Toyota Celica - ST205 - Engine Repair Manual Supplement (RM398E)

® TOYOTA
FIEPMR MANUAL SUPPLEMENT

Feb 1994
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35-GE Engine RupaIr Mlrlual (Pub, N0.RM3QBE) ,
INTRODUCTION I_L -Ir
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ENGINE :31
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STARTING SYSTEM l,_
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INTRODUCTION
HOW TC USE THIS MANUAL ---------------- -- IN

IDENTIFICATION INFORMATION IN
GENERAL REPAIR INSTRUCTIONS |y.,|
paE¢;,_u1|Q|,,| W TIJ1-I -Fl
ABE-REVIATICN5 USED IN THIS

MAHUM_
STANDARD BOLT TDRCIUE
SPECIFICATIONS
"H INTRODUCTION — HOW TO use THIS MANUAL
HOW TO USE THIS MANUAL |I|en¢—\7l
INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired.
To assist you in finding your way through the manual. the Section Title and major heading are
given at the top of every page.
G EN ERAL D ESC R I PT I O N
At the beginning of each section, a General Description (Precautions) is given that pertains to all
repair operations contained in that section.
Read these precautions before starting any repair task. lIO0N—flI
TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and
find the cause. mm
PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and
SSM (Special Service Materials) which should be prepared before beginning the operation and
explains the purpose of each one. moo: —M
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and
shows how the parts fit together.
Example:
Oil Pump Body
Driven Rotor
Drive Rotor
‘ -
OOR| ,‘\>
Hg
gg P
/,.\ La
®
\§%<, '- 0 Crankshaft Front Oil Seal
Oil Pump Oil Seal
N-m (kgf-cm, ft-lbf) 1 Specified torque

O Non-reusable part P156-t‘-1
INTRODUCTION — HOW TO USE THIS MANUAL IN-3
The procedures are presented in a step—by—step format:

O The illustration shows what to do and Where to do it.
0 The task heading tells what to do.
0 The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Exapmle:
Task heading: what to do
. 5. INSTALL CRANKSHAFT PULLEY

(8) USIFIQ SST, install the IJOII.
SST 092113254015 (90119-Q2126)
”Ius”an.on._ Set pan No. Component part No.
what I0 G/0 arid Where Detailed text: how to do task
(b) Install the b6l/t.
Torque: 30 N-m (310 kgf-cm.<2 ft-lbf)
Specification
‘IUDI
This format provides the experienced technician with a FAST TRACK to the information needed.
The upper case task heading can be read at a glance when necessary, and the text below it
provides detailed information. Important specifications and warnings always stand out in bold
type.
REFERENCES
References have been kept to a minimum. However, when they are required you are given the
page to refer to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to
leave the procedure to look up your specifications. They are also found at the end of each section,
for quick reference.
"M INTRODUCTION - IDENTIFICATION INFORMATION
IIMI —fll
CAUTIONS. NOTICES. HINTS:

0 CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
I NOTICES are also presented in bold type, and indicate the possibility of damage to the compo-
nents being repaired.
I HINTS are separated from the text but do not appear in bold. They provide additional information
to help you efficiently perform the repair.
SI UNIT .
The UNIT given in this manual are primarily expressed with the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the yard/pound system.
Example:
Torque: 30 N-m (310 kgf-cm. 22 ft-lbf)
IDENTIFICATION INFORMATION IIWO-01‘
ENGINE SERIAL NUMBER

/ The engine serial number is stamped on the engine
block as shown.
I PIBSII
IN-5
INTRODUCTION — GENERAL REPAIR INSTRUCTIONS
Negative (—) Terminal Cable GENERAL REPAIR INSTRUCTIONS
/
“Si
men-ea
Q
l. Use fender, seat and floor covers to keep the vehicle
'6 -~/‘ii clean and prevent damage.
2. During disassembly, keep parts in the appropriate
order to facilitate reassembly.
3. Observe the following: i
la) Before performing electrical work, disconnect the
negative (—) terminal cable from the battery.
lb) If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the the negative (—)
terminal cable from the battery which is grounded to
the vehicle body.
lc) To prevent damage to the battery terminal, loosen the
cable nut and raise the cable straight up without
twisting or prying it.
id) Clean the battery terminals and cable ends with a
shop rag. Do not scrape them with a file or other
abrasive objects.
la) Install the cable ends to the battery terminals with the
nut loose, and tighten the nut after installation. Do not
use a hammer to tap the cable ends onto the termi-
nals.
(fl Be sure the cover for the positive(+) terminal is prop-
erly in place.
4. Check hose and wiring connectors to make sure that
they are secure and correct.
5. Non—reusable parts.
la) Always replace cotter pins, gaskets, 0—rings and oil
seals etc. with new ones.
(bl Non—reusabIe parts are indicated in the component
illustrations by the ‘Q’ symbol.
6. Precoated parts.
Precoated parts are bolts and nuts, etc. that are
coated with a seal lock adhesive at the factory.
©‘1)Wiiii*iiiiii?= la) If a precoated part is retightened, loosened or caused
to move in any way, it must be recoated with the
Seal Lock Adhesive specified adhesive.
moose Z1155“ lb) When reusing precoated parts, clean off the old adhe-
sive and dry with compressed air. Then apply the
specified seal lock adhesive to the bolt, nut or threads.
(cl Precoated parts are indicated in the component illus-
trations by the "k" symbol.
7. When necessary, use a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
IN-6
INTRODUCTION — GENERAL REPAIR INSTRUCTIONS
9. Use of special service tools (SST) and special service

materials (SSM) may be required, depending on the
nature of the repair. Be sure to use SST and SSM
where specified and follow the proper work proce-
dure. A list of SST and SSM can be found in the
‘I?§¢=$'§'==E'E==:=E.'=i=.
isle! ik:
preparation part at the front of each section in this
15:5; ;: :;..
/
manual.
Fuse 10. When replacing fuses, be sure the new fuse has the
correct amperage rating . D0 NOT exceed the rating
Equal Amperage Rating
or use one with a lower rating.
fit I fii BE‘l366
Illustration Symbol Part Name Abbreviation
1 we
‘ B55594
.-iQ_/-vi
INO385
FUSE FUSE
é%—— MEDIUM CURRENT FUSE M~FUSE

BE 5595 M0366
_.,@.,_ HIGH CURRENT FUSE H-FUSE

BE5596 INOSB7
I
Avie? FUSIBLE LINK FL
BE5597 moan?
BE5598
~% moses
CIRCUIT BREAKER CB
V3376
11. Care must be taken when jacking up and supporting

the vehicle. Be sure to lift and support the vehicle at
the proper locations.
la) If the vehicle is to be jacked up only at the front or rear
end, be sure to block the wheels at the opposite end in
order to ensure safety.
INTRODUCTION — GENERAL REPAIR INSTRUCTIONS ‘N-7
After the vehicle is jacked up, be sure to support it on

stands. It is extremely dangerous to do any work on a
vehicle raised on a jack alone, even for a small job that
can be finished quickly.
Observe the following precautions to avoid damage to
the parts: .;.. . .- V...‘
Do not open the cover or case of the ECU unless

absolutely nnecessary. (If the IC terminals are tou-
ched. the IC may be destroyed by static electricity.)
To disconnect vacuum hoses, pull on the end. not the

WRONG CORRECT
middle of the hose.
To pull apart electrical connectors, pull on the connec-
r‘/ tor itself, not the wires.
“% INO253
Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard floor.
they should be replaced and not reused.
When steam cleaning an engine, protect the distribu-
tor, igniter and air filter from water.
Never use an impact wrench to remove or install

weowe connect temperature switches or temperature sensors.
When checking continuity at the wire connector,
Vim
insert the tester probe carefully to prevent terminals
from bending.
When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step—down
adapter instead. Once the hose has been stretched, it
INOZSZ may leak.
Example Tag hoses before disconnecting them:

When disconnecting vacuum hoses, use tags to iden-
VT? for T? , tify how they should be reconnected.
W ill 5|“ '
After completing a job, double check that the vacuum
hoses are properly connected. A label under the hood
shows the proper layout.
§ \/TV! TI’
‘ I 8"“ OSII-ilc
moooz
Unless otherwise stated, all resistance is measured at

an ambient temperature of 20°C (68° F). Because the
resistance may be outside specifications if measured
at high temperatures immediately after the vehicle
has been running, measurements should be made
when the engine has cooled down.
"M INTRODUCTION - PRECAUTION
PRECAUTION MM
FOR VEHICLES EOUIPPED WITH A CATALYTIC CONVERTER
CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create
a fire hazard. To prevent this. observe the following precautions and explain them to your customer.
N; :§;
1. Use only unleaded gasoline.
2. Avoid prolonged idling.

Avoid running the engine at idle speed for more than 20 minutes.
3. Avoid spark jump test.

(a) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(b) While testing, never race the engine.
4. Avoid prolonged engine compression measurement.

Engine compression tests must be done as rapidly as possible.
5. Do not run engine when fuel tank is nearly empty.

This may cause the engine to misfire and create an extra load on the converter.
6. Avoid coasting with ignition turned off and prolonged braking.
7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
IF VEHICLE IS EOUIPPED WITH MOBILE COMMUNICATION SYSTEM “H

For vehicles with mobile communication systems such as two—way radios and cellular tele-
phones. observe the following precautions.
ll) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
I2} Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle's
electronics systems. For details about ECU and sensors locations, refer to the section on the
applicable component.
(3) Do not wind the antenna feeder together with the other wiring. As much as possible, also avoid
running the antenna feeder parallel with other wire harnesses.
l4) Confirm that the antenna and feeder are correctly adjusted.
l5) Do not install powerful mobile communications system.
INTRODUCTION — ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL mu
A/C Air conditioner

BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve .46»
' éeaasw
..-tr
CPU Central Processing Unit
DOHC Double Over Head Cam
ECU Electronic Control Uinit
EFI Electronic Fuel Injection
ESA Electronic Spark Advance
EGR Exhaust Gas Recirculation
FIPG Formed in Place Gasket
FL Fusible Link
H ~Fuse High Current Fuse
IC Integrated Circuit
IG Ignition
ISC ldle Speed Control
LH Laft—Hand
M—Fuse Medium Current Fuse
MP Multipurpose
PCV Positive Crankcase Ventilation
PS Power Steering
RH Right — Hand
SSM Special Service Materials
SST Special Service Tools
STD Standard
SW Switch
TCCS TOYOTA Computer controlled System
TDC Top Dead Center
TEMP. Temperature
TWC Three—Way Catalyst
U/S Undersize
VSV Vacuum Switching Valve
W/ With
w/o Without
IN-10
INTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
IIDOI "DI
HOW TO DETERMINE BOLT STRENGTH
\ Mark Class Mark Class
Hexagon 4- 4T Stud bOII

head bolt -— ST
Bolt 6 -— 6T
head No. 7_ 71- No mark
4
- 8T
9— 9T
10 — 1 OT
11- 11T
( (£ (IL( ( ( ( (O
((((((
_,
© No mark 4T
Hexagon
flange bolt
No mark 4T G rooved
wl washer
hexagon bolt
Hexagon \_J
head bolt 2
G protruding
lines
5T
{( ( ( ’l( ( ( (’G
Hexagon
flange bolt 2
protruding 6T Welded bolt
wl washer lines
hexagon bolt
Hexagon
head bolt 3
protruding 7T
lines
Hexagon
head bolt 4
protruding 3T
lines
‘JIlfI7S
IN-1
INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS
SPECIFIED TORQUE FOR STANDARD BOLTS

T
Specified torque
Diameter Pitch
Class mm mm Hexagon head bolt Hexagon flange bolt
N-m kgf-cm ft-Ibf N-m kgf-cm ft~Ibf
6 1 5 55 48 in.'Ibf 6 60 52 |l'1. lbf ;- w

8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,1 50 83
6 1 6.5 65 56 in.-Ibf 7.5 75 65 in.-lbf

8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1.050 76
16 1.5 140 1,400 101
6 1 8 80 69 in.-Ibf 9 90 78 in.-Ibf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 27
6 1 10.5 1 10 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 23
16 1.5 230 2,300 166
8 1.25 29 300 22 33 330 24

8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1.100 80 120 1,250 90
a 1.25 34 340 25 37 380 27

er 10 1.25 70 710 51 78 790 57
‘ 12 1.25 125 1,300 94 140 1,450 105
, a 1.25 38 390 28 42 430 31

1OT 1o 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1 .600 116
8 1.25 42 430 31 47 480 35

11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1 .600 116 175 1,800 130
EG-1
ENGINE
ENG|NE MECHAN|CA|_ ......................... .. EG — . . . . . . . . . . . . . . . - . . . . . . . . . ..
. . . - . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EG - . . . . ........ . . . . . . . . . . . . . . . . .. .......
. . . . . . . . . . . . . . . . - . . - . . - - - . - . . . . . . . . . . . . . .- EG — . . . . . . . . . . . . . . . . . . . . . - - . . - - - - . . . . . . . . ........
2- .-'2
. . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . .. EG— . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
. . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EG - SERVICE SPECIFICATIONS ---------------------- '- EG— I83

. . . . . . . . . . . . . - . . - . . - . . - . . . . . . . . .- EG —
- . . . . . - - . . - . . - - - - - - - - - - . - .. EG—
. . . . . . . . . . . . . . . . . . . - . . . . . . . - . - . . - - -. EG—
. . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . .. EG—
REFER TO 3S-GE ENGINE REPAIR MANUAL
. . . . . . . . . . . . . . . . . . . . . . .. EG—
(Pub. No. RM396EI
TURBOCHARGER SYSTEM ................... .. EG—
. . - . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . .. EG- NOTE: The above pages contain only the points
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EG - which differ from the above listed manual.
. . . . . . . . . . . . . . . . . . . . . . - . . . . . - . . . . . . . . . . . .. EG—
. . - . - . - - - . . . . .. EG—
PRECAU-|-|QN ................ .. EG-
TROUBLESHOOTING ---- -- EG—
. . . . . . . . . . . . . . . . .. EG— 1 1 ‘-il%|<l%._IUJO ¢a.l LI'(Alf\3—*Zl-DIXUJ-‘CD ?-inG5-hl'\Jf h
. . . - . - . - . . . . . . . . . . . .. EG— 96
|N-|-ERCQOLER RELAY ............................ .. EG— 104
TURBO PRESSURE SENSOR ------------------- -- EG—1II5
VSV [For Turbocharging Pressure) ---------- -- EG—1l1B
SERWCE spEC|F|cAT|QNS ...................... .. EG— I09
EF| SYSTEM ........................................... .. EG— 110
» . ~ . - . - ¢ - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EG— I10
0PERAT|QN ........................................ .. EG— 1 12
. . - - . - . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . - ..
TROUBLESHOOTING w/ VOLT.
. . . . . . . . . . . . . . . . . . . . . . . . - . . - . . . . . . . . . . . . .-
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
. . . . . - - - . . - . - - - - - . - - - - .- EG-
. . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . - - . . . . . - . . . - - .-
INTAKE AIR TEMPERATURE SENSOR ---- -- EG—I68

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
FUEL PUMP RELAY AND RESISTOR ------- -- EG—1TU

SERVICE SPECIFICATIONS ---- EG~IT2
COOUNG SYSTEM ............................... .. EG_115
OpERA‘|'|0N ........................................ .. EG_115
. - . - . - . - - . - . - . . . - - . - . - - . . . . - . . - . - . - . . -.
SERVICE SPECIFICATIONS ---------------------- -- EG—IT3

EG-2
ENGINE - ENGINE MECHANICAL
ENGINE MECHANICAL
DESCRIPTION E6430
The 3S—GTE engine is an in—|ine, 4 cylinder, 2.0 liter DOHC 16—vaIve engine
OPERATION
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PIKJ48
ENGINE — ENGINE MECHANICAL EG-3
The 3S—GTE engine is an in—line. 4 cylinder engine with the cylinders numbered 1 — 2 — 3 —
4 from the front. The crankshaft is supported by 5 bearings inside the crankcase. These bearings
are made of aluminum alloy.
The crankshaft is integrated with 8 weights for balance. Oil holes are placed in the center of the
crankshaft to supply oil to the connecting rods, bearing, pistons and other components.
The ignition order is 1 — 3 — 4 — 2. The cylinder head is made of of aluminum alloy, with a cross
flow type intake and exhaust layout and with pent—roof type combustion chambers. The spark <
plugs are located in the center of the combustion chambers.

The intake manifold has 4 independent long ports and utilizes the inertial supercharging effect to
improve engine torque at low and medium speeds.
Both the intake camshaft and the exhaust camshaft are driven by a single timing belt. The cam
journal is supported at 5 places between the valve lifters of each cylinder and on the front end of
the cylinder head. Lubrication of the cam journals and cams is accomplished by oil being supplied
through the oiler port in the center of the camshaft.
Adjustment of the valve clearance is done by means of an inner shim type system. in which valve
adjusting shims are located below the valve lifters. To replace the shims, the camshafts must be
removed.
Pistons are made of high temperature—resistant aluminum alloy, and a depression is built into the
piston head to prevent interference with the valves.
Piston pins are the fu|l—f|oating type, with the pins fastened to neither the piston boss nor the
connecting rods. Instead, snap rings are fitted on both ends of the pins, preventing the pins from
falling out.
The No.1 compression ring is made of stainless steel and the No.2 compression ring is made of
cast iron. The oil ring is made of stainless steel. The outer diameter of each piston ring is slightly
larger than the diameter of the piston and the flexibility of the rings allows them to hug the
cylinder walls when they are mounted on the piston. Compression rings No.1 and No.2 work to
prevent gas leakage from the cylinder and the oil ring works to scrape oil off the cylinder walls to
prevent it from entering the combustion chambers.
The top of each cylinder is closed off by the cylinder head and the lower end of the cylinders
becomes the crankcase, in which the crankshaft is installed. In addition, the cylinder contains a
water jacket, through which coolant is pumped to cool the cylinders.
The No.1 and No.2 oil pans are bolted onto the bottom the cylinder block. The No.1 oil pan is
made of alumimum alloy. The No.2 oil pan is an oil reservoir made of pressed sheet steel. The
dividing plate also prevents the oil from shifting away from the oil pump suction pipe when the
vehicle is stopped suddenly.
EG-4
ENGINE — ENGINE MECHANICAL
PREPARATION may ~er
SST (SPECIAL SERVICE TOOLS)

09043-38100 Hexagon ‘I0 rnm Wrench Cylinder head bolt
X 09155-16100 Spark Plug Wrench
09216-00021 Belt Tension Gauge
09216-00030 Belt Tension Gauge Cable
%
l
09223-4601 1
09249-63010
Crankshaft Front Oil Seal
Replaoer
Torque Wrench Adaptor

Camshaft oil seal
\ 09843-18020
09960-10010
Diagnoais Check Wire
Verieble Pin Wrench Set
§%
t
0Q
<oaééil’di'666i‘""'"'“"‘
Varieble‘Pi‘V”W“'"
n H "iéiiiighaf{£;;.'.';-Qéiiiiiiii
Oil pump pulley
........... ..
mg pulleyIIIII H
IOIIW
RECOMMENDED TOOLS
09200- 0001 0 Engine Adjust Kit
% Q B
EG-5
fllll\“—0I
EQUIPMENT
Battery specific gravity gauge
CO/HC meter
Dial indicator
Engine tune— up tester
Micrometer
Precision straight edge
Torque wrench
ED-lIl—Ol
COOLANT
I Item I Capacity I Classification
Engine coolant 1 7.0 liters (7.4 US qts, 6.2 Imp. qts} I Ethylena—glyco| base
lQIlI—fl
LUBRICANT
Item Capacity Classification
Engine oil API grade SG or SH multigrade engine oil or
Dry fill 5.2 liters (5.5 US qts, 4.6 Imp. qts} ILSC multigrade engine oil and
Drain and refill recommended viscosity oil
w/ Oil filter change 4.5 liters (4.8 US qts, 4.0 Imp. qts}
w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 Imp. qts)
[9010-OI
SSM (SERVICE SPECIAL MATERIALS)

08826—00080 Seal Packing Black or equivalent Camshaft bearing cap
(FIPG) Cylinder head cover
08833-00080 Adhesive 1344. No.1 idler pulley pivot bolt

THREE BOND I344. Oil pressure switch
LOCTITE 242 or equivalent
EG-6 ENGINE — ENGINE MECHANICAL
l TUNE—UP ‘mm
/ / ENGINE COOLANT INSPECTION
\/ /—\/J CHECK ENGINE COOLANT LEVEL AT RADIATOR
RESERVOIR
___/*1
':I:-:-.w.----.---- ---.--4 - .-
ljI"|(
" - - ‘
The engine coolant level should be between the
‘LOW’ and 'FULL" lines.
-1-=11 J, If low, check for leaks and add engine coolant up to
'1'" -2->:\:-at-ass:-:-:-rice-rv.ia-s-tia-vuI#“"‘
v““"
:5,:-:¢.\-:.. .‘~. E:..
H5424 the "FULL" line.
CHECK ENGINE COOLANT QUALITY

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
S
pressure.
There should not be any excessive deposits of rust or

scale around the radiator cap or water filler hole, and
the coolant should be free from oil.
J ..“-‘é}' If excessively dirty, replace the coolant.
/ Reinstall the radiator cap.
/.19“
lo0el—ev
ENGINE OIL INSPECTION

Recommended Viscosity l$AEl :
CHECK ENGINE OIL QUALITY
QIIIIIIII Check the oil for deterioration, entry of water, dis-
--.---
coloring or thinning.
l"""“""e- l. ..‘.'.
°C—Z'9
0 F — 20
-18
O
-
20 40 GO 80 10°
If the quality is visibly poor, replace the oil.
Oil grade:
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
API grade SG or SH multigrade engine oil or ILSAC
Pnasas multigrade engine oil.
Recommended viscosity is as shown in the
Illustration.
CHECK ENGINE OIL LEVEL
I .9,»
./‘
The oil level should be between the ‘L’ and "F" marks
1-.Ijai
I:.-.
on the dipstick.
If low, check for leakage and add oil up to "F" mark.
/ M653
\
ENGINE — ENGINE MECHANICAL E6"-'
BATTERY INSPECTION ' _
1. CHECK BATTERY SPECIFIC GRAVITY AND
//. , 2 V '- 1
*
(a)
ELECTROLYTE LEVEL _ '
Check the electrolyte quantity of each cell.
If insufficient. refill with distilled (or purified) water. ,
:.'d::.~,r::-;
wr. 4...5,1»-t,
r<EG‘s=:~£
In /
(b) Check the specific gravity of each cell.

