Ignition System - IG1 IGNITION SYSTEM IG2 IGNITION SYSTEM...

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Unformatted text preview: IG1 IGNITION SYSTEM IG2 IGNITION SYSTEM PRECAUTION PRECAUTION IG05N0C 1. With a tachometer connected to the system, connect the tester probe of the tachometer to terminal IG of the DLC1. 2. 3. 4. 5. As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use. Never allow the tachometer terminals to touch ground as it could result in damage to the igniter and/or ignition coil. Do not disconnect the battery while the engine is running. Check that the igniter is properly grounded to the body. COOLANT Item Engine coolant (w/ Heater) Capacity 7.5 liters (7.9 US qts, 6.6 lmp. qts) PREPARATION EQUIPMENT Megger insulation resistance meter Spark plug cleaner Thermometer Timing light Spark plug IG02P0C RECOMMENDED TOOLS SST (SPECIAL SERVICE TOOLS) PREPARATION IGNITION SYSTEM Classification Ethyleneglycol base IG02M0B IG3 IG00B0G IG02N0B IG4 IGNITION SYSTEM ONVEHICLE INSPECTION ONVEHICLE INSPECTION IG02R08 SPARK TEST CHECK THAT SPARK OCCURS (a) Disconnect the hightension cord (from the ignition coil) from the distributor cap. (b) Hold the end approx. 12.5 mm (0.50 in.) from the body ground. (c) See if spark occurs while engine is being cranked. HINT: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1 2 seconds at time. If the spark does not occur, do the test as follows: IG5 IGNITION SYSTEM ONVEHICLE INSPECTION HIGHTENSION CORDS INSPECTION IG0CY01 1. 2. 3. 4. 5. DISCONNECT THROTTLE BODY FROM INTAKE AIR CONNECTOR WITHOUT DISCONNECTING WATER BYPASS HOSES (See throttle body removal in SFI System) REMOVE NO.3 TIMING BELT COVER REMOVE CYLINDER HEAD REAR COVER DISCONNECT HIGHTENSION CORDS FROM SPARK PLUGS AND IGNITION COIL Disconnect the hightension cords at the rubber boot. Do not pull on the hightension cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. REMOVE DISTRIBUTOR CAP WITHOUT DISCONNECTING HIGHTENSION CORDS 6. INSPECT HIGHTENSION CORD RESISTANCE Using an ohmmeter, measure the resistance without disconnecting the distributor cap. Maximum resistance: 25 kW per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the hightension cord and/or distributor cap. 7. REINSTALL DISTRIBUTOR CAP 8. RECONNECT HIGHTENSION CORDS TO SPARK PLUGS AND IGNITION COIL 9. REINSTALL CYLINDER HEAD REAR COVER 10. REINSTALL NO.3 TIMING BELT COVER 11. REINSTALL THROTTLE BODY TO INTAKE AIR CONNECTOR (See throttle body removal in SFI System) SPARK PLUGS INSPECTION IG0CZ01 NOTICE: Never use a wire brush for cleaning. Never attempt to adjust the electrode gap on a used spark plug. Spark plugs should be replaced every 100,000 km (60,000 miles). IG6 IGNITION SYSTEM ONVEHICLE INSPECTION 1. 2. DISCONNECT HIGHTENSION CORDS FROM SPARK PLUGS INSPECT ELECTRODE Using a megger (insulation resistance meter), measure the insulation resistance. Standard correct insulation resistance: 10 MW or more If the resistance is less than specified, proceed to step 7. HINT: If a megger is not available, the following simple method of inspection provides fairly accurate results. Simple Method: (a) Quickly race the engine 5 times to 4,000 rpm (b) Remove the spark plug. (See step 3) (c) Visually check the spark plug. If the electrode is dry ... OK If the electrode is wet ... Proceed to step 4 (d) Reinstall the spark plug. (See step 7) 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, install the 6 spark plugs. 4. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: ND PK16R11 NGK BKR5EP11 5. INSPECT ELECTRODE GAP Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.1 mm (0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. 6. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. IG7 IGNITION SYSTEM ONVEHICLE INSPECTION 7. 