the coils due to signals from the ECM, the rotor turns and moves the valve shaft forward or backward, changing the clearance between the valve and the valve seat. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. THere are 125 possible positions to which the valve can be opened. Reference INSPECTION USING OSCILLOSCOPE S With the engine idling, measure waveforms between terminals ISC1, ISC2, ISC3, ISC4 and EO1 of engine control module when A/C switch On or OFF. HINT: The correct waveforms are as shown. EG329 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION WIRING DIAGRAM EG330 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check IAC valve. P C OK Disconnect IAC valve connector. Measure resistance between terminals shown below. P C Remove IAC valve. (1) Connect the battery positive lead to terminals 5 (B1) and 2 (B2), and the negative lead to terminals 4(S1) 1(S2) 6(S3) 3(S4) in that order. Connect the battery positive lead to terminals 5 (B1) and 2 (B2) and the negative lead to terminals 3(S4) 6(S3) 1(S2) 4(S1) in that order. The valve moves in the closing direction. The valve moves in the opening direction. (2) OK (1) (2) OK NG Replace IAC valve. 2 OK Check for open and short in harness and connector between EFI main relay and IAC valve, IAC valve and engine control module (See page IN29). NG Repair or replace harness or connector. Proceed to next circuit inspection shown on matrix chart (See page EG260). EG331 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION VSV Circuit for ACIS CIRCUIT DESCRIPTION The circuit opens and closes the IACV (Intake AIr Control Valve) in response to the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is 4,500 rpm or less and throttle valve opening angle is 30_ or more, or engine speed is 4,500 rpm or more and throttle valve opening is 30_ or less, the engine control module turns the VSV ON and closes the IACV. At all other times, the VSV is OFF, so the IACV is open. WIRING DIAGRAM EG332 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check VSV for ACIS. P C (1) (2) Remove VSV. Disconnectr VSV connector. (1) Measure resistance between terminals. (2) Measure resistance between each terminal and the body. Resistance: At 20_C (68_F): 38.5 44.5 W Resistance: 1 MW or higher. OK (1) (2) C Check operation of VSV when battery positive voltage is applied to the terminals of VSV connector or not. OK Battery voltage is applied: Air from pipe E is flowing out through pipe F. Battery voltage is not applied: Air from pipe E is flowing out through the air filter. OK NG Replace VSV for ACIS. EG333 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 2 Check voltage between terminal ACIS of engine control module connector and body ground. P Connect SST (check harness "A"). (See page EG256) SST 0999001000 (2) Turn ignition switch ON. Measure voltage between terminal ACIS of engine control module connector and body ground. Voltage: 9 14 V (1) C OK NG OK Check for vacuum tank. (See page EG166) 2 OK Check for open in harness and connector between terminal EFI main relay and engine control module (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG334 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION VSV Circuit for Fuel Pressure Control CIRCUIT DESCRIPTION The ECM turns on a VSV (Vacuum Switching Valve) to draw air into the diaphram chamber of the pressure regulator if it detects that the temerature of the engine coolant is too high during engine starting. The air drawn into the chamber increases the fuel pressure to prevent fuel vapor lock at high enhine temperature in order to help the engine start when it is warm. Fuel pressure control ends approx. 120 sec. after the engine is started. WIRING DIAGRAM EG335 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Check VSV for fuel pressure control. P C (1) (2) (1) (2) Disconnect VSV connector. Remove VSV. Measure resistance between terminals. Measure resistance between each terminal and the body. Resistance: At 20_C (68_F): 33 39 W Resistance: 1 MW or higher. OK (1) (2) C Check operation of VSV when battery positive voltage is applied to the terminals of VSV connector or not. OK Battery voltage is applied: Air from pipe E is flowing out through air filter. Battery voltage is not applied: Air from pipe E is flowing out through pipe G. OK NG Replace VSV for fuel pressure control VSV. EG336 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION 2 Check voltage between terminal FPU of engine control module connector and body ground. P Connect SST (check harness "A"). (See page EG256) SST 0999001000 (2) Turn ignition switch ON. Measure voltage between terminal FPU of engine control module connector and body ground. Voltage: 9 14 V (1) C OK NG OK Proceed to next circuit inspection shown on matrix chart (See page EG260). 3 OK Check for open and short in harness and connector between engine control module and VSV, VSV and EFI main relay (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. EG337 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION TE1, TE2 Terminal Circuit CIRCUIT DESCRIPTION Terminals TE1 and TE2 are located in the data link connectors 1 and 2. The data link connector 1 is located in the engine compartment and the data link connector 2 is located in the cabin. When these terminals are connected with the E1 terminal, diagnostic trouble codes in normal mode or test mode can be read from the Malfunction Indicator Lamp in the combination meter. WIRING DIAGRAM EG338 ENGINE TROUBLESHOOTING CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: If terminals TE1 and TE2 are connected with terminal E1, diagnostic trouble code is not output or test mode is not activated. Even though terminal TE1 is not connected with terminal E1, the malfunction indicator lamp blinks. For the above phenomenon, the likely cause is an open or short in the wire harness, or malfunction inside the ECM. 1 Check voltage between terminals TE1, TE2 and E1 of data link connectors 1 and 2. P C OK Turn ignition switch ON. Measure voltage between terminals TE1, TE2 and E1 of data link connectors 1 and 2. Voltage: 9 14 V NG OK Check and replace engine control module. 2 OK Check continuity between terminal E1 of data link connectors 1, 2 and body ground. Repair or replace harness or connector. NG 3 OK Check for open and short in harness and connector between engine control module and data link connectors 1, 2 (See page IN29). NG Repair or replace harness or connector. Check and replace engine control module. ...
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