Standard specific gravity at 20°C (68° F):
/ ,__’ 1.25 -— 1.27
I\, 1 If the gravity is less than specification, charge the

_
\ ' v
/,=-
"?
—'
battery. .
\
I\at1-e:
_£
I ""J_\"-_v
I
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2. CHECK BATTERY TERMINALS. FUSIBLE LINK AND

l FUSES
(a) Check that the battery terminals are not loose or
\\L
@\ O "8 ‘LT’ .
il$.j‘i\
l.
1:”
corroded.
(b) Check the fusible link and fuses for continuity.
4;‘!
lGHV'Ol
AIR FILTER INSPECTION AND CLEANING
-.. . ~\‘I I.I *"\'.ll\ll.=/i\lll/

r'r . i'=i,.'4-i=.==l‘'i5.z@=-’l l5il*l"-lilillll.
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asat?‘ “‘'
,7
1.
2.
(a)
REMOVE AIR FILTER
INSPECT AND CLEAN AIR FILTER
Visually check that the air filter is not excessively
dirty, damaged or oily.
If necessary, replace the air filter.
(b) Clean the air filter with compressed air.
P151115 First blow from the inside thoroughly. then blow off
the outside of the air filter.
3. REINSTALL AIR FILTER
EG-8
_ *- .‘ I HlGH—TENSION CORDS INSPECTION

G - ‘(g\ 1 DRAIN INTERCOOLER COOLANT
er \ (See page EG—97)
‘ REMOVE INTERCOOLER
, Remove the 3 bolts.
’\.T
is T’
Effie» Y
‘K
Pl82(.Q
Disconnect the intercooler from the turbocharger and
intake air connector, and remove the intercooler and
air hose.
REMOVE COOL AIR INLET

Remove the 2 bolts and cool air inlet.
5' \
/
._ 9 \ P1821‘!
DISCONNECT HlGH—TENSlON CORDS FROM

SPARK PLUGS
Remove the 3 bolts, and disconnect the high—tension
Q"
rt
‘
cord clamp from the cylinder head cover.
‘’"\_- .. ‘ ‘II
~. _
ér
i .1£§;¥C4
(
0.'
Q
5 Y P185166
ll’ Disconnect the high —tension cords at the rubber

CORRECT [Z boot. Do not pull on the high—tension cords.
NOTICE: Pulling on or bending the cords may damage the
WRONG
X -
conductor inside.
,(.
iii I I
a
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Y Piasrz
INSPECT HIGH—TENSlON CORD RESISTANCE

_-
Using an ohmmeter, measure the resistance.
4 _‘\‘/
\j“\‘- Maximum resistance:
Ohmmeter Q‘,
_-\j\\\
tvfiag
.../‘ 25 kQ per cord
If the resistance is greater than maximum, replace the
in
4.-'4
Z
~/,1“ high —tension cord.
Y P185711
EG-9
6. REINSTALL HIGH—-TENSlON CORDS

I
WV (a) Connect the 4 high—tension cords to the spark plugs.
'7 (b) Install the high—tension cord clamp with the 3 bolts.
‘/\ kt -ii. f"-.51

I (
\_.
O"“'+\ 2
~4
1 , _.§_
was/'\r
sfitz YF-‘I566
7. REINSTALL COOL AIR INLET

lr Install the cool air inlet with the 2 bolts.
er»
1 Sig‘
'/
tr ‘
\, _ 8. REINSTALL INTERCOOLER
- 5‘ 9'3\ Connect the intercooler to the turbocharger and
PQ‘ _
/--P ’ Q
*<g\
.intake air. connector, and .install the .intercooler with
.
the 3 bolts.
\ Q
we r %“\
Q
\ it I -‘-:
\/ Y Pl82(Q
9. REFILL INTERCOOLER WITH COOLANT

(See page EG-9?) -
10. START ENGINE AND CHECK FOR LEAKS
E640 ENGINE — ENGINE MECHANICAL
E040! '01
ALTERNATOR DRIVE BELT INSPECTION

\_ INSPECT DRIVE BELT
k \‘\'~..;\. (a) Visually check the drive belt for excessive wear,
_ \.\.i_V_‘ frayed cords etc.
Q2} . _\:*§;~_\;,.§_\_;_ If any defect has been found, replace the drive belt.
A 1
O O
O o \\\ HINT: Cracks on the rib side of a drive belt are consid-
.< 00
ered acceptable. If the drive belt has chunks missing
CH0744 010004 M015 ffO|’11 1I‘lB TIIJS, I1 SI1OUICI IJ9 FBDIBCBCI.
wl A/C W/0 A/c (b) Check the drive belt deflection by pressing on the belt
Alternator Alternator at the points indicated in the illustration with 98 N (10
98N 98N kgf, 22 lbf) of pressure.
Idler ~ Drive belt deflection:
Pulley w/ A/C
New belt
fdfigy 1o - 11 mm (0.39 — 0.43 in.)
Crankshaft A/C Crankshaft used belt
Compressor mm 13 —- 16 mm (0.51 — 0.63 in.)
w/0 A/C
E
\..,»‘
-. 4 / ‘" ' I‘
\§
\-
“I
4, New belt
11 - 14 mm (0.43 - 0.55 in.)
Used belt
I-“S I rye“
‘\\\N‘* \
12 - 1a mm (0.47 - 0.11 in.)
If the belt deflection is not as specified, adjust it.
“1'>\7 /jg - \...

06,19 *
Reference:
SST 8
Using SST, check the drive belt tension.
SST 09216-00021 (A).
09216-00030 (B)
SST A
Drive belt tension:
w/ A/C
SST A
New belt
686 — 785 N (70 ~— 80 kgf)
zcoooa ecooot 100554 U399 P9“
294 — 441 N (30 — 45 kgf)
w/o A/C
New belt
461 — 706 N (47 — 72 kgf)
Used belt
353 — 610 N (36 — 62 kgf)
If the belt tension is not as specified, adjust it.
EG-11
HINT:
0 ‘New belt’ refers to a belt which has been used
less than 5 minutes on a running engine.
O ‘Used belt’ refers to a belt which has been used
on a running engine for 5 minutes or more.
I After installing a belt, check that it fits properly in
CORRECT WRONG
the ribbed grooves.
o Check with your hand to confirm that the belt has
CHOOBG not slipped out of the groove on the bottom of
the pulley.
0 After installing a new belt, run the engine for
about 5 minutes and recheck the belt deflection
or tension.
D5403-01
VALVE CLEARANCE INSPECTION AND

ADJUSTMENT
HINT: Inspect and adjust the valve clearance when
the engine is cold.
1. DRAIN INTERCOOLER COOLANT

(See page EG—97)
.. 2. REMOVE INTERCOOLER
~ _ (a) Remove the 3 bolts.
© “—. (b) Disconnect the intercooler from the turbocharger and
\/ intake air connector, and remove the intercooler and
air hose.
, at ifs
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3. REMOVE COOL AIR INLET

Se/s/o
\.
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.5
A,
A
)9
P1821‘?
EG-12
'§ 4. DISCONNECT HIGH—TENSlON CORDS FROM

fl SPARK ewes
(id \‘ (a) Remove the 3 bolts, and disconnect the high—tension
cord clamp from the cylinder head cover.
5/
\
an ,
QQ \_.
A
#-
3’
.'{fwr
F.
O.it'\ Y P18566
K ,4,
CORRECT 1/
(b) Disconnect the high — tension cords at the rubber
boot. Do not pull on the high—tension cords.
1.Er la 45
wnouc
1/
4
w conductor inside.
'F’/*1
~_.4
P‘ — 7 E V
'*\"'
er
C/l
/
\ “ 5. DISCONNECT NO.1 PCV HOSE
C.)
Q‘.
\Q
6. REMOVE VENTILATION CASE

l / 9- (a) Disconnect the No.2 PCV hose from the cylinder head
74 "in X \ .
‘- ‘w (b) gcitzonnect the No.3 water bypass hose (for PCV
Q‘ V J) hose) from the ventilation case.
(c) Remove the ventilation case from the bracket.
0 ”
7 r>isss4
7. REMOVE THROTTLE BODY

(a) Remove the 4 bolts, accelerator cable bracket and
l
intake air connector.
% e$"-5/
r
i .-r
P1825‘!
EG-13
(1)— / 7 7
(bl Disconnect the following hoses and connectors:
(I) Vacuum hose from "P" port of throttle body
_\
(2) Vacuum hose from ‘E’ port of throttle body
Q! (3) Vacuum hose from throttle opener
(4) Throttle position sensor connector
- » fast
0 (5) ISC valve connector
D‘\‘\it)
2\
v“\A<,§i -- -' ~ .232:
<5) //@@ Y pm
___ “' lc) Remove the 6 bolts and air connector stay, and dis-
connect the throttle body from the intake manifold.
C‘ *4’ *Q. T 5" “RI I _

‘I
(d) Remove the throttle body gasket.
-Q.\_ ‘rd’!/‘ /
\c?
\\./' "
,_ ‘
YPI$6I
(9) Remove the No.3 cylinder head cover gasket and
efe
Gasket \L L3] spacen
I/'_\
Spacer I
Jfl
P162131
Q 1 (fl Disconnect the following hoses from the throttle

body, and remove the throttle body:
(1) Air hose from No.1 air tube
"3 1 (2) 2 ISC water bypass hoses from No.1 air tube
% YN8555
B. REMOVE CYLINDER HEAD COVER
/<
\ la) Disconnect the vacuum hose from the VSV.
lb) Disconnect the EGR vacuum modulator from the bra-
cket.
%”/
E ’>atL
\i
E \-
\-.- ‘_' //Wife
/@@;.?/
EG-14
~tea». (c) Remove the 2 bolts holding the No.2 timing belt cover
to the No.4 timing belt cover.
1 *3‘
~§ '
T
/ D 1/§§\®
(d) Pull up the engine wire protector as shown in the

5””
cg.” illustration.
§,”9;= /-' ‘\
efilfl
"\)
U
/Q K;~<> ‘4/Z/J):
\ /
(e) Remove the 10 bolts, seal washers, cylinder head

16‘ ._ cover and 2 gaskets.
7 <5.% \6\4,
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.
1?
Q< \
P1681)
(b) Check that the grooves of the camshafts are aligned

with the dot marks of the No.1 camshaft bearing caps.
If not. turn the crankshaft I revolution (360°) and
v align the mark as above.
\
/
455
-re...'_ Q
$5
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EG-15
10. INSPECT VALVE CLEARANCE

A (al Check only the valves indicated.
O Using a feeler gauge, measure the clearance be-
| l—¢|g| ||Il|||Eli||_:aliil@|
tween the valve lifter and camshaft.
- QC) I Record the out— of—specification valve clear-
ance measurements. They will be used later to
!
M,T]
_-t-|= 'r=1n'P
(El)
Fl") ‘N;
:-:;>_<¥s‘
4I“ (055)
ahe determine the required replacement adjusting
shim.
\ -\1§-\;\- Q
._ OJ
Y P1855?
Valve clearance (Cold):
Intake
A 4 0.15 — 0.25 mm (0.006 — 0.010 in.)
Exhaust
0.28 — 0.38 mm (0.011 - 0.015 in.)
I
(bl Turn the crankshaft 1 revolution (360°) and align the
Q
3 Q QQQ mark as above. (See procedure in step 9)
(0) Check only the valves indicated as shown. Measure
!_. 5 In
1 the valve clearance. (See procedure in step (a))
2 2 4 4 vrieeer
11 ADJUST VALVE CLEARANCE

A: Remove alternator
(a) Loosen the pulley nut and adjusting bolt.
(bl Remove the drive belt.
hill
-Q
ax.» ti-
\\
7
ggiusting
(c) Disconnect the following wires and connectors:

I lI (1) (1 l Alternator wire
1 ‘-Q
<3» ’:,\ (2) Alternator connector
(3) Oxygen sensor connector
l
(4) Oxygen sensor wire clamp from bracket
(5) Oxygen sensor connector from bracket
g,
(2)
l» ‘\ - z ' P1859]
Remove the 2 bolts and ground strap. and disconnect

the engine wire protector from the brackets.
ll Ground ‘ (‘V
Strap -
i-.v__\¢.\ ‘
' @>
Y H8550
EG-16
;-— \3~»'"'\/ (e) Remove the 2 bolts and alternator.
T‘ tr“
r<
K F E-""'» / Y P162334
/ x $ )2 g B. RH front engine hanger and alternator

bracket
Remove the 3 bolts, engine hanger and alternatol
)@ ‘ Hanger bracket.
‘\ ‘ -\ ,1
$Q ("I 1‘
Alternator *§ $/
Bracket ® R 4 ' a\\'\\
i I
'
C. Remove No.2 timing belt cover
Remove the 3 bolts. timing belt cover and gasket.
L1 I
/
ii“ .
.....
D. 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.
, Q
X
;% /
5 \
sf
‘(O \
Plfifi
(b) Check that the grooves of the camshafts are aligned

with the dot marks of the No.1 camshaft bearing caps.
"“ If not, turn the crankshaft 1 revolution (360°).
-'q,
/
.. I-§\,I
~e-£4
T\Pet
“~\-\i 90:42‘: Pl85|8
EG-17
Disconnect timing belt from camshaft timing

pulleys
Place matchmarks on the timing belt and camshaft
timing pulleys.
Q~>..#a
‘ll’
__
'v)! /P185116
A 3 Fulcru
- / (bl Turn the No.1 idler pulley bolt to obtain the specified
- - .1
Q‘ Length *-
torque or less, and align the holes of the pulley brack-
et and cylinder head, pass a 3.0 mm hexagon wrench
through the holes to keep the setting position of the
pulley bracket.
Torque:
I
69 N-m (700 kgf-crn. 51 ft-lbf)
48 N-m (490 kgf-cm. 35 ft-lbf) for SST
3.0 mm Hexagon Wrench _ P185211 HINT (On vehicle):
I Use SST.
SST 09249-63010
0 Use a torque wrench with a fulcrum length of
340 mm (13.39 in.).
Hold the hexagon wrench head portion of the cam-

"I Q:
{/12!... <2 fie /'

/
<a
shaft with a wrench, and loosen the intake camshaft
timing pulley bolt.
<§>“*-.r/
_-"Q -
&\<’,’/¢/Yr)? _
» ;-._ ~v -I (d) Remove the intake camshaft timing pulley bolt.
'l% / .
. a
-$ O O ‘Q’
P1855
‘IQ (Bl Disconnect the intake camshaft timing pulley togeth-

er with the timing belt from the camshaft, and remove
the intake camshaft timing pulley.
Q
\°\
\Q g N(Q
fl.\
4
<0
*1
Q
\- 1'‘(fag
_
P185116
EG-18
(f) Remove the knock pin from the intake camshaft.
.IQ
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e»~» ¢‘%<__"'Q\._
Y H8525
F. Remove exhaust camshaft timing pulley
1
D
fix I
I
(a) Hold the hexagon wrench head portion of the cam-
shaft with a wrench. and loosen the pulley bolt.
(bl Remove the bolt. timing pulley and knock pin.
f.e\, ,.§9z@,
ti
*1..
/\
4 sq"
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NOTICE:
0
O
Be careful not to drop anything inside the timing
belt cover.
Do not allow the belt to come into contact with oil.
2%-%
water or dust.
Pl7%S
~ _. c. Remove camshafts
Uniformly loosen and remove the 10 bearing cap bolts
/ -‘I.‘*1
/R
in several passes. in the sequence shown. and remove

43*¢§5
(‘gels J
the 5 bearing caps, oil seal and camshaft. Remove the
as
—/4‘ intake and exhaust camshafts.
/‘Q
0
.1. /R‘ @
I O 1%
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\ \“ L)
H. Remove adjusting shims
Lifter
Remove the valve lifter and adjusting shim.
Shim (
?
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l
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M
%\f‘<§%=-\i,.-_, N Pl85Tl
EG-1 9
Replace adjusting shims

Determine the replacement adjusting shim size by
following the Formula or Charts:
I Using a micrometer, measure the thickness of
the removed shim.
O Calculate the thickness of a new shim so that the
valve clearance comes within the specified value.
/ Pisvos T Thickness of removed shim

A Measured valve clearance
N Thickness of new shim
Intake:
N = T + (A — 0.20 mm (0.008 in.))
Exhaust:
N = T + (A — 0.33 mm (0.013 in.))
I Select a new shim with a thickness as close as
possible to the calculated value.
HINT: Shims are available in 19 sizes. 18 sizes are
available in equal increments of 0.05 mm (0.002O in.),
from 2.50 mm (0.0984 in.) to 3.35 mm (O.1319 in.).
The largest shim size available is 3.39 mm (O.1335 in.).
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5°42 ENGINE — ENGINE MECHANICAL
/ \W J. Reinstall adjusting shims
L‘“°' \ a- »>, (a) Install the adjusting shim and valve lifter.
Shim Q
C
\§c
, C
C/A‘Tic
E=:§5255¥z§§izEzE5=aEai5zf. §' l ’“ ( H8571
(b) Check that the valve lifter rotates smoothly by hand.

Q
\
I
Aug"
1
J
VI'“\
C ~% if
kw] K. Reinstall camshafts
l
\-_-,\\, la) Align the cutout portion of the coupling with the
groove of the distributor housing.
J 4» K
\\
99$/53/
(6
Oiward lb) Attach the slit of the intake camshaft to the coupling
of the distributor.
/ax _~ ‘Z
1591/
(0) Place the camshafts on the cylinder head with the
W
Cam ‘ ‘*6
”’-/y \' No.1 cam lobes facing outward as shown.
Lobe 7‘ O4 ¢ Q‘?
V HINT: Intake camshaft have an slit; exhaust camshaft
-QOWLQ
’§;§\"“%’@_‘ Cam
do not.
Intake \'
.
' F‘ » “ \~$§~'4’
‘ti%t\5l Lobe
Exhaust 'j‘ 9'sard V H8546
(dl Apply seal packing to the No.1 bearing cap as shown

in the illustration.
Seal Packing Seal pecking:
Part No. 08826-00080 or equivalent
EMZ252
ENGINE - ENGINE MECHANICAL E643
(e) Install the bearing caps in their proper locations.
9 -1. . HINT: Each bearing cap has a number and front mark.
,7 @
@
=..=
- I
Front Y H8543
(fl Apply a light coat of engine oil on the threads and

5 under the heads of the bearing cap bolts.
5 6 (9) Install and uniformly tighten the 10 bearing cap bolts
ES -.4‘
éitl“ 7: on one side in several passes, in the sequence shown.
'Q
?‘¢.' ’\
P~9~_-‘J31
NI »\.z’:‘~o: [9
Ll)
\
9°
\.3
9
\.
I,
9/-
\‘»O=/A?
YPl8635
L. Check valve clerance

Turn the camshaft and position the cam lobe upward.
and check and adjust the valve clearance.
Intake
0.15 — 0.25 mm (0.006 — 0.010 in.)
Exhaust
0.28 — 0.38 mm (0.011 — 0.015 in.)
M. Reinstall camshaft oil seals

M Ping
la) Apply MP grease to a new oil seal lip.
"
Q
\\
_
ii
‘*1
"v
’» p
;//-
EM0050
(b) Using SST, tap in the 2 camshaft oil seals.