8. REINSTALL SPARK PLUGS Torque: 18 Nm (180 kgfcm, 13 ftlbf) RECONNECT HIGHTENSION CORDS TO SPARK PLUGS IGNITION COIL INSPECTION IG02U0B 1. 2. 3. NOTICE: "Cold" and "Hot" in the following sentences express the temperature of the coils themselves. "Cold" is from 10C (14F) to 50C (122F) and "Hot" is from 50C (122F) to 100C (212F). DISCONNECT IGNITION COIL CONNECTOR DISCONNECT HIGHTENSION CORD FROM IGNITION COIL INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and negative () terminals. Primary coil resistance (Cold): 0.21 0.33 W Primary coil resistance (Hot): 0.27 0.39 W 4. If the resistance is not as specified, replace the ignition coil. INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and hightension terminals. Secondary coil resistance (Cold): 6.4 11.1 kW Secondary coil resistance (Hot): 8.2 13.0 kW 5. 6. If the resistance is not as specified, replace the ignition coil. RECONNECT HIGHTENSION CORD TO IGNITION COIL RECONNECT IGNITION COIL CONNECTOR IG8 IGNITION SYSTEM ONVEHICLE INSPECTION DISTRIBUTOR INSPECTION IG07505 1. 2. 3. NOTICE: "Cold" and "Hot" in the following sentences express the temperature of the coils themselves. "Cold" is from 10C (14F) to 50C (122F) and "Hot" is from 50C (122F) to 100C (212F). REMOVE DISTRIBUTOR CAP WITHOUT DISCONNECTING HIGHTENSION CORDS REMOVE ROTOR INSPECT AIR GAP Using SST (G1 and G2 pickups) and a feeler gauge (NE pickup), measure the air gap between the signal rotor and pickup coil projection. SST 0924000020 for G1 and G2 pickups Air gap: 0.2 0.5 mm (0.008 0.020 in.) 4. If the air gap is not as specified, replace the distributor housing assembly. DISCONNECT DISTRIBUTOR CONNECTOR 5. Terminal G1 and G G2 and G NE and G Cold 125200 W 125200 W 155250 W Hot 160235 W 160235 W 190290 W INSPECT SIGNAL GENERATOR (PICKUP COIL) RESISTANCE Using an ohmmeter, measure the resistance between terminals. 6. 7. 8. If the resistance is not as specified, replace the distributor housing assembly. RECONNECT DISTRIBUTOR CONNECTOR REINSTALL ROTOR REINSTALL DISTRIBUTOR CAP IGNITER INSPECTION IG02W0H (See spark test in onvehicle inspection) IG9 IGNITION SYSTEM HIGHTENSION CORD AND CORD CLAMP HIGHTENSION CORD AND CORD CLAMP COMPONENTS FOR REMOVAL AND INSTALLATION IG07A06 IG10 IGNITION SYSTEM HIGHTENSION CORD AND CORD CLAMP HIGHTENSION CORDS AND CORD CLAMPS REMOVAL IG07A01 DISCONNECT THROTTLE BODY FROM INTAKE AIR CONNECTOR WITHOUT DISCONNECTING WATER BYPASS HOSES (See throttle body removal in SFI System) 2. REMOVE NO.3 TIMING BELT COVER (a) Remove the oil filler cap. (b) Using a 5 mm hexagon wrench, remove the 6 bolts and timing belt cover. 3. REMOVE CYLINDER HEAD REAR COVER Using a 5 mm hexagon wrench, remove the 4 bolts and rear cover. 1. 4. REMOVE HIGHTENSION CORDS AND CORD CLAMPS ASSEMBLY (a) Disconnect the 2 hightension cord clamps from the claws of the No.3 cylinder head cover. (b) Remove the bolt holding the hightension cord clamp to No.2 cylinder head cover. (c) Disconnect the hightension cords from the distributor and ignition coil. Using a screwdriver, lift up the lock claw and disconnect the holder from the distributor (ignition coil). Disconnect the hightension cord at the grommet. Do not pull on the cord. NOTICE: Pulling on or bending the cords may damage the conductor inside. (d) Disconnect the hightension cords from the spark plugs. (e) Remove the 7 hightension cords and 8 cord clamps assembly. IG11 IGNITION SYSTEM HIGHTENSION CORD AND CORD CLAMP 5. REMOVE CORD CLAMPS FROM HIGHTENSION CORDS IG0D101 HIGHTENSION CORDS AND CORD CLAMPS INSTALLATION 1. INSTALL HIGHTENSION CORDS (a) Connect the hightension cords to the spark plugs. Face the cord of the hightension cord as shown in the illustration. Fit the hightension cord by pushing the center and its