SST 09223-46011
$55! ssr
D ‘*0 {K
I
Y M8549
EG-24
Reinstall exhaust camshaft timing pulley

Slide the timing pulley onto the camshaft, facing
g \ .> 1» A ""$“* ,1‘ ,. mark "S" outward.
iv?‘ D-’ Align the pin holes of the camshaft and timing pulley.
lw \'
\Q‘-viz? '
1 and insert the knock pin.
s “”"»$;§'é
4 1.4»
. Q
Knock Pin p‘$2?
-" (cl Hold the hexagon wrench head portion of the cam-
r shaft with a wrench, and install the pulley bolt.
4/
Torque:
/| I
V
, »_\ -3;?’
.. a, 4| 59 N-m (600 kgf-cm. 43 ft-lbf)
Q‘) )7 I *'
\'
v
2 HINT (On vehicle):
w’ .99‘
w
SS
\
0 Use SST.
‘\ 4'
. _,
’ Fulcrum _ SST 09249—6301 0
Lenglh v Pl852l 0 Use a torque wrench with a fulcrum length of
340 mm (13.39 in.).
Set No.1 cylinder to TDC/compression
, “
/lat*EEK!"
Turn the crankshaft pulley, and align its groove with
timing mark '0' of the No.1 timing belt cover.
_, '
“'1 V-
(b) Turn the hexagon head portion of the camshaft. align

the groove of the camshaft with the dot mark of the
No.1 camshaft bearing cap.
r’?
2'1 (Was
1--. Pl85l'I
Reconnect timing belt to camshaft timing pulleys

Turn - Remove any oil or water on the exhaust camshaft
timing pulley. and keep it clean.
(
Oo- Turn the hexagon wrench head portion of the cam-
shaft with a wrench, and turn the exhaust camshaft
timing pulley clockwise. Align the matchmarks of the
» "" .
\-.er;
\ eA
3 timing belt and exhaust camshaft timing pulley, and
hang the timing belt on the exhaust camshaft timing
Y P135213 pulley.
EG-25
_ (cl ' the groove of the camshaft with the dot mark of
Align
the No.1 camshaft bearing cap.
W...“ ‘ ' Check that the timing belt has tension between the
crankshaft timing pulley and exhaust camshaft timing
///
\/??
KL. ‘$3 pulley.
-"="-"5 ....=
J ,.
i-.,(Q
.,...
r YHEQ
:1: .-.-::,......,¢\-
i~w.~++>~...x
Remove any oil or water on the intake camshaft
V/Z12 ‘/
r..~" * ' (fl
timing pulley and No.1 idler pulley, and keep them
clean.
Align the matchmarks of the timing belt and intake
camshaft timing pulley. and hang the timing belt on
it 5: 7‘ /
‘A.///IE3‘: ‘I. i
" ~fl..\
5.9 the intake camshaft timing pulley, facing mark "S"
outward.
. _ ,' Slide the intake camshaft timing pulley on the cam-
§ \& ‘
C) -»____ .,
T M8515 shaft.
Turn the hexagon wrench head portion of the cam-

"
Turn Q
'li"‘
""51!*
I
/
shaft with a wrench. and align the knock pin hole of
mbQ\I C.-3 the camshaft with the knock pin groove of the pulley
and install the knock pin.
‘K
‘hp
Q)
I,
I
D ‘ “‘:\-7.3".-. '1 _.
Q
I2
weé ;?4i.
I
Knock Pi °*:.~ '~" ‘l _

Y P1542
Hold the hexagon wrench head portion of the cam-

§-' I shaft with a wrench, and install the intake camshaft
, " ‘Q
~\ timing pulley bolt.
0 sag’??? “‘ Torque:
59 N-m (600 kgf-cm, 43 ft-lbf)
4..
u 41 N-m (420 kgf-cm. 30 ft-lbf) for SST
SST
= *~ ‘L. HINT (On vehicle):
Fulcru 0 Use SST.
Length (9,854; SST 09249-63010
0 Use a torque wrench with a fulcrum length of
340 mm (13.39 in.).
. , *"*-= (ll Turn the No.1 idler pulley bolt to obtain the specified
_ r 1 FUlCfUl'l’\=-‘ / torque or less, remove the 3.0 mm hexagon wrench.
/ N‘ Lenth
Q l ~ Torque:
=‘@QA§\‘'4'?”'
gflrw
_919'q§"§».
1 \\~.
“* (Q
69 N-m (700 kgf-cm. 51 ft-lbf)
;@T\ HINT (On vehicle):
I Use SST.
.<>‘ SST 09249-63010
3.0 mm Hexagon Wrench y mm O Use a torque wrench with a fulcrum length of
340 mm (13.39 in.).
o. Check valve timing
//l/\ Q “ Slowly turn the crankshaft pulley 2 revolutions from

TDC to TDC.
NOTICE: Always turn the crankshaft clockwise.
x“ Dfflr.
'1-
Check that each pulley aligns with the timing marks as

shown in the illustration.
If the timing marks do not align, disconnect the timing
belt and reconnect it.
@®\
».
*
Reinstall No.2 timing belt cover
H474 19.25%
y; Q) la) Install the gasket to the timing belt cover.
(Z)
Install the timing belt cover with the 3 bolts.
1 HINT: Use the 20 mm (0.79 in.) long bolt.
/ U 17’ \r
._ ,
Y PIBSIQ
\ r .~/~_ s. Reinstall alternator bracket and RH front engine

hanger
\/’»>,f§.::::. Install the alternator bracket and engine hanger with
the 3 bolts.
s “ I . v
;'::;::::°' 1
' Q t ......
ENGINE - ENGINE MECHANICAL E6":-'
,@'-— \$+- ' " 1, T. Reinstall alternator
fix”? W (a) Install the alternator with the 2 bolts.
‘(I _
/ :9
‘ Tor qua.'
1
.-. \ Q -
12 mm head 19Nm(190 kg r- c m, 14 ft-lbf )
14 mm head 52 N-m (530 kgf-cm. 38 ft-lbf)
kt;
'
‘N
~‘3"1%.@ / set
\"_j-
Y PIBS34
"Y
“'1
,-9,551
5 lb) Install the engine wire protector and ground strap
with the 2 bolts.
Ground wmllll
1/‘ '
O
) ~»¢;'* Y P1550
(3)
/ (0) Connect the following wires and connectors:
§ (1 I Oxygen sensor connector to bracket
1:" (2) Oxygen sensor connector
' ll .9 ‘/ I3) Oxygen sensor wire clamp to bracket
T6':: I (4) Alternator connector
QqT3\\ i / (5) Alternator wire
T
"'
~r4§“‘ it
§
1\ \
_»LS1
\‘
)_\\O
§§
\
\ H8592
$40‘ Install the drive belt with the adjusting bolt.

w Q (6) Tighten the pulley nut.
Pulley
>~ kl
Adjusting
Nut \ Bolt
‘s\ fig.
~ ..5
1,.
YN8573
REINSTALL CYLINDER HEAD COVER
El -Q0
E lillll
Q.
D
O
’a
I3 .
/1
la) Apply seal packing to the cylinder head as shown in
the illustration.
©0 OX0 Q
Seal packing:
ts. ti_
(QED
.,.
JHHM as l|— l|l|all|lEl||lall|lgl|l|
: Seal Packing
i 2
EG'28 ENGINE —- ENGINE MECHANICAL
(b) Install the 2 gaskets to the head cover.
‘ 2‘l it»
9?
_'~
H8233
(0) Install the head cover with the I0 seal washers and
\A screws. Uniformly tighten the screw in several passes.
\
>
_
-
7
ey,
—
2%
B\
_'\~=/
/A
Torque: 6.0 N-m (61 kgf-cm. 53 in.-lbf)
HINT: Each bolt length is indicated in the illustration.
Bolt length:
(5"ul-\
I’ A: 25 mm (0.98 in.)
B: 50 mm (1.97 in.)
R.H—""
\J=0-X? 04
\
fee
6K)
(Du
pk)
, \ D’:-K),
)% A M8548
(dl Settle in the engine wire protector as shown in the
L//if illustration.
. T¥¥\4§”(
‘E’ a//if‘ 5
Y -
419552
(e) Install the 2 bolts holding the No.2 timing belt cover to
the No.4 timing belt cover.
HINT: Use the 25 mm (0.98 in.) long bolt.
5"‘
\ as
law“ ‘m/‘.95-J
\
/\ ‘Q
(f) Connect the EGR vacuum modulator to the bracket.

(g) Connect the vacuum hose to the VSV.
r eye
9J
I‘ ts@%
\\ J4 7
/ ’ ‘
//3%/;,fi'KJ
ism
\
18558
EG-29
ENGINE — ENQINE MECHANICAL
Qv
Q 13. REINSTALL THROTTLE BODY
31 la) Connect the following hoses to the throttlebody.

(l) 2 ISC water bypass hoses from No.1 air tube
1"
E_"'*“"' "" " (z?
\;‘ 7
YPl856B
lb) Insert the spacer into the cylinder head cover, and
a et /4 install the gasket.
_-._
\\j /\ 5/
,-.
eel” /a
Spacer \
-’
~/
P113281
(c) Attach a new gasket to the throttle body, facing the

Profrusion protrusion upward.
‘ll
. .4. A.
"'=:~.-,-vrfig},
, ‘\
’§
9'
A (dl Install the gasket, throttle body and air connector stay
Q. with the 6 bolts in several passes.
II " Torque: 21 N-m (210 kgf-cm. 15 ft-lbf)
HINT: Different bolt lengths are used for locations A.
B and C.
"-I-. Bolt length:
‘\.>=a
(if/gi,/. A: 40 mm (1.57 in.)
B: 80 mm (3.15 in.)
C: 70 mm (2.76 in.)
YPIBSTO
(5)~ (4) (B) Connect the following connectors and hoses:

(1) ISC valve connector
x (3) Vacuum hose to throttle opener
(4) Vacuum hose from "P" port of throttle body
3z. J
\\fiB_t'
g/
few
0 (5) Vacuum hose from "E" port of throttle body
Y P1855?
563° ENGINE — ENGINE MECHANICAL
(f) Install the accelerator cable bracket and air intake
connector with the 4 bolts.
. -5;-'?§.*.5?<§§
,—:%!l e§l9/
%//./ \ _
P1825‘!
14. REINSTALL VENTILATION CASE

I
,
(a) Install the ventilation case to the bracket.
(b) Connect the No.3 water bypass hose (for PCV hose) to
the ventilation case.
' "@»':.(?*’~'i
‘.4 ’;
(c) Connect the No.2 PCV hose to the cylinder head
cover.
15. RECONNECT NO.1 PCV HOSE
-
..
“K 16. RECONNECT HlGH—TENSlON CORDS TO SPARK

PLUGS
4 (a) Connect the 4 high—tension cords to the spark plugs.
\“.5 ~
/%*lQ/ ‘N4 (b) Install the high—tension cord clamp with the 3 bolts.
?‘»2i>%
’ .'7
. #14
/../\§g5j
,,9(__
.-3.‘!
0&
.
Q
5:- Install the cool air inlet with the 2 bolts.
~ A
3?
/J‘
a -~ "/
\
/I \ Pram
\_, 18 REINSTALL INTERCOOLER
@
Connect the intercooler to the turbocharger and
40 intake air connector, and install the intercooler with
the 3 bolts.
/‘E
7 iQ‘7*
?..t<@* /; ‘K
REFILL INTERCOOLER WITH COOLANT

e'?.‘*-‘3.3 39
£1’
(See page EG-9?)

START ENGINE AND CHECK FOR LEAKS
IGHZ-OZ
IGNITION TIMING INSPECTION AND

ADJUSTMENT
WARM UP ENGINE
Allow the engine to warm up to normal operating
temperature.
Tachometer CONNECT TACHOMETER AND TIMING LIGHT TO

_ ENGINE
'
[DEE _
Connect the tester probe of a tachometer to terminal
lG@ of the check connector.
I ~\@i"V NOTICE:
O Never allow the tachometer terminal to touch
@§’)
Check Connector
be. Y PI86l3 I
ground es it could result in damage to the igniter
end/or ignition coil.
As some techometers are not compatible with this
ignition system, we recommend that you confirm
the compatibility of your unit before use.
EG-32
ADJUST IGNITION TIMING

I-II 1'2 TE‘ Ia) Using SST, connect terminals TE1 and E1 of the check
II =:i E1 I COHHGCTOF e
Elm \§i \ 4)‘ SST ssr 09843-18020
$3@/I/I/asQ
Qi
V ‘E I‘ '1
§.¢"/
/
i‘
'I_ I
HINT: After engine rpm is kept at 1,000 - 1,300 rpm
for 5 seconds, check that it returns to idle speed.
Check Connector
Y PIBEI2
3/tv‘ I /
Using a timing light, check the ignition timing.
\ _. ,\ (H N?‘ (bi lgnitiontiminq:
/1.<®'
10° BTDC @ idle
I?7% c L (Transmission in neutral position)
N ‘!’T;;,__. ’t
r’ /,‘\
(I
I k F
/4,
Y P18533
'?is
~» (c) Loosen the 2 bolts, and adjust by turning the distribu-
10!.
Q7 fiv
Tighten the 2 bolts. and recheck the ignition timing.
‘- \-
E4;
..../Il '/ )k\
'/ Y 1718526
/
d
\\§‘ 4 *
g
I
" K
// — SST
(e) Remove the SST from the check connector.
SST 09843-18020
W Check Connector
Y M8611
*‘\_/ 9‘ A ‘ 4. CHECK |GNITIoN TIMING AGAIN

:3 ‘ i Ignition timing:
\
_ _ @ v O7\"/1. ®®
. g, i ‘F
,K 1 22° eroc @ idle
. . . ..
(Transmission In neutral position)
\ \/‘um
-fi.)!_1~.,»
§.*2;§'/iv by (r and -
22°- ~- ‘
- /
5. DISCONNECT TACHOMETER AND TIMING LIGHT

HINT ' The timing mark moves in a range between 7°
o1.}1,¢‘i.'/' ¢ 3“ FROM ENGINE

YPl355O
EG-33
_ ENGINE — ENGINE MECHANICAL
IDLE SPEED INSPECTION '°‘"i"

1. INITIAL CONDITIONS
(H) Engine at normal operating temperature
(bl Air cleaner installed
(cl All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(B) All vacuum lines properly connected
(fl EFI system wiring connectors fully plugged
(9) Ignition timing set correctly
(h) Transmission in neutral position
2. CONNECT TACHOMETER
(See step 2 on page EG—31)
Z500 rpm 90 seconds 3. INSPECT IDLE SPEED

(a) Race the engine at 2,500 rpm for approx. 90 seconds.
R PM
Tachometer
EC0137 EMB144
men
(b) Check the idle speed.

Idle speed:
w/ Daytime running light system
750 1' 50 rpm
___..-oi w/o Daytime running light system
700 i 50 rpm
ORPM
If the idle speed is not as specified, check the ISC
Tachometer valve.
P02463 Z9997?
4. DISCONNECT TACHOMETER
“'34 ENGINE — ENGINE MECHANICAL
IDLE CO/HC CHECK
HINT: This check is used only to determine whether or
not the idle CO/HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(bl Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
(f) EFI system wiring connectors fully plugged
(g) Ignition timing set correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
2,500 rpm
180 Seconds
_ 3. RACE ENGINE AT 2.500 RPM FOR APPROX. 180
SECONDS
Tachometer
ECOIB7 EM8144 ZCIIJ47’
4. INSERT CO/HC METER TESTING PROBE AT LEAST

K CO/HC Meter
/iF\ 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
as TI
5. CHECK CO/HC CONCENTRATION AT IDLE
Idle CO concentration:
0 — 0.5 96
Idle HC concentration:
§ Applicable local regulation
\\_// I,sf’~:
Y P185213
ENGINE - ENGINE MECHANICAL EG'35
Troubleshooting
If the CO/HC concentration does not comply with
regulations. perform troubleshooting in the order
given below.
(a) Check oxygen sensor operation.
(See Pub. No. RM396E on page EG--286)
(b) See the table below for possible causes, and then §EI:I:' f, ._ 5;-
.-T
inspect and correct the applicable causes if neces-
sary.
HC CO Symptom 39 "888
High Normal Rough idle 1. Faulty ignitions:
0 Incorrect timing
0 Fouled, shorted or improperly gapped plugs ;
e Open or crossed highstension cords
0 Cracked distributor cap
2. Incorrect valve clearance
3. Leaky EGR valve
4. Leaky intake and exhaust valves
5. Leaky cylinder
High Low \ Rough idle 1. Vacuum leaks:

I (Fluctuating HC reading) e PCV hose
‘ O EGR valve
e Intake manifold
e Throttle body
1 e ISC valve
e Brake booster line
2. Lean mixture causing misfire
High High Rough Idle 1. Restricted air filter
(Black smoke from exhaust) 2. Faulty EFI systems:
I 0 Faulty pressure regulator
e Clogged fuel return line
I O Defective water temp. sensor
I e Faulty ECU
e Faulty injector
I O Faulty throttle position sensor
e Faulty vacuum sensor
\-O5545
EG'3° ENGINE - ENGINE MECHANICAL
COM PRESSIONI CHECK
HINT: If there is lack of power, excessive oil consump-
tion or poor fuel economy, measure the compression
pressure.
1. WARM UP AND STOP ENGINE

its:
__
it . - .3Q Allow the engine to warm up to normal operating
.-
J’ 3"‘
temperature.
\-> . (See page EG—-97)
. 3. REMOVE INTERCOOLER
@ I ‘~11.-\ (a) Remove the 3 bolts.
(b) Disconnect the intercooler from the turbocharger and
“ \/ intake air connector, and remove the intercooler and
E,
I55’
‘_ air hose.
3.3.3;
\ W
/
Eh.‘K
‘QT’!
Y P182132

Remove the 2 bolts and cool air inlet
cui-
"\
/ PIQIQ
5. DISCONNECT DISTRIBUTOR CONNECTOR
( gr.
\a --*<\’ *'‘eI’‘(Q
/Q.
4|
6. DISCONNECT HlGH—TENSlON CORDS FROM

SPARK PLUGS
\ (a) Remove the 3 bolts, and disconnect the high—tension
cord clamp from the cylinder head cover
I
->1
74
\ \ **-I-> ‘H Qj’
Y" ' YPIE66

EG-37
,4» lb) Disconnect the high —tension cords at the rubber

CORRECT boot. Do not pull on the high—tension cords.
vs S3 WRONG
'\
conductor inside.
u * __,
(I
/../M Q.
__ €-4-» \€
.l\ Y Pl$?2
REMOVE SPARK PLUGS

Using SST, remove the 4 spark plugs.
'\
‘_~_?é( SST 09155-16100
2 mi IQ.)as :-/ii‘
I
1918519
CHECK CYLINDER COMPRESSION PRESSURE

/” -. ° “."'J5
1 Q 2.3 Insert a compression gauge into the spark plug hole.
Fully open the throttle.
While cranking the engine. measure the compression
\ e. I
pressure.
HINT: Always use a fully charged battery to obtain
it engine speed of 250 rpm or more.
. ...:\
Compression id) Repeat steps Ia) through (c) for each cylinder.
Gauge \/ Y P1854] NOTICE: This measurement must be done in as short a
time es possible.
Compression pressure:
1.130 kPe (11.5 kgf/cm‘. 164 psi) or more
Minimum pressure:
880 kPe (9.0 kgf/cm’. 128 psi)
Difference between each cylinder:
100 kPe (1.0 kgf/cm’. ‘I4 psi) or less
If the cylinder compression in one or more cylinders is
low, pour a small amount of engine oil into the cylin-
der through the spark plug hole and repeat steps (a)
through (c) for cylinders with low compression.
I If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
0 If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
EG-38
9. REINSTALL SPARK PLUGS

12: . '\ Using SST, install the 4 spark plugs.
:-I Q SST 09155 16100
v '& Torque: 18 N-m (180 kgf-cm. 13 ft-Ibf)
‘ 0 QJQ /K
SST 0
Y P1851‘?
7 10. RECONNECT HlGH—TENSlON CORDS TO SPARK

PLUGS
N/1
¢ (a) Connect the 4 high—tension cords to the spark plugs.
(b) Install the high—tension cord clamp with the 3 bolts.
-.
“is:./
11. RECONNECT DISTRIBUTOR CONNECTOR
7.;
4
t- "Q5 I $5 -__.-F
'6
la it. §\
Install the cool air inlet with the 2 bolts.
6* .
yr?
R AX.
13. REINSTALL INTERCOOLER
=‘
intake air connector, and install the intercooler with
the 3 bolts.
14. FILL WITH INTERCOOLER COOLANT
(See page EG—97)
/g It
55' lair 15. START ENGINE AND CHECK FOR LEAKS
iilg
’
/ Y P182112
CYLINDER HEAD _m_

COMPONENTS FOR REMOVAL AND
INSTALLATION
intercooler 9 0'Ri"9
Distributor
//- III‘
_R __ '5'-="/fill (with High-Tension Cord) 1
U W. &
4: X __7v.
E’
.--kt
e
e-’
I‘;
Y’...\\
|
e . Gasket Water Out et
e
_\f Pm“ ‘D \ Water Bypass Pipe
‘Av “E4-its
4 ~ 0 0-nine I .9 i
Com Air |n|et - I sh.’

s» -' ‘P Turbocharger
Heat Insulator
’ O Gasket
O Gasket '
2 - Exhaust
IQ, .0
_a O . Manifold
(W
2%
Oxygen Sense
Heat Insulator
. '
. Gasketi "'
<==='~*
° ' . 6......
it.//1
»¢
(ii..=-pi
. j \ *j._ . *“'“°°“a'Q°'
Turbine I :I \\‘)i"'i
O S n r Outlet Elbow ' ' ‘ " ‘ ~-\
xygen e so ' _~‘-‘ . g ’ -01> q Turbocharger
6 Gasket * ~; Q o\ Stay
Y .I- .\
Turbine Outlet Elbow _ '~ _ P Q "9
Heat Insulator w __._ é
’4+;G
‘.-
RH Front Engine Hanger , O Gasket

I J
Alternator Bracket @ y \/
, e Gasket
‘I
I
W~ W .
I“-.> /l
../' .~ ,. I .:- '-I» 59l 43)
gr I-ii;-‘
- ~' "1-' I RH Catalytic
; ' g;_ Converter Stay
A 1‘ - '
Ground Strap '0 ' Q I 59; .5.§
§
Engine Wire Protector ‘ | u _
Ahemamr 1""""s_,%) ,,, \ g--J
______ Catalytic Converter
iii .
N-m (kgficm, ft-lbf) : Specified torque L I-H Catai‘/tic C°'“'°"°' Sta)!

6 Non-reusable part M8368
EG'4° ENGINE — ENGINE MECHANICAL
No.2 Air Tube and Ventilation
Case Assembly
sit \
Intake Manifold
St av
/" I
,_, ‘Q’
I L-,_
'~'ls
EGR Vacuum
M°d“|3'°r wd
VSV
”
ff No.1 All’ Tube
_ \\ '11 .-
,'' » EGR Valve
and pipe
G, Q Intake Manifold
‘ _%
4 ? Q
Q ,
81% O Gasket O Gasket
Fifi) Throttle Body $9 Gasket
. Q2 » ,'\
Q K P
Air / I / \ \ \ ‘ ‘
V P 'i\\l\\
Q \\“\‘. °‘) f L ‘x \
acuum ipe 0 v l’ r
t. $.¢‘*> T0?’
Q. 5
\'/
/Jul
, '9"-""\
\
' 3%)’ C7 l Q \\/ -__ Q
gW *~, ~~ 0 ~ ‘R
3?"
\\
\_ $ 0I
\
\\
\\_/$§__
\5.?
Engine Wire
.."QQOQ4
IIIII
0
‘K
‘ @
C 0
W
O Gasket
I
<’
///Q
Ir /’ <\ \
5 ./
s
Intake Air
Connector
l“% VSV for \\ .K All’ \%

1 $5,.‘ Turbocharging Pressure '\ | Connector
"-4 _ Stay Accelerator
\\\\\\\\‘\m(('f_%’? 1 \\ Cable Bracket
\
~
Mr .\“ 9\°
I
E‘ L \\
Gasketi@
~, Spacer-w
|
>.
\ 0V" A
E 1)
Fuel Return Hose I ,

1.‘
\
O Gasket
/P‘) Fuel Inlet Hose A

/-ext
\
-' P 4
'‘ ‘G Delivery Pipe Assembly
Spacer ‘
@i—————0 Insulator
T
./A
Nrm (kgf-cm. ft-lbf) : Specified torque
O Non-reusable part P181969
Spark Plug
~=- 9i—Seal Washer
No.4 Timing Belt Cover ' Cy|mde|- Head Cover
<\\\l ‘\\>
4
_ _ @———Valve Lifter
3 " » ‘ o———Adius:ing Shim
a» ’ ' \ h
L ' ‘ ' fl}~————Keeper
|\*l\
' . Gasket @—-iSpring Retainer
A
_ Intake Camshaft Valve Spring
Camshaft Bearing Cap
O Camshaft Oil Seal
Intake Camshaft
-
@§
19 "9° 1“
,,ni\““
‘V
_ l ‘N
T
§—i-Spring Seat
O Valve Guide
Bushing
Valve
T~»
>-'._
iiming Pulley /- I
. V _ r x Exhaust Camshaft LH Engine
K k P‘ .- ’ '*/ l
not In .3’,
0-
. - é l_ \
Exhaust Camshaft Timing Pulley l
‘ _
H3"99\'
llti
in-~\\‘ ‘ _ \\‘_.? _‘_- Seepage EG-55
’ ' Plate Washer \ ;std4_?|50g638l
at /QW
'-181430.35) _ I1 urn °
Cylinder Head
N0.3‘l'|ming BeltCover _ " '. '9"
Plate Washer _
‘D ; __ ' ' , ressure
Switch
No.1 Idler Pulley ‘
*
Gasket
and ,--'
- -mi,-'
A C 6\ " E, , 0 Cylinder
* A , 4. Head
l ' \ Gasket
la I ‘liming Belt
/ _, ' 11‘
”_,’/ ~“ <"' r 4
-‘\ _.= E’ I/'

I '
ea” e I
No.2 ‘liming Belt Cover
i _,5
Timing Belt Tensioner
Nm (kgf-cm, ft-lbfl : Specified torque

Q Non-reusable part
at
*
Precoated part
For use with SST
(‘Q0\ wi- H8285
EG-42
CYLINDER HEAD REMOVAL

(See Components for Removal and Installation)
1. DRAIN ENGINE COOLANT
2. REMOVE INTERCOOLER
(See steps 3 and 5 on page EG—88)
3. REMOVE DISTRIBUTOR
kg
O (a) Disconnect the distributor connector.
i
/‘--..
I
Ax. \\\'=‘-.w‘§-\ M8286
(b) Remove the 2 bolts and cool air inlet.

li
/<3’ t
,5
‘~ PIBQIQ
4 Q‘ ~» Q lc) Remove the 3 bolts, and disconnect the high—tension
/
I Q1 cord clamp from the cylinder head cover.
Y
t_/J
Q\
\\\)
£O)<\ I J
(d) Disconnect the high —tension cords at the rubber

§ / //mi
(\cORHECT '% I)oot. o o not p ull on th e hi g h—- tension
' co rd s.
__ F\ NOTICE: Pulling on or bending the cords may damage the
\ A 9 ~ Q go
f t WRONG- conductor .inside
.
R t /X I
/
< \ ‘A, PI8287
EG-43
(e) Remove the 2 bolts, and pull out the distributor.

(f) Remove the O—ring from the distributor housing.
< \
J {,» ;-..-.~
J \'-.-=5 '<>:
H3244
4. REMOVE ALTERNATOR
I4)
ix.‘ :1 (1)
(a) Disconnect the following wires and connectors:
(1) Alternator wire
<3» iii (2) Alternator connector
Iii ‘Iii’ (3) Oxygen sensor connector
(4) Oxygen sensor wire from wire clamp
k (5) Oxygen sensor connector from wire bracket
(21 *3"
e\ PI8220
.. 1/ .‘ (b) Remove the 2 bolts and ground strap, and disconnect

Ground ,¢ ‘-._ the engine wire protector from the brackets.
S trap é ...,
\-fl’
\\\\\
Q , H " -“*1 QS%%
§.L “‘
>’/ P1822]
K (c) Remove the 2 bolts and alternator.
gfi \\
t4.:1/ -Raga’
t
(@
\ \ \ %
I " V I’ Pm
5 REMOVE RH FRONT ENGINE HANGER AND
~. /"i ALTERNATOR BRACKET
Q, Remove the 3 bolts. engine hanger and alternator
' “ bracket.
Q-
7
é.~\
\ /
H8245
EG-44
6. REMOVE LH AND RH CATALYTIC CONVERTER

C,
STAYS
(a) Remove the 3 bolts and LH converter stay.
.1?‘
/\=:{i./ ‘V P1824?
(b) Remove the 3 bolts and RH converter stay.

“Q
2<\‘3,
./Va»
\‘.//
H8246
AW ég/A) \ 7. REMOVE CATALYTIC CONVERTER

.> Remove the 3 bolts, 2 nuts, catalytic converter and
gasket.
_-1
. REMOVE TURBOCHARGER
L11
""~ 8
'
EM
.\' (See steps 6 to 14 on pages EG—88 to 90)
6'>-'.~.‘
5
PI8248
} H‘) vi L 9. REMOVE EXHAUST

Remove the MANIFOLD
8 nuts. exhaust manifold and gasket.
4 » " “‘\ W Q
/ ""' /.
(1) 10. REMOVE WATER OUTLET
( ) . . :
,9? . l\fi
/
//~
I
'§
(3)
a Dlsconnec t the follow |n g conne ct or s
(1) Oll' pressure swltch
' connector
(2) Water temperature sensor connector
(3) Water temperature sender gauge connector
\ ‘$3 ‘
P16250
EG-45
(1) \‘ (b) Disconnect the following hoses from the water outlet:
(1) ISC water bypass hose
\
(2) 2 vacuum hoses
0,
~n @*\:'/ /v
es.\ /” N
I
/-\
\/ ,!. "'r>"’g\°
Pl8251
‘ (C) Remove the 3 nuts.

)3
\ /I ’/ (d) Disconnect the water bypass hose from the water
outlet, and remove the water outlet and gasket.
éex»-*s
I€d\3» I"
Q
Water Bypass Hose
P18252
REMOVE WATER BYPASS PIPE

\\#-~/ Disconnect the following hoses from the water
bypass pipe:
(1) ISC water bypass hose
/‘~2-ll?
(2) Air hose from turbocharging pressure VSV
s3/1.
~».; ~¢ Pl8253
--:1 (b) Remove the 2 bolts and 2 nuts.

\_., < %
ss» ~»
1~;’[
:’nlegnf‘
'35 ._=
~‘|l_
M8288
,~ Gasket > R A (c) Disconnect the water bypass pipe and hose from the
\ J ‘W ,~ water pump cover and oil cooler. and remove the
.- , O-Ring water bypass pipe.
‘Tl id) Remove the gasket and O—ring.
9 yd \
\/
e1///
J’/@);§; L~‘7 )5
1
K
\o ‘ .V
Z?“
O
P1828?
(3) 12. REMOVE NO.2 AIR TUBE AND VENTILATION CASE
<1!
ASSEMBLY
i
e‘ "\§ \
‘,
,.\
;.~_:»~ (a) Disconnect the following hoses:
(1) PCV hose from cylinder head cover
(2) PCV hose from ventilation case
. \ '“ (3) Vacuum hose from intake manifold
. 5-'~‘§‘\l " M’ ( 4A'h
) 1r ose f rom N1'tb
o. a|r u e
(1) (2)
P182541
\-__A\ (b) Remove the bolt, No.2 air tube and ventilation case
Q {N assembly.
M. s3;o Pi?
-6
3
l
\
c: M2‘ k '2'.
N M8255
_ (2) I 13. REMOVE EGR VACUUM MODULATOR AND VSV

ASSEMBLY
... Disconnect the following connector and hoses:
" (1) VSV connector for EGR
" (2) Vacuum hose from throttle body
(3) Vacuum hose from EGR valve
‘,.
>/Qt qét mes
(b)
(4) EGR hose from EGR valve
Remove the 2 bolts, EGR vacuum modulator and VSV

AT Q \ 3
assembly.
\"<> \t-$1;
~"~.A ~
./~\ "\ v' ~e»I
\
g.
14. REMOVE EGR VALVE AND PIPE

%
11"’ Remove the 4 bolts, EGR valve and pipe assembly and
\ ~ ; 2 gaskets.
\
< if;
X t A
/ii‘)
E/ I 6 mm
_.' ‘ ‘ Hexa on
f ‘ ‘ Wrengh
I \ M8258
EG-47
ENGINE — ENGINE MECHANICAL _

(a) Remove the 4 bolts, accelerator cable bracket and
4
(P/
( 1-’%\
/
(4) (bi Disconnect the following hoses and connectors:
(1) Vacuum hose from throttle body
.~.\ ~<e,;,=»,._. =
‘ " 3-
:é "51":
(2) Vacuum hose from throttle opener
‘les- i (3) Throttle position sensor connector

? ’ (3)
II.’ rs./
\Q'
(5) 2 ISC water bypass hoses from No.1 air tube

(7) PCV hose from cylinder head
-PM <5,
(1) R‘ J
PIQEU
(c) Remove the 6 bolts. air connector stay, throttle body

F »— ~‘?~ ’ ~11
and hose assembly and gasket.
(d) Remove the gasket and spacer.
*
1:1‘: _
/* '3"-~
‘ ‘ '
-1 -
i
Q)
// ( P1826l
K 16. REMOVE NO.1 AIR TUBE

(1) \ ‘S’ (a) Disconnect the following hoses:
(1) Air hose from intake manifold
(2) 2 PS air hoses from air tube
(3) Air hose from air tube
<3) \ Q
&:\ r\ P1822?!
M i 4
' \, ' (b) Remove the 3 bolts and No.1 air tube.
’_\ /
W '
‘-'4
4-» . I
‘L 17. REMOVE INTAKE MANIFOLD STAYS

I K hx X C Remove the 2 bolts and manifold stay. Remove the 2
‘(D I‘)
K
manifold stays.
' '
» In
QQ ./‘
‘r2 av’ (
/\ L ¥ Elf“ 18225
l DISCONNECT HOSES
W\/
HINT (On vehicle): Disconnect the following hoses:
(1) Brake booster vacuum hose from intake manifold
(2) Vacuum hose from vacuum pipe
'QQ@.<~
(ll
P122262
13> (3) Disconnect the following hoses:

(1) PCV hose from PCV valve
(2) Vacuum sensing hose from fuel pressure regula-
/X& ’ <1) tor
(3) Vacuum hose from gas filter
\(@, In lb) Remove the bolt and vacuum pipe.
(2) ‘ /
DISCONNECT ENGINE WIRE
‘ \ ‘Kit
EV
Disconnect the following connectors and ground
cable:
(1) VSV connector for turbocharging pressure
V‘ (2) Knock sensor connector
if~@
\_4“
|I.
Ig’é'
C |
(3) Ground cable
Ki:Q/:11’
(1) (2) rv M8221
EG-49
(4) Intake air temperature sensor connector
Olk .-2 - _V I
(5) 4 injector connectors
1%
I -14 ;_J
5
1
.7 Q?‘
'/
. "'
E 34%’
/"wt H8253
(b) Remove the 2 bolts, and disconnect the engine wire

protector from the intake manifold.
I. "\\. is‘!
I\
:\'\\\
‘/C/\/(;)l,/£1” ‘* »/is P1826-4
. * _ (c) Disconnect the engine wire protector from the 2 mou-

D'5°°""°°l Disconnect . . .
_
t e \\ nting bolts of the No.2 timing belt cover.
as “C
~." M8265
“ea
Fuel Inlet Hose~ Z T 20. DISCONNECT FUEL INLET HOSE
Remove the union bolt and 2 gaskets, and disconnect
the inlet hose from the delivery pipe.
;>.-;i0Q
~f}&i§
/\% 21. DISCONNECT FUEL RETURN HOSE FROM RETURN
PIPE
A
Fuel Return Hose mm
22. REMOVE VSV FOR TURBOCHARGING PRESSURE
fliii’;
Remove the 2 bolts and VSV.
ifiite a\°©*”"‘
EG-5° ENGINE — ENGINE MECHANICAL
t
23. REMOVE INTAKE MANIFOLD
¢ \\ -.0‘ I Remove the 4 bolts. 3 nuts, intake manifold and
. »§ 9 gasket
.<
2 ‘rt
,-~--~ .A( /.-J iv’!
9
(iii?/~I‘f’f 5%
‘v
(“'3
In
Z
.
A /av
\
.3(‘
..fi"“"§@
I’,-,1,
24. REMOVE DELIVERY PIPE ASSEMBLY
(a) Remove the 3 bolts and delivery pipe assembly
N
(b) Remove the 4 insulators from the delivery pipe
Insulator
H8230
/ (0) Remove the 3 spacers from the cylinder head.
8/ L)/
Q ‘
/9»
.
\\ /r
\ .1. Q X Spacer P18266
25. REMOVE LH ENGINE HANGER

I.I'I/gl/QIFIB HBLIPSFI’
Remove the 3 bolts and engine hanger.
. \ I 26. REMOVE OIL PRESSURE SWITCH
C
. ,._\ .;/.> v/2
5...... §.;>/
‘ ‘))/ PI3267
EG-51
27. REMOVE SPARK PLUGS

Using SST, remove the 4 spark plugs.
sst sst 09155-16100
W Ccx @\ mm ,1.“
~' ‘ \, 28. DISCONNECT TIMING BELT FROM CAMSHAFT
/~\ TIMING PULLEYS

(See Pub.No.RM396E, steps 4 to 6 on pages EG—5O
K \ to 51)
5' .
'
W TZ\\
x
29. REMOVE EXHAUST CAMSHAFT TIMING PULLEY
(a) Using SST. loosen the pulley bolt.
SST 09960-10010 (09962—01000, 09963-01000)
(b) Remove the bolt, timing pulley and knock pin.
"“'9.
Y:
\-gr,
: A' 3“\\_PISZQ
30. REMOVE NO.1 IDLER PULLEY

(a) Turn the No.1 idler pulley bolt to obtain the specified
F lcrum 9 torque or less, and remove the 3.0 mm hexagon
. I Lgngth
be ‘J wrench.
'-©J‘:’
.\/ a \ 23.0mm
Hexagon
Torque:
69 N-m (700 kgf-cm. 51 ft-lbf)
_..
_ Wrench
%i1iI"‘”/"\ 48 N-m (490 kgf-cm. 35 ft-lbf) for SST
HINT (On vehicle):
sst 5' ‘T ’ —¢=1"
°Remove V 0 Use SST.
Pl6?28
SST 09249—6301 0
___-
,,- I Use a torque wrench with a fulcrum length of
340 mm (13.39 in.).
%?s _
..*
/@} \F
“VI U (bl Remove the pivot bolt, pulley and plate washer.
*3 P1692‘!
EG'52 ENGINE - ENGINE MECHANICAL
31. REMOVE TIMING BELT TENSIONER
ks) Remove the 2 bolts and tensioner.
I1
J":
U1» Q K/em
32. REMOVE NO.3 TIMING BELT COVER
Remove the 5 bolts and timing belt cover.
\~l.)
2% 91'\
9
i P1824)
33. REMOVE NO.4 TIMING BELT COVER

I-an-1 3/ Remove the 3 bolts and timing belt cover.
)\\ ,
\.\(Z
IQ5 .9 K’
£32 i@li\sf‘)
.5
,.
5"’
\ Q“
<3/i
ia»
p
NOTICE:
0 Be careful not to drop anything inside the timing
\
/Av belt cover.
\\fi@ $0 O Do not allow the belt to come into contact with oil.
) _r" water or dust.
ii’ H6725
34. REMOVE CYLINDER HEAD COVER

Remove the 10 bolts, seal washers, cylinder head
‘-
cover and 2 gaskets.
,1in
/I
.
"/*:“*~?i.,x;?_\.
Pl82?O
ENGINE — ENGINE MECHANICAL “'53
35. REMOVE CAMSHAFTS
5
3 .__, 6 Uniformly loosen and remove the IO bearing cap bolts
_ --
1 -919 '- ’ ~ -_ 5,_ .\
3_- ‘- in several passes.
, in the
_ sequence shown, and remove
‘ ._ ,’ 7 the 5 bearing caps, oil seal and camshaft. Remove the
9 -,__ 3 §,_(§ intake and exhaust camshafts.
K
i»t ~)\
'3
">~< %"
W
§;i§é2i:i
P1823)
36. REMOVE CYLINDER HEAD

(a) Using SST, uniformly loosen and remove the 10 cylin-
der head bolts in several passes. in the sequence
shown.
331' - SST 09043-38100
HINT: Cylinder head warpae or cracking could result
from removing in the incorrect order.
3Y°gL%§)>UO'\
'§‘-:1!-"ill
»>_ii 3’)
"‘ O
O-I4.
terse-iaia
"'?#¥ O0
‘ai2'.‘15$
‘Q IF SO
1°II
ii? pqQdifiii
"Q LI.-
_g) ’ 001%
ll I
P‘l8Z7I
918272 Z131"!!!
(b) Lift the cylinder head from the dowels on the cylinder
(?\,\ block. and place the cylinder head on wooden blocks
—\/ on a bench.
»\ /,V f‘~'
_l,j
HINT: If the cylinder head is off, pry between the
K \ xk cylinder head and cylinder block with a screwdriver.
\ 7 > Qinsen NOTICE: Be careful not to damage the contact surfaces
X F f/ @ of the cylinder head and cylinder block.
Pry
PISYW
56'“ ENGINE — ENGINE MECHANICAL
CYLINDER HEAD COMPONENTS
INSPECTION AND REPAIR
1. INSPECT CAMSHAFTS
Inspect cam lobes
§" -iillq ,_ Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
EM 201 1 41.510 — 41.610 mm (L6342 - 1.6382 in.)
Exhaust
41.100 — 41.200 mm (1.6181 -- 1.6220 in.)
Minimum cam lobe height:
Intake
41.40 mm (1.6299 in.)
Exhaust
41.00 mm (1.61-$2 in.)
If the cam lobe height is less than minimum, replace
the camshaft.
2. INSPECT MANIFOLDS
Intake Manifold:
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder head for
I warpage.
Maximum warpage:
0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the man-
P182'-I3 ifold.
Exhaust Manifold:
Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head for war-
Z"___ O , I_L\ Q 4‘ page.
* I-~-~< Meximum warpage:
° 1.00 mm (0.0394 in.)
If warpage is greater than maximum. replace the man-
ifold.
PIB274
EG-55
CYLINDER HEAD INSTALLATION '""'°'

;=1|"'f/'52 (See Components for Removal and Installation)
1. INSTALL CYLINDER HEAD
. ?A__.. I ‘7 A. Place cylinder head on cylinder block
@ (a) Place a new cylinder head gasket in position on the
‘-2- (W I cylinder block.
' / NOTICE: Be careful of the installation direction. 2.:/"\
H8275 (b) Place the cylinder head in position on the cylinder
head gasket.
B. Install cylinder head bolts
HINT:
0 The cylinder head bolts are tightened in 2 pro-
gressive steps (steps (b) and (d)).
ssr H I If any cylinder head bolt is broken or deformed,
replace it.
P“ - (a) Apply a light coat of engine oil on the threads and
i 1
(b)
under the heads of the cylinder head bolts.
Install and uniformly tighten the 10 cylinder head
bolts and plate washers in several passes, in the se-
quence shown.
. r-\J\ r\ FL!“' A Torque: 49 N-m (500 kgf-cm. 36 ft-lbf)
If any one of the cylinder head bolts does not meet the
Y5eY§eYe§Y|E§ torque specification, replace the cylinder head bolt.
O Bio
O0 O0
-2’)
-77-
.- ' A
,_1O
° ll
I
I F
J) e_J>Qjg ' .3’:Q
P18276
H5272 mm
Painted Mark (c) Mark the front of the cylinder head bolt head with
paint.
'3
v
Front
4”‘ J
if"-if
2
‘Ti’? | :0
§\ /’ PI82?T
(d) Retighten the cylinder head bolts 90° in the numerical

90°; order shown.
Painted ‘ (e) Check that the painted mark is now at a 90° angle to
I_ \ .
.2
Mark the front.
. \ -4*‘
‘ ’_)"
5I30
\\ / Pl82?8
EG'5° ENGINE - ENGINE MECHANICAL
INSTALL CAMSHAFTS
Outward Sm
Place the 2 camshafts on the cylinder head with the
‘ ¢@ 1
~. -—> YAall‘
“‘ No.1 cam lobes facing outward as shown.
%§\ ,.*~ir“>‘1‘-‘-/“In T“ - , *1")\ HINT: Intake camshaft have an slit; exhaust camshaft
an’-;._§Y_gP\’ ',",‘_é*1\)\\\‘/ do not.
.
Sow
it
' Outward
P1823?
Apply seal packing to the No.1 bearing cap as shown

in the illustration.
Seal Packing Seal packing:
EM2252
Install the bearing caps in their proper locations.