outer ring. IG12 IGNITION SYSTEM HIGHTENSION CORD AND CORD CLAMP (b) Connect the hightension cords to the distributor and ignition coil. Align the spline of the distributor (ignition coil) with the spline groove of the holder. Push in the holder together with the grommet until the claw of the holder locks securely. NOTICE: Check that holder is correctly installed to the grommet and distributor (ignition coil) as shown in the illustration. Check that the lock claw of the holder is engaged by lightly pulling the holder. IG13 IGNITION SYSTEM HIGHTENSION CORD AND CORD CLAMP (c) Secure the hightension cords with the 8 cord clamps as shown in the illustration. 2. 3. 4. INSTALL CYLINDER HEAD REAR COVER INSTALL NO.3 TIMING BELT COVER INSTALL THROTTLE BODY TO INTAKE CONNECTOR (See throttle body removal in SFI System) AIR IG14 IGNITION SYSTEM DISTRIBUTOR DISTRIBUTOR IG02X07 COMPONENTS FOR REMOVAL AND INSTALLATION IG0D201 DISTRIBUTOR REMOVAL 1. 2. DISCONNECT DISTRIBUTOR CONNECTOR DISCONNECT HIGHTENSION CORDS FROM DISTRIBUTOR Disconnect the 7 hightension cords from the distributor. NOTICE: Pulling on or bending the cords may damage the conductor inside. REMOVE DISTRIBUTOR Remove the nut. Pull out the distributor. Remove the O ring from the distributor housing. 3. (a) (b) (c) IG15 IGNITION SYSTEM DISTRIBUTOR IG0470C COMPONENTS FOR DISASSEMBLY AND ASSEMBLY IG0D301 DISTRIBUTOR DISASSEMBLY 1. Assembly is in the reverse order of disassembly. REMOVE HEAT INSULATOR Remove the 3 screws and heat insulator. 2. REMOVE DISTRIBUTOR CAP Loosen the 3 bolts, and remove the distributor cap and Oring. ASSEMBLY HINT: Use a new Oring. IG16 IGNITION SYSTEM DISTRIBUTOR 3. REMOVE ROTOR Remove the 2 screws and rotor. ASSEMBLY HINT: Align the hollow of the signal rotor with the protrusion of the rotor. IG0130K DISTRIBUTOR INSPECTION INSPECT SHAFT Turn the shaft and check that it is not rough or worn. If it feels rough or worn, replace the distributor housing assembly. IG0D401 DISTRIBUTOR INSTALLATION 1. REMOVE NO.3 TIMING BELT COVER 2. 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. (b) Check that the timing marks of the camshaft timing pulleys and No.4 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360) and align the mark as above. IG17 IGNITION SYSTEM DISTRIBUTOR 3. (a) (b) (c) (d) INSTALL DISTRIBUTOR Install a new Oring to the distributor housing. Apply a light coat of engine oil on the Oring. Align the marks of the drive gear and distributor housing. Insert the distributor, aligning the protrusion of the flange with that of the stud bolt on the cylinder head. (e) Install the distributor with the nut. Lightly tighten the nut. 4. REINSTALL NO.3 TIMING BELT COVER 5. CONNECT HIGHTENSION CORDS TO DISTRIBUTOR Connect the 7 hightension cords to the distributor. Firing order: 153624 6. 7. CONNECT DISTRIBUTOR CONNECTOR ADJUST IGNITION TIMING (See ignition timing inspection and adjustment in Engine Mechanical) TORQUE SPECIFICATIONS SERVICE DATA IG18 Distributor Ignition coil Firing order Hightension Cord Spark plug Air gap Pickup coil resistance Resistance SERVICE SPECIFICATIONS Spark plug X Cylinder head Distributor X Cylinder head Recommended spark plug Correct electrode gap for new plug Maximum electrode gap for used plug Primary coil resistance Secondary coil resistance Part tightened IGNITION SYSTEM at cold at hot at cold at hot at cold (G1G) (G2G) (NEG) at hot (G1G) (G2G) (NEG) ND NGK Maximum SERVICE SPECIFICATIONS PK16R11 BKR5EP11 1.1 mm (0.043 in.) 1.3 mm (0.051 in.) 0.210.33 W 0.270.39 W 6.411.1 kW 8.213.0 kW 0.20.5 mm (0.0080.020 in.) 125200 W 125200 W 155250 W 160235 W 160235 W 190290 W 153624 25 kW per cord Nm 18 19 kgfcm 180 195 ftlbf 13 14 IG02F0D IG0320E ...
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