HINT: Each bearing cap has a number and front mark.
@@@.-;,.
V3 at
~qra‘\‘-
t ;- 1--.8?‘
/yj,/K.
lg .\
/3-?*“@I§@
/
it
Front Ft
\
;@
“Pi P182313
6 (d) Apply a light coat of engine oil on the threads and

under the heads of the bearing cap bolts.
5
o 4 -
1...-__‘?_‘~Z~' 6.,_“
8 .'-"
'_, I
(B) Install and uniformly tighten the 10 bearing cap bolts
__ 10 -_.-v on one side in several passes, in the sequence shown.
i Torque: 19 N-m (190 kgf-cm. 14 ft-lbf)
‘ D?!
’- ' KP’
P1823)
\
W
a.
\'°\
Qv “iigéw K) ZI30?0
CHECK AND ADJUST VALVE CLEARANCE

(See page EG-11)
Turn the camshaft and position the cam lobe upward.
and check and adjust the valve clearance.
Intake
0.15 — 0.25 mm (0.008 — 0.010 in.)
Exhaust
0.28 -— 0.38 mm (0.011 -— 0.015 in.)
EG-57
4. INSTALL CAMSHAFT OIL SEALS

(a) Apply MP grease to a new oil seal lip.
MP Grease
//vs. _/
...-. -. ‘\'¢ ,
\ ...........,_:.E:.
EMO050
(b) Using SST, tap in the 2 camshaft oil seals.

5 SST 09223-4601 I
/ Lk\ 't/
6/?‘
PI&34
‘ 5. INSTALL CYLINDER HEAD COVER

(a) Turn the hexagon head portion of the camshaft. align
the groove of the camshaft with the dot mark of the
N No.1 camshaft bearing cap.
\
C‘ be
/
QC/[ PIQGS
(b) Apply seal packing to the cylinder head as shown in

. . . . . the illustration
.)t1||:i|igi|-||§i|iia||igi|iirii||i_i|i| |i 3,,“ ,,,ck,,,g
Qp fcxc C Pm No. oaaza-oooeo or equivalent
(E)):||igi|_|igiliililligiliie|i|i§i||i
I-I
: Seal Packing
P1827‘?
(c) Install the 2 gaskets to the head cover.

I Gasket
14/Q‘) / '7‘
if-
$1?
/I
\I
P182817
EG'58 ENGINE - ENGINE MECHANICAL
(d) Install the head cover with the 10 seal washers and
or bolts. Uniformly tighten the bolts in several passes.
Q it l>. \>1'16 . K
.) Torque: 6.0 N-m (61 kgf-cm. 53 in.-Ibf)
A A-,
Q’
~"-.‘ T’. A HINT: Each bolt length is indicated in the illustration.
5% .-*2 . ’t Bolt length:
@\
Z’
/
A: 25 mm (0.98 in.)
B: 50 mm (1.97 in.)
<.
P18270 g\¢ /‘Q“)t\ \ \
2131165
41.. 6. INSTALL NO.4 TIMING BELT COVER

Torque: 8.0 N-m (82 kgf-cm. 71 in.-Ibf)
:1»@ ./)0
(“"‘\
~"~'>Q5);
*1
.0 )
‘
\
P1826‘)
7. INSTALL NO.3 TIMING BELT COVER

O<\ O/v Torque: 8.0 N-m (82 kgf-cm. 71 in.-Ibf)
\ \O\ r If g
/t c ""\ \
P182411
8. SET TIMING BELT TENSIONER

(a) Using a press, slowly press in the push rod using 981
® — 9.807 N (100 — 1,000 kgf. 220 — 2,205 Ibf) of
-/§\ force.
1.27 (b) Align the holes of the push rod and housing, pass a
Hexagon 1.27 mm hexagon wrench through the holes to keep
Wrench
the setting position of the push rod.
(c) Release the press.
/ mam
r 91 INSTALL TIMING BELT TENSIONER

@ \ Install the tensioner with the 2 bolts.
?@&~ X-<’> Torque: 21 N-m (210 kgf-cm. 15 ft-Ibf)
/
1/
IE0U
(lit 10: L...
ENGIN E — ENGINE MECHANICAL EG'59
10. INSTALL NO.1 IDLER PULLEY

(a) Apply adhesive to 2 or 3 threads of the pivot bolt.
Adhesive:
Part No. 08833-00080. THREE BOND 1344.
LOCTITE 242 or equivalent
PI6339
V; U;-= Install the plate washer and pulley with the pivot bolt.
\ "\
@;!
Torque: 52 N-m (530 kgf-cm. 38 ft-Ibf)
Check that the idler pulley moves smoothly.
L
ML“ P1693?
INSTALL EXHAUST CAMSHAFT TIMING PULLEY

. /‘r Slide the timing pulley onto the camshaft, facing
mark 'S" outward.
cg
J:
Align the pin holes of the camshaft and timing pulley,
and insert the knock pin.
»\ /9‘?
of
ygl ‘
@ I
SH»/ET wiezse
Using SST (A), install the pulley bolt.

SST 09960-10010 (09962—01000, 09963-01000)
Torque:
89 N-m (700 kgf-cm. 51 ft-Ibf)
\ ll
48 N-m (490 kgf-cm, 35 ft-Ibf) for SST
/’
/
oi HINT (On vehicle):
@il‘
2. vizK. I Use SST (B).
SST 09249-63010
SST (Bl
P1823? 0 Use a torque wrench with a fulcrum length of
340 mm (13.39 in.).
CONNECT TIMING BELT TO CAMSHAFT TIMING
PULLEYS
(See Pub.No.RM396E, steps 14 to 17 on pages EG—
\ 61 to 64)
e ..
O
-S
Q
‘*1’/IF . L P
v~\
C
P1823‘!
EG-60
ENGINE - ENGINE MECHANICAL
13. INSTALL SPARK PLUGS

I’ b
Using SST, install the 4 spark plugs.
SST 09155-16100
._ "':\_,§. Torque: 18 N-m (180 kgf-cm, 13 ft-Ibf)
!1’=:;
\“ <. /if C \@ .....

14. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833-00080. THREE BOND 1324 or
equivalent
Adhesive
mesa
(b) Install the oil pressure switch.

15. INSTALL LH ENGINE HANGER
T 1- I ’ Install the LH engine hanger with the 3 bolts.
?/
au V’ Torque: 44 N-m (450 kgf-cm. 32 ft-Ibf)
be --Y“
Switch \' -0%
&' / / P1826?
16. INSTALL DELIVERY PIPE ASSEMBLY

(a) Install 4 new insulators to the delivery pipe.
NY
(b) Install the 3 spacers to the cylinder head as shown in
fa‘/°’
§\I>—l
the illustration.
\_Cylinder/
Head )
>Slde \
_,
Ia
_ . \aé;a/
r \ 5
$3 _\ 'ir,_,l/
\L pacer
PI3293
(c) Install the delivery pipe to the cylinder head with the 3
,,>/ r's§_»
M Z> v bolts.
I, Torque: 29 N-m (300 kgf-cm. 21 ft-Ibf)
Z {"‘;@9
\ I74’
ér %
/ -
INSTALL INTAKE MANIFOLD
Install a new gasket and the intake manifold with the
4 bolts and 3 nuts. Uniformly tighten the bolts and
nuts in several passes.
31 1
" 26?
INSTALL VSV FOR TURBOCHARGING PRESSURE
Install the VSV with the 2 bolts.
>z;2"""
%én\O@O»i
CONNECT FUEL RETURN HOSE T0 RETURN PIPE
CONNECT FUEL INLET HOSE
-—
3&3»
i, 7\ti;-All
‘.“l\_,0
afi ,<i'*" '/*\‘@">f1 Connect the fuel inlet hose to the delivery pipe with 2
new gaskets and the union bolt.
Fuel Return Hose

P1815?
INSTALL ENGINE WIRE

CORRECT Connect Install the engine wire protector to the 2 mounting
\\
bolts of the No.2 timing belt cover.
{A
(. g
M
‘\
Pis2s§
rf\ I‘
(b) Install the engine wire protector to the intake manifold

with the 2 bolts.
/ "Q ‘
5,-,1 it” 3.7,.
‘;
Q;
(cl Connect the following connectors and ground cable:
(1) VSV connector for turbocharging pressure
II‘ Q? (2) Knock sensor connector
(3) Ground cable
/sq-©@Ii‘
‘E i
-1
— mi: QV
_
R3.
‘Z’ P1822?
0
(4) Intake air temperature sensor connector
(5) 4 injector connectors
HINT: The No.1 and No.3 injector connectors are
brown, and the No.2 and No.4 injector connectors are
black.
~,.1: 1'av»;/‘£3 T’;

xt 1,2
PI8263
22. CONNECT HOSES

(al Install the vacuum pipe with the bolt.
(bl Connect the following hoses:
(1) PCV hose to PCV valve
(2) Vacuum sensing hose to fuel pressure regulator
(3) Vacuum hose to gas filter
HINT (On vehicle): Connect the following hoses:
'Qgs1
/2
\§
(1) Brake booster vacuum hose to intake manifold
(2) Vacuum hose to vacuum pipe
4(R /“I M8262

EG-63
INSTALL INTAKE MANIFOLD STAYS

XI. Install the manifold stay with the 2 bolts. Install the 2
manifold stays.
1114 Torque: 39 N-m (400 kgf-cm. 29 ft-Ibf)
\ \ ‘is
Ht?‘
‘A
/\ _ '>i $11” P123225
INSTALL NO.1 AIR TUBE
.I IE
(1) Q /-\ Db /
s Install the No.1 air tube with the 3 bolts.
gill: \
-
r’ . Connect the following hoses:
'1 ‘£1
(1) Air hose to intake manifold
(2) 2 PS air hoses to air tube
-2.
(3) Air hose to air tube
‘O 5
a .
‘I Ix <2\\ W3
e ' 4"’
INSTALL THROTTLE BODY

Gasket I. 7L "“ /\] Insert the spacer into the cylinder head cover. and
,2/ WE
_ Ll’/'_\\
install the gasket.
Spacer l
Pl828l
Attach a new gasket to the throttle body. facing the

Protrusion protrusion upward.
‘lg:
’ "1~'% ’ 4,
aé.
PIB242
56'“ ENGINE - ENGINE MECHANICAL
(cl Install the gasket. throttle body and hose assembly
so
>4@@& " -
‘K-2. ti-"‘
and air connector stay with the 6 bolts in several
passes.
‘Q-is ‘ 1', 0 ( \\
HINT: Different bolt lengths are used for locations A,
B and C.
£5}.
E - )B Bolt length:
..'.\.'.'.')§ P1826‘ \~\.
\ ‘-1421 an?
A: 40 mm (1.57 in.)
B: 80 mm (3.15 in.)
C: 70 mm (2.76 in.)
(4) (d)
Connect the following hoses and connectors:
(1) Vacuum hose (from lower port of BVSV) to throt-
tle body
(2) Vacuum hose to throttle opener
lF§l‘
§'
QI (4) ISC valve connector
/‘\.t//
er ‘EF~119
M8293
\l6l (5) 2 ISC water bypass hoses to No.1 air tube

(6) Air hose to No.1 air tube
(7) PCV hose to cylinder head
/
5'1“ P182510
I (e) Install the accelerator cable bracket and intake air

~\ connector with the 4 bolts.
J9 15;‘ Torque: 21 N-rn (210 kgf-cm. 15 mar)
\ Z
\K - ’@’\
saw 5%
1*
“ Fa-J’
\‘\ $1:
at
2e. INSTALL EGR VALVE AND PIPE
Install 2 new gaskets, the EGR valve and pipe assem-
bly with the 4 bolts.
Torque:
< <1» xL.-T5’ Wrench

\
PI3258
Intake manifold
Cylinder head
EG-65
_ 21 INSTALL EGR VACUUM MODULATOR AND VSV

A7 ASSEMBLY
Install the EGR vacuum modulator and VSV assembly
with the 2 bolts.
\@> '\ "4 ‘E/~

7
. (2) lbl Connect the following connector and hoses:

Q7 0‘
(1) VSV connector for EGR
<1) »§\\ {;n ta) (2) Vacuum hose to throttle body
‘E a 1'3“ I (3) Vacuum hose to EGR valve
(4) EGR hose to EGR valve
18256
INSTALL NO.2 AIR TUBE AND VENTILATION CASE

Q (er ASSEMBLY
vile? Install the No.2 air tube and ventilation case assembly
with the bolt.
K13 \*‘/~,
P18255
I3) ~ (bl Connect the following hoses:

(1) PCV hose to cylinder head cover
9» (2) PCV hose (from cylinder head) to ventilation case
(3) Vacuum hose (from No.2 air tube) to intake man-
I
.<. '- I
g ' <4:
(4)
ifold
Air hose to No.1 air tube
%‘!.:#-$171
E0ris", H6254
NeGasl<j-rt) / INSTALL WATER BYPASS PIPE

Install a new gasket to the water pump cover.
/I \® C r-
,‘ 1',-a ; rgew O R|n9 Install a new 0—ring to the bypass pipe.
Apply soapy water on the 0—ring.
2 V
‘ ..\\ ‘
W1-1 _ I
Connect the water bypass pipe and hose to the oil
cooler and water pump cover.
\ Q H4‘ / P18331
EG-66
(e) Install the bypass pipe with the 2 nuts and 2 bolts.
Torque: '
Nut: 10 N-m (1 O0 kgf-cm. 7 ft-Ibf)
$1“- Mns- Bolt: 24 N-m (240 kgf-cm. 18 ft-Ibf)
, L"/J ‘E:. “'

\_,'._
nl‘
i¥z__/
T‘7/2;?“ ’%
\'
I I
“<:.<,., .-
5*'-31
(f) Connect the following hoses to the water bypass pipe:

\\-~/ (1) ISC water bypass hose
i
(2) Air hose from turbocharging pressure VSV
I
qg
Ill slit e.,‘;~$/'1]:
/‘ (2) //I
P182233
30. INSTALL WATER OUTLET

Jfi K
Q
/ Ia) Install a new gasket to the cylinder head.
(bl Connect the water bypass hose to the water outlet,
and install the water outlet with the 3 nuts.
E Yeriill.
Water Bypass Hose
PI8252
(c) Connect the following hoses:

/ i ifllig
(1) ISC water bypass hose to water outlet"
(2) Vacuum hose (from charcoal canister) to upper
port of BVSV
(3) Vacuum hose (from port P of throttle body) to
‘i
V(
¢§9":'\e<“‘1l"@\c
lower port of BVSV .
$251 Hg’
(1) ldl Connect the following connectors:

(1) Oil pressure switch connector
(2) Water temperature sensor connector
(3) Water temperature sender gauge connector
I 2I P182150
ENGINE - ENGINE MECHANICAL 56'“
-E L 31 INSTALL EXHAUST MANIFOLD
L \ I Install a new gasket and the exhaust manifold
' ' the
with
4 _‘§\,§,) € 8 nuts. Uniformly tighten the nuts in several passes.
H Torque: 52 N-m isso kgf-cm. ea ft-Ibf)
Q * ‘E \ _L__( Q 32. INSTALL TURBOCHARGER
w \ Q Q‘, (See steps 4 to 12 on pages EG—92 to 94)
-.4; \ s1
/ / C‘ / mg M“ N
’“~
{V I
Lngllj \
J
33 INSTALL CATALYTIC CONVERTER
" .
Install a new gasket and the catalytic converter with
.
the 3 bolts and 2 nuts.
-"fig-. Torque: 29 N-m (300 kgf-cm. 21 ft-Ibf)
\i> Ear /\@/D
’15”‘
LH side A
P1824-8
34. INSTALL LH AND RH CATALYTIC CONVERTER

Cd A STAYS
\ / Ia) Install bolts A and D to converter stays LH and RH,
£-
CH‘ 9. and tighten them by hand.
»‘ (b) Temporarily tighten bolts C and F so that the convert-
\ g G er and stays fit securely together.
“L\
I i Torque: 10 N-m (100 kgf-cm. 7 ft-Ibf)
_ V (c) Torque the bolts in the order A. B, c, o. E. F.
C Torque: 59 N-m (600 kgf-cm. 43 ft-Ibf)
RH Side
"‘\
ll ‘ ‘De
aYs
\ '3/\p 9|“ 3
.l/
O
1
F
PIB247
PI B245 1132a)
1 M - 35. INSTALL ALTERNATOR BRACKET AND RH FRONT

-I ENGINE HANGER
'/7, Install the alternator bracket and engine hanger with
' ‘ 5/ the 3 bolts.
'\
/(Q
+;a(
'\
/
P182115
36. INSTALL ALTERNATOR

(a) Install the alternator with the 2 bolts.
'\ Torque:
"A 91
12 mm heed 19 N-m (190 kgf-cm. 14 ft-Ibf)
wX\\\/% 14 mm heed 52 N-m (530 kgf-cm. 38 ft-Ibf)
§ __
Ii. wig‘. .-valQZ\‘
te(
as->/2 €% PI3222
(b) Install the engine wire protector and ground strap

G
Sggign d,
\<*/
kg}‘Q
'\
_
WI th th 6 2 b O It S .
wig)
f"Q
3
*1»)
\
F 1
7 \\\\\\\
\
L_
l PI822I
(c) Connect the following wires and connectors:

(3)
(W Q (1) Oxygen sensor connector to wire bracket
(2) _;if.- (5) (2) OXY99n sensor connector
ff’,
If ~._.
_ _, 1:
,_ (3) Oxygen sensor wire to wire clamp
‘iii? (4) Alternator connector
(//Wm»? (5) Alternator wire
'
(4l ‘ I
/
P181720 \ Hwy]
I 37. INSTALL DISTRIBUTOR

f/,3 \/ (a) Turn the crankshaft clockwise, and position the slit of
I M \ / -$0 the intake camshaft as shown in the illustration.
Q ‘ ’ '*»/
Ir.
Q:
QR |(~
\
-__/
Ll
cf’
0 Slit
C‘
P18282 H3372
EG-69
/ \4/ f (b) Install a new O—ring to the distributor housing.

(c) Apply a light coat of engine oil on the O—ring.
|G‘l312
W gw New O-Ring
Z1232,
(d) Align the cutout portion of the coupling with the

groove of the housing.
(e) Insert the distributor. aligning the center of the flange
/ L ' ‘ \. \ with that of the bolt hole on the cylinder head.
:_y//' 6
t ~‘ 5 I Jil
/fir?
Qpfcfivg‘ I "
(f) Lightly tighten the 2 bolts.
<
§\
/\
1 I
:9’
22
1% és~—»
/
P182811
(g) Connect the 4 high—tension cords to the spark plugs.

(h) Install the high—tension cord clamp with the 3 bolts.
7PR 0
~..
‘ix;-‘. ~/1,6
?,_/
/
,-
I
J
2,» J’/Q.
\
PI 8243
(i) Install the cool air inlet with the 2 bolts.
44’ \
é
03
’>‘*‘:
*‘\.
EG-70 ENGINE - ENGINE MECHANICAL
kfi (j) Connect the distributor connector.
“.?.l \> ,5‘
K QIII I! &\
v _‘h_
”
1‘ \\‘% "Q
'
38. INSTALL INTERCOOLER
39. FILL RADIATOR WITH ENGINE COOLANT
40. START ENGINE AND CHECK FOR LEAKS
41. PERFORM ENGINE ADJUSTMENT
(See pages EG—31 and 32)
42. RECHECK ENGINE COOLANT LEVEL AND OIL
LEVEL
ENGINE — ENGINE MECHANICAL EGJ1
CYLINDER BLOCK ___
COMPONENTS FOR DISASSEMBLY AND -W
ASSEMBLY
No.1 Piston Ring

(Compression Ringl No.2 Piston Ring (Compression Ring)
Oil Ring lSide Rail) Oil Ring (Expander)
r>————O Snap Ring
PlStOh Pin
Piston _ _ *
Q O Connecting Rod Bushing New Bolt 101 (1.090. 191
Q’ Used Bolt 112 (1.140. eel
Connecting Rod Q No.1
¢ 5 N .
Rear End Plate
“ '
PS Pump Bracket
. 0"
andD'p"'°"
.
Guide
KI
' R2; End Plate I "“
?»
$ ‘ ‘ 1!’/"‘\ J /T“ ."\
Connecting Rod Bearing » \ (,4: 4/ F“/whee‘
Connecting Rod Cap /“E __ J '\_
. O Ring
I
Water Pump and
Water Pump a¢
Knock Sensor @
.1"-\r-a"
,~’.-f;<gEi)'
_ Q
-
1‘
\\ - P’ -1
Im‘~
II,
I
°—§ O Ring
- - __
\~ I "Crankshaft
.‘
‘\
‘
~kn
‘ ‘”1<
‘
. Valve
Relief
Cover Assembly EC“ U lfit
'
ldl P ll ‘R2 '-o ' _ - . Rear Oil Seal
Brgckeltl av 4“ ‘‘r_;.. - GR 2/ Real Oil Seal ‘Q
5 1'-‘it
.'\ Retainer Q»
Cylinder Block > \ Gasket Seal Washer
es kt
as 8 '=.Ta I‘ {-1
1
=-fa-51
T,
.§‘i/1fie
99st? 1
§=@——~—Oil
'
\
Nozzle
i
Oil Cooler
O0-Ring
O"0 cPumpk h ft—® “ Q - ' $2.“ ‘i‘i
\J S 2
1'2
fan S .3 ' Crankshaft I \ - ll \ _ Oil. Cooler Bracket
Front Oil \ v O Ring
Seal . ‘II " 9
_ 7’ E y Mimfiankshaft Thrust Washer
25 mm Length Bolt Mam Bea
9.0 I92. B0 in.-Ibf)
ring M Main Bearing Cap
35 mm Length Bolt
8.0 [82, 71 in.-lbfl
Oil Pan Baffle Plate
5.0 I92, DO IIIJIDN
0 Gasket “(,1 //\_ "
I
Oil Strainer . _ - /
/jg.11 I
No.1 Oil Pan
10 mm Heed Bolt
O O-Ring 4*-= _ .1’? - 12 I120, 9)
12 mm Heed Bolt
\ _,_ ' 211210.151
‘I->539’ r I’ k
\\\9l -
9.0 192, so imlbfl X x ‘JV L
f
No.2 Oil Pan - g_fir Q@i—Drain Plug

r" Gasket
“i"=‘"
N-m (kgf-cm. ftlbf) : Specified torque
6 Non-reusable part
it Precoated part
mam?
56'” ENGINE - ENGINE MECHANICAL
P|$TON AND CONNECT|NG ROD
/7 |N$PECT|QN
Front Mark £7 1 INSPECT PISTON

(Ca\"tY> /1 Inspect piston oil clearance
i
Mark HINT: There are 3 sizes of the standard piston diame-
\h 1'2°r3 I av I I I I I I
ter, marked 1 , 2 and 3 accordmgly. The mark |s
W stamped on the piston top.
W2»
P1815
EG-73
SERVICE SPECIFICATIONS WM
SERVICE DATA _
Tune—up Battery specific gravity at 20°C (68°Fl 1.25 — 1.27
High—tension cord resistance Limit 25 kQ per cord
Alternator drive belt deflection w/ A/C New belt 10 — 11 mm (0.39 — 0.43 in.)
Used belt 13 — 16 mm (0.51 — 0.63 in.)
1 r
w/o A/C New belt 11 — 14 mm (0.43 — 0.55 in.) x=,?a.
Used belt 12 — 18 mm (0.47 — 0.71 in.)

Alternator drive belt tension (Reference)
w/ A/C New belt 686 — 785 N (70 — 80 kgf)
Used belt 294 — 441 N (30 — 45 kgf)
w/o A/C New belt 461 — 706 N (47 — 72 kgf)
Used belt 353 — 610 N (36 - 62 kgf)
Valve clearance (Cold) Intake 0.15 — 0.25 mm (0.006 — 0.010 in.)
Exhaust 0.28 — 0.38 mm (0.011 — 0.015 in.)
Valve clearance adjusting shim (for repair part)
No.00 2.500 mm (0.09B4 in.)
No.53 2.550 mm (0.1004 in.)
No.10 2.600 mm (0.1024 in.)
No.15 2.850 mm (0.1043 in.)
No.20 2.700 mm (0.1063 in.)
No.25 2.750 mm (0.1083 in.)
No.30 2.800 mm (0.1 I02 in.)
No.35 2.850 mm (0.1 122 in.)
No.40 2.900 mm (0.1 142 in.)
No.45 2.950 mm (0.1161 in.)
No.50 3.000 mm (0.1181 in.)
No.55 3.050 mm (0.1201 in.)
No.60 3.100 mm (0.1220 in.)
No.65 3.150 mm (0.1240 in.)
No.70 3.200 mm (0.1260 in.)
No.75 3.250 mm (0.1280 in.)
No.80 3.300 mm (0.129!-1 in.)
No.85 3.350 mm (0.1319 in.)
No.89 3.390 mm (0.1335 in.)
Ignition timing 10' BTDC Q idle
(w/ Terminals TE1 and E1 of check connector connected)
Idle speed w/ Daytime running light system 750 :1: 50 rpm
l
w/o Daytime running light system 700 :1: 50 rpm
Idle CO Concentration 0—0.5%
Intake at idle speed 57 kPe (430 mmHg, 16.8 in.H9)
manifold
vacuum
Compression at 250 rpm STD 1,130 kPa (11.5 kgf/cm’. 164 psi) or more
pressure Limit 880 kPe (9.0 kgf/cm‘, 128 psi)
Difference of pressure between each cylinder 100 kPe (1.0 kgfcm’. 14 psi) or less ‘
Timing belt Protrusion 10.0 — 11.0 mm (0.394 -~ 0.433 in.)
tensioner
G-74
Cylinder head Warpage

Cylinder block side Limit 0.20 mm (0.0079 in.}
Intake manifold side Limit 0.20 mm (0.0079 in.)
Exhaust manifold side Limit 0.30 mm (0.01 18 in.)
Valve seat
Refacing angle 30°, 45°, 75°
45°
Contacting angle
Contacting width 1.0 — 1.4 mm (0.039 — 0.055 in.)
> . . .. . we
Valve guide Inside diameter I 6.000 — 6.018 mm (02362 ~ 0.2369 in.)
bushing Outside diameter (for repair pert) STD 11.040 — 11.051 mm (0.4346 — 0.4351 in.)
O/S 0.05 11.090 — 11.101 mm (0.4366 — 0.4370 in.)
Valve Valve overall length STD Intake 99.80 — 100.20 mm (3.9291 — 3.9449 in.)
Exhaust 98.55 — 99.25 mm (3.891? — 3.9075 in.}
Limit Intake 99.30 mm (39094 in.)
Exhaust 98.35 mm (3.8720 in.)
Vale face angle 44.5‘
Stem diameter Intake 5.960 — 5.975 mm (0.2346 — 0.2352 in.)
Exhaust 5.955 — 5.970 mm (0.2344 — 0.2350 in.)
Stem oil clearance STD Intake 0.025 — 0.058 mm (0.0010 — 0.0023 in.}
Exhaust 0.030 — 0.063 mm (0.0012 — 0.0025 in.}
Limit Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
Margin thickness STD 0.8 — 1.2 mm (0.031 — 0.047 in.)
Limit 0.5 mm (0.020 in.)
Valve spring Squareness Limit 2.0 mm (0.079 in.)
Free length Intake 43.18 mm (1.7000 in.)
Exhaust 43.34 mm (1.7063 in.)
Installed tension at 35.4 mm (1.394 in.) Intake 163 — I90 N (16.6 — 19.4 kgf. 36.6 — 42.8 lbf]
Exhaust 153 — 180 N (15.6 — 18.4 kgf. 34.4 — 40.6 lbf]
Valve lifter Lifter diameter 30.975 — 30.985 mm (1.2195 — 1.2199 in.)
Lifter bore diameter 31.000 — 31.021 mm (1.2205 - 1.2213 in.)
Oil clearance STD 0.015 — 0.046 mm (0.0006 — 0.0018 in.)
Limit 0.07 mm (0.0028 in.)
Manifold Warpage Limit Intake 0.30 mm (0.01 18 in.)
Exhaust 1.00 mm (0.0394 in.)
Camshaft Thrust clearance STD 0.100 — 0.240 mm (0.0039 — 0.0094 in.)
Limit 0.30 mm (0.01 18 in.)
Journal oil clearance STD 0.0025 — 0.062 mm (0.0010 — 0.0024 in.)
Limit 0.08 mm (0.0031 in.)
Journal diameter 26.959 — 26.975 mm (1.0614 — 1.0620 in.)
Circle runout Limit 0.06 mm (0.0024 in.)
Cam lobe height STD Intake 41.510 — 41.810 mm (1.6342 — 1.6382 in.)
Exhaust 41.100 — 41.200 mm (1.61B1 - 1.6220 in.)
Limit Intake 41.40 mm (1.6299 in.)
Exhaust 41.00 mm (1.6142 in.)
(Minder block Cylinder head surface warpage Limit 0.05 mm (0.002O in.)
Cylinder bore diameter STD Mark 1 86.000 — 86.010 mm (3.3858 — 3.3862 in.)
Mark 2 86.010 — 86.020 mm (3.3862 - 3.3866 in.]
Mark 3 86.020 — 86.030 mm (3.3886 — 3.3870 in.)
Limit 86.23 mm (3.3949 in.)
Piston and Piston diameter STD Mark 1 85.970 — 85.980 mm (33846 — 3.3850 in.)
piston ring Mark 2 85.980 — 85.990 mm (33850 — 3.3854 in.)
Mark 3 85.990 — 86.000 mm (3.3854 — 3.3858 in.) =_=E,'E3=5 =-%!":_Z.§.§
‘ >1./: 3»:
--¢-:.=....',.,z;=;._.;
Piston oil clearance STD 0.020 — 0.040 mm (0.0008 — 0.0016 in.)
Limit 0.08 mm (0.0024 in.)
Piston ring groove clearance No.1 0.040 — 0.080 mm (0.00‘l6 - 0.0031 in.)
No.2 0.030 — 0.070 mm (0.0012 — 0.0028 in.)
Piston ring end gap STD No.1 0.330 — 0.550 mm (0.0130 — 0.0217 in.)
No.2 0.450 — 0.670 mm ( 0 .0177 - 0.0264 in.)
Oil 0.150 — 0.500 mm (0.0059 — 0.0197 in.)
Limit No.1 0.85 mm (0.0335 in.)
No.2 0.97 mm (0.0382 in.)
Oil 0.80 mm (0.0315 in.)
Connecting Thrust clearance STD 0.160 — 0.312 mm (0.0063 — 0.0123 in.)
rod Limit 0.35 mm (0.0138 in.)
Connecting rod bearing center wall thickness
(Reference) STD Mark 1 1.484 — 1.488 mm (0.0584 — 0.0586 in.)
Mark 2 1.488 — 1.492 mm (0.0586 — 0.0587 in.)
Mark 3 1.492 — 1.496 mm (0.0587 — 0.0589 in.)
Connecting rod oil clearance STD STD 0.024 — 0.055 mm (0.0009 — 0.0022 in.)
U/S 0.25 0.023 — 0.069 mm (0.0009 — 0.0027 in.)
Limit 0.08 mm (0.0031 in.)
Rod bend Limit per 100 mm (3.94 in.) 0.05 mm (0.002O in.)
Rod twist Limit per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)
Bushing inside diameter 22.005 — 22.017 mm (0.8663 — 0.8668 in.)
Piston pin diameter 21.997 — 22.009 mm (0.8660 — 0.8885 in.)
Piston pin oil clearance STD 0.005 — 0.011 mm (0.0002 — 0.0004 In.)
Limit 0.05 mm (0.002O in.)
E6‘-'6 ENGINE — ENGINE MECHANICAL
Crankshaft Thrust clearance W 7T STD 0.020 — 0.220 mm (0.0008 — 0.0087 in.)
Limit 0.30 mm (0.01 18 in.)
Thrust washer thickness Main journal oil clearance 2.440 —— 2.490 mm (0.098! — 0.0980 in.)
STD No.3 STD 0.028 — 0.047 mm (0.0011 — 0.0019 in.)
No.3 U/S 0.25 0.027 — 0.067 mm (0.0011 — 0.0026 in.)
Others STD 0.018 — 0.037 mm (0.0007 — 0.0015 in.)
Others U/S 0.25 0.019 — 0.059 mm (0.0007 — 0.0023 in.)
%%§%§%%
Limit 0.08 mm (0.0031 in.)
Main journal diameter STD 54.985 —- 55.000 mm (2.164-8 — 2.1654 in.)
U/S 0.25 54.745 — 54.755 mm (2.1553 — 2.1557 in.)
Main bearing center wall thickness (Reference)
STD No.3 Mark 1 1.992 — 1.995 mm (0.0784 — 0.0785 in.)
Mark 2 1.995 — 1.998 mm (0.0785 — 0.0787 in.)
Mark 3 1.998 -— 2.001 mm (0.0787 — 0.0786 in.)
Mark 4 2.001 — 2.004 mm (0.0788 — 0.0789 in.)
Mark 5 2.004 — 2.007 mm (0.0789 —- 0.0790 in.)
Others Mark 1 1.997 — 2.000 mm (0.0786 -— 0.0787 in.)
Mark 2 2.000 — 2.003 mm (0.0787 — 0.0789 in.)
Mark 3 2.003 — 2.006 mm (0.0789 — 0.0790 in.)
Mark 4 2.006 - 2.009 mm (0.0790 — 0.0791 in.)
Mark 5 2.008 ~ 2.012 mm (0.0791 — 0.0792 in.)
Crank pin diameter STD 47.905 - 4e.0oo mm (1.8892 - 1.8898in.)
U/S 0.25 41.745 - 47.755 mm (1.879? - 1.8801 in.)
Circle runout Limit 0.0a mm (0.0024 in.)
Main journal taper and out—of—round Limit 0.02 mm (o.000e in.)
Crank pin taper and out—of—round Limit 0.02 mm (0.0008 in.)
TORQUE SPECIFICATION
Part tightened N-m kgf-cm ft-lbf
Distributor x Cylinder head 39 4-00 29
Spark plug x Cylinder head 18 180 13
Oil pump pulley x Oil pump drive shaft 35 360 26
No.2 idler pulley x Oil pump 44 450 32
Timing belt tensioner x Cylinder head 21 210 15
No.1 idler pulley x Cylinder head 52 530 38
Crankshaft pulley x Crankshaft 107 ( 1.090 79
RH engine mounting bracket x Cylinder block 52 530 38
Camshaft timing pulley x Camshaft 69 700 51
for SST 48 490 35
Alternator bracket x Cylinder head 39 400 29
Alternator x Altemator bracket 12 mm heed 19 190 14
14 mm head 52 530 38
I Idler pulley for alternator drive belt x Idler pulley bracket 39 400 29
I RH front engine hanger x Cylinder head 39 400 29
Cylinder head x Cylinder block 1st 49 500 36
2nd Tum 90°
Camshaft bearing cap x Cylinder head 19 190 14
Cylinder head cover x Cylinder head 6.0 61 53 in.-lbf
No.4 timing belt cover x Cylinder head cover 8.0 82 71 in.-lbf
EG-77
No.3 timing belt cover X Cylinder head I 8.0 82 71 in.-lbf

0il~pressure switch x Cylinder head 15 150 117
LH engine hanger x Cylinder heed 44 450 32
Delivery pipe x Cylinder head 29 300 21
Intake manifold x Cylinder heed 20 200 15
Fuel inlet hose x Delivery pipe 32 330 24
.29, .
Intake manifold stay x Intake manifold 39 400
Intake manifold stay x Cylinder block 39 400 29
Throttle body x Intake manifold 21 210 15
Air connector stay x Intake manifold I 21 210 15
Air connector stay x Cylinder head 21 210 15
Intake air connector x Throttle body 21 210 15
EGR valve x Intake manifold 19 190 14
EGR pipe x Cylinder head 25 250 18
Water bypass pipe x Water pump cover 10 100 7
Water bypass pipe x Cylinder head 24 240 18
Water outlet x Cylinder head 20 200 15
Exhaust manifold x Cylinder head 52 530 38
Catalytic converter x Turbine outlet elbow 29 300 21
LH catalytic converter stay x Cylinder block 59 600 43
LH catalytic converter stay x Catalytic converter 59 600 43
RH catalytic converter stay xICylinder block 59 600 43
RH catalytic converter stay x Catalytic converter 59 600 43
Oil nozzle x Cylinder block 9.0 92 80 in.-lbf
Main bearing cap x Cylinder block 59 600 44
Connecting rod cap X Connecting rod 67 680 49
Rear oil seal retainer x Cylinder block 9.0 92 80 in.-lbf
Knock sensor x Cylinder block 37 380 27
Oil cooler bracket x Cylinder block 6.5 66 58 in.-lbf
Oil cooler x Oil cooler bracket (Relief valve) 59 600 44
Water pump x Cylinder block 7.5 776 68 in.-lbf
Idler pulley bracket for altemator drive belt x Cylinder block
Water pump side 23 230 17
Cylinder block side 19 190 14
PS pump bracket x Cylinder block 43 440 32
No.1 rear end plate x Cylinder block 9.3‘ 95 a2 in.-lbf
No.2 rear end plate x No.1 rear end plate 9.3 95 82 in.-lbf
Flywheel x Crankshaft New bolt 107 1.090 79
Used bolt 112 1.140 83
EG-78
ENGINE — TURBOCHARGER SYSTEM
TURBOCHARGER SYSTEM
DESCRIPTION 8940-02
The CELICA 3S—GTE engine uses a turbocharger to increase engine power (without increasing
engine speed) by sending a greater amount of air—fuel mixture to the engine.
_ y The engine is equipped with a water cooled intercooler with improved cooling capability. The
* 3% .33 Q
intercooler, located above the engine, cools the turbocharged air by way the cooled water from
the sub radiator located in the front of the vehicle.
Waste Gate Valve
Water Cooling Channel
Oxygen
Sensor ator
/
Turbine /7
Wheel
lmpellerWheel
l
Oil Passage
lntercooler
‘<l\
l I
(
-.
\
sgy-'_.'f
l_‘iI|;,_n
8"
_~__unl-'1-I
mu
/
Sub Radiator
I
_,
I‘
7~
,..~ 3l..-
~:==:._
1::==;.~_ ‘qr.
I“
'-=5=::=~ .»-...
\
o ip‘
-Q
|- I —-‘"77
.~.~_ \ lntercooler
~
".~:==E:'- -. ,.
S-3.:
‘ '4 ~: 1‘.
--s.,=;~ -\ /. Water Pump
.
' —-E
,_. ' .
P184195
P18390
Z13?
ENGINE — TURBOCHARGER SYSTEM EG-79
Turbo Pressure Sensor Fuse IGN

7.5A
it M-Fuse
AM1 40A
C] O g Throttle Position ‘CID
I: Sensor _ _ -cm: —c:n:i I:-Im
1 '
VSV F1159
U 575665
1 OA
ECILJ-IG U
lntercooler Relay A .
("INTR CLR“) é E€§_("°
I
Fuse AM2 E_n%iine Main Relay
v< /
M-Fusg
MAIN 60A
30A 1 E MAIN )
Q
“I ‘
\ \, J 4
I1
-\
r 4 = CID
J
=E
.K$9
ZZ
CD 3
ii 2% =1M
FL MAIN 2.0L
lntercooler I ‘ I C I I 1A ~
Water Pum I'l BTCOO BF 00 an
P Wm, Lave, Sam, H-Fuse ALT 100A M-Fuse cos 30A
Y H8491
SYSTEM CIRCUIT
Mili-
Engine ECU
l. BATT
" ~- - Check En ine
lgnmon swltch UGE Waming Light To Turbo Meter
AM1 K31‘
OM) 0
A M2 IG 2 @ W PM Eiiessure
mo
ansoE2
Egu-IGZ lGl~i VC-Q

A 7.5 .
;h0S:Il|0‘i1 Sensor
FELZ §fl6’l‘ Q51? ‘ SEFI __ .
Main IDL
' R°'aY vgv E2
Q“ ”"l"
100A ’_ 60 = T"°
e '|-B
lntercooler
CDS Water Level
306 Sensor
MAIN 5 2 ... 14 LEV
;!I)|_ é E"9I"° _ , . _ lntercooler
Main = |:Ie|ay
Relay .nZ 4 '
'
Battery " h-'5 _ +8
--
'
- M-
M+
-
lntercooler t /
Water Pump
Y P184192
E6-8° ENGINE — TURBOCHARGER SYSTEM
OPERATION
VSV ____
ell-H IIIII
IIIIII
IIIIIII
lntercooler
iiiF p =9 "
“Ii”'1‘.III»!JaI
Waste
Gaute
Valve _ a \ C: Q: _
t._
».2 111117))
Air Cleaner
/ Turbocharger \
Turbine Wheel Impeller Wheel
Please
Exhaust gas acts on the turbine wheel inside the turbine housing, causing it to rotate. The
impeller, located on the turbine shaft, thus rotates and compresses the intake air which has
passed through the air cleaner. This high pressure air than passes into the cylinders for
combustion.
As the engine speed increases, the exhaust gas volume increases causing the turbine wheel
speed to increase up to a maximum of approximately 120,000 rpm. The consequent increase in
the impeller rpm increases the pressure of the intake air. which when accurately combined with
an appropriate quantity of fuel, increases engine power.
Waste Gate Valve

Although turbocharging increases engine power, if the turbocharged air pressure becomes too
high, knocking occurs which reduces engine power. If the intake air pressure exceeds a pre-
determined valve, the waste gate valve causes the exhaust gas to bypass the turbine. This
reduces the speed of the turbine, thus reducing the intake air pressure.
lntercooler
The intercooler cools the turbocharged intake air, thereby increasing the air density. With a
redustion in intake air temperature, the reduced combustion temperature suppresses the occur-
rence of knocking and allows full engine power to be realized.
EG-81
ENGINE - TURBOCHARGER S YSTEM
PREPARATION
p 09992 -00241 Turbocharger Pressure Gauge
RECOMMENDED TOOLS um - n
. Q‘
09062 —00050 T0YOTA Electrical Tester Set
4% ~\;=9
09258—00030 Hose Plug Set
<5“? ‘Y
DD'I—0A
EQUIPMENT
Dial indicator Impeller wheel
Radiator cap tester lntercooler coolant filler cap
Torque wrench
ME
COOLANT
lntercooler coolant 2.5 liters (2.6 US qts, 2.2 Imp. qts) Ethylene—glycol base
Engine coolant 7.0 liters (7.4 US qts, 6.2 Imp. qts) Ethylene — glycol base
113-1
LUBRICANT
Engine oil API grade SG, SH or ILSAC multigrade
. . .|
Dry fill 5.2 liters (5.5 US qts, 4.6 Imp. qts) engine oiI and recommended vlscoslty OI
Drain and refill
w/ Oil filter change 4.5 liters (4.8 US qts, 4.0 Imp. qts)
w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 Imp. qts)
EG-82
PRECAUTION
Do not stop the engine immediately after pulling a
trailer or after high speed or uphill driving. Idle the
engine for 20 — 120 seconds, depending on how
hard the vehicle has been driven.
Avoid sudden acceleration or racing immediately
after starting a cold engine.
Do not run the engine with air cleaner removed. as
this may cause foreign material to enter and
damage the impeller wheel operating at high speed.
If a turbocharger is found to be defective and must
be replaced, check for the cause and repair or re-
place the following items as necessary:
I Engine oil level and quality
0 Conditions under which the turbocharger was used
I Oil lines leading to the turbocharger
Use caution when removing and reinstalling the tur-

bocharger assembly. Do not drop it or bang it aga-
NO! inst anything or grasp it by easily—deformed parts,
".4-5 such as the actuator or rod. when moving it.
P)
Before removing the turbocharger, plug the intake
and exhaust ports and oil inlet to prevent entry of
dirt or other foreign material.
TC0054
If replacing the turbocharger. check for accumula-

tion of sludge particles in the oil pipes, and if neces-
t sary. replace the oil pipes.
Completely remove the gasket adhered to the lubri-
\‘O cation oil pipe flange and turbocharger oil flange.
When replacing bolt or nuts, use only anthorized
replacement parts to prevent breakage or deforma-
tion.
Y P1620!
If replacing the turbocharger, put 2 cm (0.12 cu in.)

a: of oil into the turbocharger oil inlet and turn the
impeller wheel by hand to spread oil to the bearing.
I
If overhauling or replacing the engine. cut the fuel
Q
supply after reassembly and crank the engine for 30
l'.’ D
seconds to distribute oil throughout the engine.
/
E4 TC0055
Then allow the engine to idle for 60 seconds.
EG-83
TROUBLESHOOTING
IGMV1-M
HINT: Before troubleshooting the turbocharger, first check the engine itself. (Valve clearance,
engine compression, ignition timing etc.)
INSUFFICIENT ACCELERATION, LACK OF POWER OR EXCESSIVE FUEL

CONSUMPTION .?.;..
Possible Cause Check Procedure and Correction Method §'£ass= -.
I 1. TURBOCHARGING PRESSURETOO LOW — Check turbocharging pressure. (See page EG-85)

Turbocharging pressure:
82 - 115 kPa
(0.84 - 1.11 kgflcmz, 11.9 - 16.1 psil
If the pressure is below specification, begin diagnosis from
item 2.
2. RESTRICTED INTAKE SYSTEM i Check intake air system, and repair or replace parts as
"B<>65$8I'Y- (See page EG-85)
3. LEAK IN INTAKE AIR SYSTEM —~ Check intake air system, and repair or replace parts as
necessary. (See page EG-85)
4. RESTRICTED EXHAUST SYSTEM i Check exhaust system, and repair or replace parts as
necessary. (See page EG-85)
5. LEAK IN EXHAUST SYSTEM —- Check exhaust system, and repair or replace parts as
necessary. [See page EG-85)
6. ERRATIC TURBOCHARGER OPERATION Check rotation ofturbine shaft. If it does notturn orturns with
a heavy drag, replace the turbocharger assembly.
Check axial and radial play of turbine shaft.
(See page EG-91}
Maximum axial play: 0.110 mm {0.0043 in.) ,
Maximum radial play: 0.136 mm {0.0054 in.) ;
If the play is greater than maximum, replace the
turbocharger assembly. I
VIBBII
EG-B4
ABNORMAL NOISE
Possible Cause Check Procedure and Correction Method
1. TURBOCHARGING HEAT INSULATOR —— Check for loose, improperly installed or deformed insulator
RESONANCE mounting bolts, and repair or replace as necessary.
Iii
2. EXHAUST PIPE LEAKING OR VIBRATING Check for deformed exhaust pipe, loose mounting bolts or
damaged gasket, and repair or replace as necessary.
_, .
3. ERRATIC TURBOCHARGER OPERATION Refer to item 6 of INSUFFICIENT ACCELERATION, LACK OF
POWER OR EXCESSIVE FUEL CONSUMPTION.
EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST

Possible Cause Check Procedure and Correction Method
FAULTY TURBOCHARGER OIL SEAL ——— Check for oil leakage in exhaust system.
I Remove the turbine elbow from the turbocharger and
check for excessive carbon deposits on the turbine wheel.
Excessive carbon deposits indicate a faulty turbocharger.
Check for oil leakage in intake air system.
0 Check for axial and radial play of turbine shaft and
replace the turbocharger if necessary.
(See page EG-91)
Maximum axial play: 0.110 mm (0.00-43 in.) .
Maximum radial play: 0.136 mm (00054 in.)
NOTICE: Some oil mist in the blow-by from the PCV
is normal.
Do not mistake it for an oil leek from the turbocharger.
VUSSI2
ENGINE - TURBOCHARGER SYSTEM E6435
TURBOCHARGER
ON—VEHlCLE INSPECTION
INSPECT INTAKE AIR SYSTEM
Check for leakage or clogging between the air cleaner
housing and turbocharger inlet and between the tur-
bocharger outlet and cylinder head.
0 Clogged air cleaner Clean or replace element
O Hoses collapsed or deformed Repair or replace
I Leakage from connections Check each con-
nection and repair
0 Cracks in components Check and replace
INSPECT EXHAUST SYSTEM
Check for leakage or clogging between the cylinder
head and turbocharger inlet and between the turboch-
arger outlet and exhaust pipe.
I Deformed components Repair or replace
0 Foreign material in passages Remove
I Leakage from components Repair or replace
I Cracks in components Check and replace
4-
INSPECT TURBOCHARGING PRESSURE
Using a 3-way connector. connect SST (turbochar-
‘*3- ger pressure gauge) to the hose between the vacuum
pipe and turbo pressure sensor.
SST 09992-00241
/\
'a(\‘Q<-\=."'*“3“‘\
at». While driving in 2nd gear with the engine running at
4,000 rpm or more with the throttle valve fully open.
check the turbocharging pressure.
Standard pressure:
- -._::.-_::¢°\\\ 82 —- 115 kPe
I; a2 - 115 kPa (0.84 — 1.17 kgf/cm‘, 11.9 — 16.7 psi)
ll SST If the pressure is less than that specified. check the
intake air, VSV and exhaust systems for leakage. If
~¢ there is no leakage, replace the turbocharger assem-
//. bly and/or VSV.
rJt’?\\ .@" * /
Pl830l
If the pressure is above specification. check if the
actuator hose is disconnected or cracked. If not. re-
place the turbocharger assembly.
INSPECT TURBO METER OPERATION

4-=1 PUG‘, O (a) Turn the ignition switch ON.
NOTICE: Do not start the engine.
st‘ ":=@Z¢
""#1§~
t\
PI 3663
EG-86 ENGINE — TURBOCHARGER SYSTEM
(b) Check that the turbo meter indication is zero.

+
@
.<. » “ ,
'?‘"='=-'-'- 1 ,_
Y Pl 8476
(c) Check that the turbo meter indication is negative (—)

/ Q when a vacuum is applied to the turbo pressure
/ sensor.
ix-
/ Vacuum
PIWB8
Check that the turbo meter indication is positive (+)

when a pressure is applied to the turbo pressure
SST
@ O W
\
sensor with SST (turbo pressure gauge).
SST 09992-00241
nil:-/I
/
gt‘ P1848‘!
Ohr-nfnetef COFIIIITUITY
INSPECT EFI MAIN RELAY
N° 1 Inspect relay continuity
E Contin Ui Using an ohmmeter, check that there is continuity
QM i;
Fiislmt./1J:
between terminals 1 and 2. A
Check that there is no continuity between terminals 3
3 a meter and 5.
2
If continuity is not as specified, replace the relay.
P071 ?0
Ohmmeter Inspect relay operation

Apply battery voltage across terminals 1 and 2.
Continuity Using an ohmmeter, check that there is continuity
:1
\ _ _—~ between terminals 3 and 5.
3 ii
‘iifllall
' .1
. .l-.4." If operation is not as specified, replace the relay.
INSPECT VSV FOR TURBOCHARGING PRESSURE ~
2 l I
(See page EG—108)
<9 ®
Battery INSPECT TURBO PRESSURE SENSOR
PO7I7l (See page EG— 105)
1
ENGINE - TURBOCHARGER system EG'87
KIIJ-OI

INSTALLATION
@ |mem°°;8|. Turbocharger Heat Insulator

. st -
Turbo Water Pipe
O Gasket
as (400, 29)
‘$ Q Gasket
*7‘®
Oil Dipstick Guide / ‘\‘\~>
I Water Hose N Gasket
\
Air Hose
~1- 1r(11s 1:)
.-. I 9 __ Q
Turbo Oil Pipe and
I g '/ I“ Outlet Pipe Assembly
0 6
l Oil DipsticliT 4 Q Gasket -
4e9alt_
V‘/I/I
. O-Hing Air Connector
Oxygen Sensor Q Gasket . Gaske‘
Heat Insulator \ ¢
' -\ O .
Side .
Beanng
% . Gasket »= -.~ ';\ Housing Plate
Oxygen Sensor /(1 X ‘Q.
. Gasket Q /_ gt) Turbocharger
'
* .1
I
F =
lie‘
.,/———+
.3
,
Turbine Outlet Elbow T rb h Sta
Heat Insulator > _ l $ U 0° arger y
°' 1.»\--/‘¥ e O Gasket
b
FiH Catalytic Converter Stay
Turbine Outlet Elbow Turbine Outlet Elbow ...
H eat l nsu I ator ‘’
LH Catalytic Converter Stay

1-, lF_ ‘
-I Catalytic Convener
\‘- “ I ,
N-m (l<gi~ cm, it-Ibf) : Specified torque

O Non-reusable part Y New
E6438 ENGINE - TURBOCHARGER SYSTEM
TURBOCHARGER REMOVAL
1. DRAIN ENGINE OIL
(See page EG-9?)
4. REMOVE CATALYTIC CONVERTER
-=-=.=.¢.:-=-;. ,-=-=-
5. REMOVE INTERCOOLER
_ O (a) Remove the 3 bolts.
/" __‘—-
(bl Disconnect the intercooler from the turbocharger and
intake air connector. and remove the intercooler and
J3
air connector.
,-
1;
J. ~,.
K
1
\ Y Pl8202
6. REMOVE TURBOCHARGER HEAT INSULATOR

Remove the 3 bolts and heat insulator.
/\fit\/‘
43% i )3‘
/%r\f3> WP‘? “W
7. REMOVE OXYGEN SENSOR
Q’ Remove the 2 nuts, heat insulator, oxygen senso::.and
\ gasket.
Q‘; /O _/
E-' < !4'‘F‘\
al Y PIBIE
a. REMOVE on. DIPSTICK AND cums

Q Q(a) Pull out the oil dipstick.
f \
"_ “
\
Pull
1
o-Ring
(C)
Remove the bolt and oil dipstick guide.
Remove the O—ring from the oil dipstick guide.
0 1;. féf
/\<>
1
§‘k Y P186413
ENGINE — TURBOCHARGER SYSTEM EG-B9
9. REMOVE HEAT INSULATORS OF TURBINE OUTLET

“ 3‘ /~
*
ELBOW
(a) Remove the 3 bolts and RH heat insulator.
(b) Remove the 2 bolts and LH heat insulator.
‘see “ L
% /
"0 . ......
10. REMOVE TURBING OUTLET ELBOW
"/k " g Remove the 7 nuts. outlet elbow and gasket.
\ ‘it
/_. .
filse T
Y PISZDT
‘H
11. DISCONNECT WATER BYPASS HOSES FROM
TURBO WATER PIPE
*4“ 12. DISCONNECT AIR HOSE FROM ACTUATOR
..J9 - \@.\\\
*1; r.
FY -*"§%:**
\ ¢7F"'~*’
\ .W
13. REMOVE TURBOCHARGER STAY
Remove the 3 bolts and turbocharger stay.
I
7.;
"C
\!
14. REMOVE TURBOCHARGER
"" AJ If
(a) Remove the 2 nuts holding the turbo oil outlet pipe to
the No.1 oil pan. Remove the gasket.
I
___ o @ Q? (b) Remove the bolt and union bolt holding the turbo oil
_.._ /J]; pipe to the cylinder block. Remove the 2 union bolt
gaskets.
1;..
",\ V
__ IJU
P‘
Y main
EG-90
i ENGINE —- TURBOCHARGER SYSTEM ‘
Y V ii.1 (c) Remove the 4 nuts. turbocharger and turbo OII pipe
L
assembly, and gasket. "
é I 0 o
_. r
l\'t
E3
~ ~
‘
-s:-;=:;5r@-:5:5<5:5:5:5:;.5s=-
vfl’/A
M-g,@1I I I
15. REMOVE TURBO OIL PIPE AND OUTLET PIPE
ASSEMBLY
Remove the 2 nuts, oil pipe and gasket.
\-‘k
,. F ':|n‘»?@‘
"r an
,-4
Y M3312
16. REMOVE TURBO WATER PIPE
it
Remove the 2 nuts, bolt, water pipe and gasket.
e» ~ P1831 3
17. REMOVE SIDE BEARING HOUSING PLATE

1-? Remove the 2 nuts. housing plate ari¢'1.;gasket.
'-=
Y H8203
EG-91
TURBOCHARGER INSPECTION
J' 1 I
INSPECT ACTUATOR OPERATION
®~ ; 71kP
Disconnect the actuator hose and plug it.
..-...»' ~ lb) Using SST (turbocharger pressure gauge) apply

approx. 71 kPa (0.72 kgf/cm’, 10.2 psi) of pressure to
the actuator and check that the rod moves.
If the rod does not move. replace the turbocharger
Plug ssr Y mm assembly.
izie=zis=s;=e
SST 09992 —0024l

NOTICE: Never apply more than 88 kPa (0.90 kgf/cm‘,
12.8 psi) of pressure to the actuator.
/ as
P? \ . Z’ 2. INSPECT IMPELLER WHEEL ROTATION
Grasp the edge of the turbine wheel and turn it. Check
that the impeller wheel turns smoothly.
If the impeller wheel does not turn or if it drags
heavily, replace the turbocharger assembly.
TCOOS7
INSPECT AXIAL PLAY OF IMPELLER WHEEL

_/' ‘ Insert a dial indicator into the intake side hold the
L
turbine wheel edge by hand, and check the axial play.
Standard clearance:
0.110 mm_(0.0043 in.) or less
T \’ '\| “$3. If the axial D_l@¥._;l§ not as specified, replace the turbo-
charger assemlily.
M6238
INSPECT RADIAL PLAY OF IMPELLER WHEEL

From oil outlet hole, insert a dial indicator through the
a/Q.‘ /""\ hole in the spacer bearing and set it in the center of
4/T #1/\'€W.'.4L‘ / the impeller shaft.
s lb) Move the impeller shaft in a radial direction, measure
./*9‘)?
. ) 1:22
the radial play of the impeller shaft.
Standard clearance:
0.136 mm (0.005-G in.) or less
If the radial play is not as specified, replace the turbo-
charger assembly.
Dial Indicator Needle
§ Spacer Bearing
TC0061
TC0039 zogsyg
EG-92
IIIUA—O\
TURBOCHARGER INSTALLATION
4
w‘ (See Components for Removal and Installation)

x NOTICE: After replacing the turbocharger assembly,
pour approx. 2 cm‘ (0.12 cu in.) of fresh oil into the oil
I‘ ' Inlet and turn the impeller wheel by hand to spread oil on
the bearing.
"
M. TCCIO55
INSTALL SIDE BEARING HOUSING PLATE

r‘? Install a new gasket and the housing plate with the 2
l'IU'I$.
Torque: 11.5 N-m (120 kgf-cm. 9 ft-Ibf)
@‘£‘€
K U,
la
P182133
INSTALL TURBO WATER PIPE

Install a new gasket and the water oipe with the 2
. L - ' nuts and bolt.
"~.= ', ‘," - Torque: 11.5 N-m (120 kgf-cm. 9 ft-Ibf) for nut
e» ~ PINI3
INSTALL TURBO OIL PIPE AND*OUi'I'LET PIPE AS-

SEMBLY
Align the oil holes of the a new gasket and the turbo-
\ ; .,\ .\.‘\'?
charger housing.
\ »:’ -1:3 ~" (b) Install the gasket and oil pipe with the 2 nuts.
'\ .=;I
Y PI83I2
INSTALL TURBOCHARGER
Place a new gasket on the turbocharger.
Install the turbocharger and turbo oil pipe assembly
with the 4 new nuts. Do not toroua the nuts.
)J O ‘
q Q $35,211»
._ I
ENGINE - TURBOCHARGER SYSTEM EG-93)
/“t '1 Fl‘ (c) Tighten the union bolt holding the oil pipe to the
." _ /J_ cylinder block.
(d) Tighten the bolt holding the bracket of the oil pipe to
the cylinder block.
mm: ' 1: Torque: 37 N-m (380 kgf-cm. 27 ft-Ibf)
T "%lI°\ *W°
@u
j
__,- \E
9c (e) Install a new gasket and tighten the 2 nuts holding the
turbo oil outletppipe to the No.1 oil pan.
-<=.=-=- -=:;-
—_/r",1 5-
" Pissio Torque: 20 N-m (200 kgf-cm;'I'I5 ft-Ibf)
7’ ‘~ 1 (f) Tighten the 4 nuts holding the turbocharger to the

/ exhaust manifold.
° <2. ' Torque: 64 N-m (650 kgf-cm. 47 ft-Ibf)
I 41-1.)? ill} 1 Ii
5)»?
tfiij
2/ Y Passe;
‘ _ 5. INSTALL TURBOCHARGER STAY

Install the turbocharger stay with the 3 bolts.
Torque:
Turbocharger side:
69 N-m (705 kgf-cm, 51 ft-Ibf)
Cylinder block side:
\ 58 N-m (590 kgf-cm. 43 ft-Ibf)
/ |._I
6. CONNECT WATER HOSES TO TURBO WATER PIPE)
7. CONNECT AIR HOSE TO ACTUATOR
{iv .’
~/\
ti};ta
I/ ‘.2’
\\
i’ ’>.‘<9~,‘!r=i¢“r? .-"is Y P183138
; E; '. ___
8. INSTALL TURBINE OUTLET ELBOW
(a) Place a new gasket on the turbocharger.
W£ '\ 7 ' K“
F A-' i‘ Q
" ° 45' W‘-T‘

<9’
*7‘)
"
| D\- ‘I
__'._-F
W8?
E’
Y mama
E684 ENGINE — TURBOCHARGER SYSTEM
Q‘. (b) Install the outlet elbow with the 7 new nuts.
‘:1 4 Q Torque: 64 N-rn (650 kgf-cm, 47 ft-Ibf)
_'E. \
(.__ ' S ,_
Y":£51\u
Y PI3:{I7
INSTALL HEAT INSULATORS OF TURBINE OUTLET

\ Q‘ ‘ ELBOW
’ Install the RH heat insulator with the 3 bolts.

Install the LH heat insulator with the 2 bolts.
'
l
/
\)Q1,/’—-\\r
rP"
;a°»‘i
‘U Y
INSTALL OIL DIPSTICK AND GUIDE
Install a.new O—ring to the oil dipstick guide.
Apply soapy water to the O—ring.
Install the oil dipstick guide with the bolt.
\l- :
'
Ins
C5“so» y
New
O-Ring
Insert the oil dipstick.
P1544
INSTALL OXYGEN SENSOR

Install a h3“w gasket, the oxygen sensor and heat
insulator with the 2 nuts.
\ Torque: 20 N-m (200 kgf-cm. ‘I5 ft-Ibf)
V/
Q‘
rat‘
INSTALL TURBOCHARGER HEAT INSULATOR
Install the heat insulator with the 3 bolts.
$1,’
/E “\ <\ ‘,,' V Pm
EG-95
\, ‘ . 13 INSTALL INTERCOOLER
intake air connector, and install the intercooler with
0- =" the 3 bolts.
4. K
Z Y rism
INSTALL CATALYTIC CONVERTER

FILL WITH INTERCOOLER COOLANT
(See page EG—97) I
FILL WITH ENGINE COOLANT
FILL WITH ENGINE OIL
START ENGINE AND CHECK FOR LEAKS
CHECK COOLANT AND OIL LEVELS
56'“ ENGINE - TURBOCHARGER SYSTEM
INTERCOOLER mm
INTERCOOLER COOLANT CHECK
CHECK INTERCOOLER COOLANT QUALITY
Remove the intercooler coolant filler cap.
\
remove the filler cap while the engine and radiator are
Al
still hot. as fluid and steam can be blown out under
Y Pl84?8 pressure. _
There should not be any excessive deposits of rust or

scale around the filler cap or hole, and the coolant
should be free from oil.
If excessively dirty. clean the coolant passages and
replace the coolant.
Check that the level of intercooler coolant is full.

HINT: The coolant level should be within 37 mm (1.46
3 37 mm in.) from the top of the hole, as shown in the illustra-
or less
tion.
If the coolant level is not sufficient. add coolant until
J‘ the coolant level is close to the top of the filler hole.
Y PI84?9
Reinstall the intercooler coolant filler cap.
Y I-H8478
INTERCOOLER COOLANT REPLACEMENT

(a) Remove the intercooler coolant filler cap.
remove the filler cap while the engine and radiator are
still hot. as fluid and steam can be blown out under
Al 1}
éI’ pressure. K.
Y PIMTB
_’_‘_____--—-—'_' (bl Loosen the drain cock (for the sub radiator) and drain
the coolant.
(c) Close the drain cock.
Ifitlzlliz/ii’
TQi -_______£
ME‘
Y P184181
2. FILL WITH INTERCOOLER COOLANT

\ (v T. #0, (a) Slowly fill coolant until it reaches the top of the inter-
cooler refill inlet.
I Use a good brand of ethylene—glycol base cool-
ant and mix it according to the manufacturer's
"”"'@n
\r/ I
directions.
Using coolant which includes more than 50 %
ethylene—glycol (but not more than 70 %) is
Y PI84&) recommended.
NOTICE:
0 Do not use an alcohol type coolant.
O The coolant should be mixed with demineralized
water or distilled water.
O Do not mix engine coolant with the intercooler cool-
ant.
O Do not add coolant to the reservoir.
I Do not mix engine coolant with the intercooler cool-
ant.
0 Performance is reduced if the coolant level is not
full. so make sure all air is bled from the cooling
system.
Capacity:
2.5 liters (2.6 US qts, 2.2 Imp. qts)
EG-98
Start the engine.

Open the throttle valve (IDL contact OFF) to operate
the water pump.
Stop the pump and add coolant if the coolant level has
dropped.
HINT: If the coolant level falls below 33 mm (1.30 in.)
from the full level, the coolant level warning sensor
comes on and the water pump stops.
Repeat steps (c) and (d) above.
When the coolant level stops dropping when the
\\~\§
water pump is turned 0N—0FF, open the bleeder
cock at the top of the sub radiator and bleed the air
out.
NOTICE: After air—bleeding is completed. make sure the
cock is closed securely.
Add coolant and repeat steps (c) to (f).
Y PIBQB2
When the coolant level stops dropping, install the filler

cap on the refill inlet.
Y PI84?8
-4 Remove the EFI fuse (15 A) frorn the R/B No.2 for 10
seconds or more, then reinsert the fuse to erase the
diagnostic code from the ECU.
HINT:
’// .1
I Cancellation can also be done by removing the
EFI Fuse I 7;
‘v \ negative (—) terminal cable from the battery. but
'0
H7244 Q
re \
\\-s R/B No.2
Z13253 0
in this case, other memory systems (clock. etc.)
will also be cancelled out.
If the diagnostic code is not cancelled out, it will
be retained by the ECU and appear along with a
new code in the event of future trouble.
I 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 code has been recor-
ded.
EG-99
INTERCOOLER RADIATOR CLEANING """'"

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 2.942 -—~ 3,432 kPa (30 — 35 kgf/cm‘
427 — 498 psi). keep a distance of at least 40 cm (1 5.75
in.) between the radiator core and cleaner nozzle.
ON —VEHICLE INSPECTION '"""'"

\9Q“ /r O
¢ 1. CHECK ENGINE WARNING LIGHT OPERATION
° = . (a) Turn the ignition switch ON.
} ’<Yn'\\é NOTICE: Do not start the engine.
P13663
(b) Check that the warning light comes on.

(c) When the engine is started, check that the warning
light goes out.
"CHECK" Engine Warning Light
P07???
\ (d) Disconnect the intercooler coolant level warning

Lave I W ammg
I S
ens“ sensor connector.
(e) Check that the warning light does not light up.
\\\ \ Disconnectg
Y PIQQS
(f) Open the throttle valve, and check that the warning
light comes on after. approx. 20 seconds.
PW775
E64 0° ENGINE — TURBOCHARGER SYSTEM
Ohmmeter Ohmmeter INSPECT ENGINE MAIN RELAY

rt 1 Inspect relay continuity
gfi Continuity
J‘ ji
Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
is 1 Check that there is continuity between terminals 2
Ohmmeter 5 '_' and 4.
|:J'_,--ll
‘-3
3 No Continuity Check that there is no continuity between terminals 1
and 2.
‘ Continuity
PIBICD If continuity is not as specified, replace the relay.
Ohmmeter Ohmmeter Inspect relay operation

Apply battery voltage across terminals 3 and 5.
. Q ontinuity
Using an ohmmeter, check that there is no continuity
EI!I3 ' ‘
Ila’
ii_ _ . Li Check that there is continuity between terminals 1
\t~.r‘\-".i
(> l l T-I| and 2.
/ 1,,‘ 1'-15»
ll
mt attery
@-5: 3
Continuity
t -
PIIBIIJI
If operation is not as specified, replace the relay.
INSPECT INTERCOOLER RELAY

(See page EG—104)
INSPECT THROTTLE POSITION SENSOR
(See page EG—161)
INTERCOOLER WATER PUMP OPERATION

4:-= PU86’ O (a) Turn the ignition switch ON and engine running.
S
/4,”;
‘\-
PII53
~" lb) Open the throttle valve, and check that the water
I 7'1.)
\\
pump rotates.
When the throttle valve is closed, check that the
water pump stops after approx. 30 seconds.
\
1
w.5?‘_ - /-
‘I’ '7'§\
F is §
EG-101
Negative (—) Terminal Cable INSPECT INTERCOOLER WATER PUMP

Disconnect the negative (—) terminal cable from the
"l —l _l 4‘? battery.
/1| at Disconnect the intercooler water pump connector.
P1357?
Ammeter Connect the battery and ammeter to terminals +B

and E— of the water pump connector.
s Check that the water pump rotates smoothly, and
‘§_,=
_i'
‘I
..-‘“_
9; IQI check the reading on the ammeter.
Standard amperage:
5.6 A or lass
E- r
NOTICE: Do not operate the pump for more than 30
D Batle
Y P183853
seconds.
Reconnect the intercooler water pump connector.
INSPECT ENGINE ECU FOR CIRCUIT

ECU _7 Disconnect the connectors from ECU.
Alli‘ I Check the connectors on the wiring harness side as

--._ --__..
I H __ I 4 _ A _ J _ ._._.,.,._._._. .,,._.,.,._._.v._._. shown in the chart below.
Ohmmele //
I
E M+
E2 LEV
I Y P1396
Check for I Tester connection Condition I Specified value J

Continuity E2 — Ground - Continuity
M+—Ground I if
Voltage Ignition SW ON 9 — 14 V
M—— Ground
G d Level warning sensor ON (float up) _ Continuity
Continuity LEV — roun _ ~ — ' 3 3 _ _-
Level warning sensor OFF (float down) No continuity
vossos
If circuit is as specified, replace the ECU.

(c) Reconnect the negative (—) terminal cable to the
battery.
EG-102 ENGINE TURBOCHARGER SYSTEM
COMPONENTS
lntercooler Coolant Level Warning Sensor
\\_ ' ®\———i lntercooler Coolant Filler Cap

lntercooler \ ?
_.;|—_~
\ _,
,1" _; (k
/""3 I‘ I
is $1
.‘ \\
l
le'I.,,,
via T@@
T I
\ ‘I \ x ‘ \
\\
Radiator Water Hose \
ifi
-wl
\ \
"k
\
\
\ Reservoir Tank
\ \
*5 \
\ \-
\ \
\ ‘\
\ \
\ \
\ "vs
\
I ’ \\ \
"- ‘h
\ \-
\\ \\
Sub Radiator 5,.
\
g
\-
'5
‘M
\. W
®_, -----.
-e
\Illlll IIIIIIII -.\
‘—- {IllIII II
IIIIIII llllllIIIII-
Radiator Water Pipe --
,
J‘
<8__r~- \_
./
Q-
I
/____
Ct
'.
r
I
_‘
\
Ig,\
i! Cg? \.I‘/)1’.
I Radiator Water Hose
\/
/
,/ Q»\.
I; I II
I
‘a 1
-t
-v ?
» II Ill
[III IIIIII
IIIIIII IIIIIII
\IIIIIII
Jig). _/ I
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\
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I
W1
@ lntercooler Water Pump
Radiator Water Hose

Y H8389
EG-103
INTERCOOLER COMPONENT INSPECTION

40((» Radiator Cap Tester
ls-,, 1. INSPECT INTERCOOLER COOLANT FILLER CAP
Using a radiator cap tester, pump the tester and meas-
‘@§rc_./'0 ure the relief valve opening pressure.
Standard opening pressure:
74 — 103 kPa
Filler Cap
‘ a
(0.75 —- 1.05 kgf/cm‘. 10.7 — 14.9 psi) §»;»;{.;.\
COO034 Z13254
Minimum opening pressure:
59 kPa (0.6 kgf/cm’. 0.5 psi)
If the opening pressure is less than minimum, replace
the filler cap.
2. INSPECT INTERCOOLER COOLING SYSTEM FOR

W Radiator Cap Tester LEAKS
S.
egg,-
L _/
_
*-
la) Fill the cooling system with coolant and attach a
radiator cap tester.
:1’ (bl Warm up the engine.
7}’ (6) Pump it to 118 kPa (1.2 kgf/cm’, 17.1 psi), and check
that the pressure does not drop.
If the pressure drops, check the hoses, radiator or
Y P1829? water pump.
3. INSPECT INTERCOOLER COOLANT LEVEL WARN-

Ohmmeter ING SENSER
ai @~
(B) Check that there is no continuity between terminals
with the switch ON (float up).
lb) Check that there is continuity between terminals with
G61"-'I= 4-DOFF the switch OFF (float down).
ii -
_
If operation is not as specified, replace the sensor.
PO323B 213255
EG-104 ENGINE — TURBOCHARGER SYSTEM
INTERCOOLER RELAY
INTERCOOLER RELAY INSPECTION
1. REMOVE INTERCOOLER RELAY
2. INSPECT INTERCOOLER RELAY

No Continuity
A Inspect relay continuity
Using an ohmmeter, check that there is no continuity
J 1 Ohmmeter
J
-b between terminals 1 and 2.
Ohmmeter Check that there is continuity between terminals 3
2
(bl
and 4.
(0 IF2.-"_.. If continuity is not as specified, replace the relay.
1_T- if
zq
1 Continuity
Y PlB%
B. Inspect relay operation

Continuity
la) Apply battery voltage across terminals 3 and 4.
1 ‘Z lb) Using an ohmmeter, check that there is continuity
as-/I
1‘h
Ohmmeter If operation is not as specified, replace the relay.

2
._-a Eéw I
S Q)
a
Battery
Y P1838?
3. REINSTALL INTERCOOLER RELAY

TURBO PRESSURE SENSOR W

TURBO PRESSURE SENSOR INSPECTION
//
D|sconnect/
1. INSPECT POWER SOURCE VOLTAGE OF TURBO
PRESSURE SENSOR
(a) Disconnect the turbo pressure sensor connector.
/ P184841
i;sz;Y;'-
(b) Turn the ignition switch ON.

&== PU8
/Y O
% ’*un§~
P13663
voltmeter (c) Using a voltmeter, measure the voltage between con-

nector terminals VC and E2 of the wiring harness side.
Voltage:
EB. 4.5 _ 5.5 V
__,_
_ ~
E2 '\
H8485
o<,~(~ F PU (d) Turn the ignition switch to LOCK.
\/ 8*
“ ‘F0.°1.
g in
1:
~?
P136611
/ (e) Reconnect the turbo pressure sensor connector.
\ ~;;e%
“i
\ %% M8486
2. INSPECT SUPPLY POWER OF TURBO PRESSURE

SENSOR
(a) Turn the ignition switch ON.
t\
’<9b'1§
%
(b) Disconnect the vacuum hose from the turbo pressure
//Q sensor.
e \
(c) Connect a voltmeter to terminals PIM and E2 of the
ECU. and measure the output voltage under ambient
ECU
atmospheric pressure.
[ilk ’\
Voltmeter V /:: ---.é=
r
(d) Apply vacuum to the turbo pressure sensor in 13.3
kPa (100 mmHg, 3.94 in.Hg) segments to 66.7 kPa
,0 (500 mmHg, 19.69 in.Hg).
(e) Measure the voltage drop from step (c) above for each
segment.
\\ Voltage drop:
Applied
Vacuum
i 1 3.3 26.7 40.0 53.3 66.7
($23.)
in.Hg.
(5.33) (32%) (13951) <1?-.935) (12929)
Voltage
drop v . _ . . _ OSJOS
. . _ 07
. . _ 09
. . _ .
0103 03 07 0911
W550?
EG-107
. ENGINE — TURBOCHARGER SYSTEM
(f) Using SST (turbocharger pressure gauge). apply pres-

x
sure to the turbo pressure sensor in 9.8 kPa (0.10 kgf/
cm’, 1.4 psi) segments to 49.0 kPa (0.50 kgf/cm’, 7.1
\~‘ psi).
£111 I
I/
SST 09992—00241
/
t Q)‘ P184-89
(g) Measure the voltage up from step (c) above for each
I
segment.
Voltage up:
Applied
jet’
,.,s.».-.-=:¢.¢-Ki
2:9;-;:=:1:~<;;:;:;:;:;:=r:r' s_.\
Pressure 19.6 29.4 39.2 49

kPa
<*@z;:~*>
Voltage
I"_‘\
0.05 —
l (3?) (°f§°) (‘l-3°) (°1'.51°)
-mom._,.-ham
0.20 — 0.35 - 0.50 — 0.65 -

up V 0.20 0.35 0.50 0.65 0.80
VO55Cl8
(h) Reconnect the vacuum hose to the turbo pressure

sensor.
‘.9. l *6‘
,.
3” st.1
Reconne
W
P184911
EG-108
(For Turbocharging Pressure)

VSV INSPECTION
1 REMOVE vsv
C . Ohmmeter INSPECT VSV

Ommulw Inspect VSV for open circuit
Using an ohmmeter, check that there is continuity
between the terminals
I/ Ii
Fri")
22 — 26 Q at 20°C (68°F)
at lf there is no continuity replace the VSV
Ohmmeter Inspect VSV for ground

No Confinuny Usin 9 an ohmmeter, check that there is no continui TY
- Li
between each terminal and the body
If there is continuity replace the VSV
EHer-gm
1-‘- /
Inspect VSV operation

Check that air does not flow from port E to F
Apply battery voltage across the terminals

Air
Check that air flows from port E to F
If operation is not as specified, replace the VSV
7* "\ I I 3
REINSTALL VSV
\ E ;=,~,__
Fe in
lies
EG-109
SERVICE SPECIFICATIONS
SERVICE DATA
Turbocharger Turbocharging pressure e2 — 115 kPa (0.84 — 1.17 kgf/cm’. 11.9 — 16.7 psi)
Impeller wheel axial play 0.110 mm (0.0043 in.) or less
Impeller wheel radial play 0.136 mm (0.0054 in.) or less
lntercooler Relief valve opening pressure STD 74 — 103 kPa (0.75 — 1.05 kgf/cm’. 10.7 — 14.9 psi)
coolant Limit 59 kPa (0.6 kgf/cm‘. 8.5 psi)
fmercap
lntercooler Rotating amperage 5.6 A or less
water pump
VSV for turbo Resistance at 20°C (68° F) 22-261‘!
—charging
DFBSSUTB
TORQUE SPECIFICATIONS
Side bearing housing plate x Turbocharger 1 1.5 120 9
Turbo water pipe x Turbocharger Nut 11.5 120 9
Turbo oil pipe x Turbocharger 17 175 13
Turbocharger x Exhaust manifold 64 650 47
Turbo oil pipe x Cylinder block Bolt 37 380 27
Union bolt 39 400 29
Turbo oil outlet pipe x No.1 oil pan 20 200 I5
Turbocharger stay x Turbocharger 69 705 51
Turbocharger stay x Cylinder block 58 590 43
Turbine outlet elbow x Turbocharger B4 650 47
Oxygen sensor x Turbine outlet elbow 20 200 15
EG-110
ENGINE — EFI SYSTEM
EFI SYSTEM
DESCRIPTION
[O-lIl'l—Q_l_
Fuel Pump
Intake Air Temp. Sensor
‘l
VSV
:_—- — —-
_ _:-_-__ Fu 9| -|-an k Fuel Filter _A
_ _ ___
r ISC
. . I J ll. — ’€
i 4 Valve
T -
. ‘ '1--.
2 5---‘ .5; ,
r__‘|‘,:’_
lntercooler Coolant ' I ' . 4--4 I _ _j N
Level Warning Sensor I IiI
I
,_ .
-9 -
_ v‘ ----.,‘l “
'-'9 Throttle Q] GR Valve.
_ "“" Position
Sensor
lntercooler
; , Fuel Pressure
i , Ftegulator _ _
:_ ln|ector
\‘“\ _\§\‘- \
Turbocharger I gm .,_
e- nunu-i Q
\..
, ‘T ' ' ' ' ' ' ' ' ' ' ’ ” ' ’ ' "\ ~_ I '-------------- ,-/I
\\\\.
,“;,,,,,,,',l,. I"- 1/ I 1
Y_
~\\
Oxygen Sensor I | I Water Temp. Vacuum
(hi. _ v-_\\ Sensor Sensor ‘
._,_\_
I1l
.. 1
\\\\\\\‘-'
mt
$\‘§\\\\;\‘\\ Intake Air
Knock Sans
T-‘\<O - Temp. Sensor :
\ \__-- . -_I
._. .“\ §'
'\ \ \ \ \ \ \
-i--i
(I)1.<
‘T 1..l . ._._-‘_\
Fuel Pump
- Relay *
l
0 Ignition Switch —
ECU
"CHECK" Engine
Warning Light
~ Dellogger Ftelay TO
.. lntercooler Coolant
= Vehicle Speed Sensor
- Tallight Relay water Pump
—
A/C Idle-Up Valve I
igniter
Check Connector - Starter
Q stributor
Ill
Stop Light Switch I
A/C Arnplilier
Pl79?l
ENGINE - EFI SYSTEM E64"
The EFI system is composed of three basic sub—systems: Fuel, Air Induction and Electronic
Control Systems.
FUEL SYSTEM
Fuel is supplied under constant pressure to the EFI injectors by an electric fuel pump. The
injectors inject a metered quantity of fuel into the intake manifold in accordance with signals
from the ECU (Engine Control Unit).
AIR INDUCTION SYSTEM

The air induction system provides sufficient air for engine operation.
ELECTRONIC CONTROL SYSTEM
The 3S—GTE engine is equipped with a TOYOTA Computer Controlled System (TCCS) which
centrally controls the EFI, ESA, ISC, Diagnosis systems etc. by means of an ECU—formerly EFI
computer employing a microcomputer.
The ECU controls the following functions:
1. Electronic Fuel Injection (EFI)
The ECU receives signals from various sensors indicating changing engine operating conditions
such as:
0 Intake manifold pressure
Intake air temperature
Engine coolant temperature
Engine speed
Throttle valve opening angle
0 Exhaust oxygen content etc.
The signals are utilized by the ECU to determine the injection duration necessary for an optimum
air—fue| ratio.
2. Electronic Spark Advance (ESA)
The ECU is programmed with data for optimum ignition timing under all operating conditions.
Using data provided by sensors which monitor various engine functions (rpm, coolant tempera-
ture, etc.), the microcomputer (ECU) triggers the spark at precisely the right instant.
3. Idle Speed Control (ISC)
The ECU is programmed with target idling speed values to respond to different engine conditions
(coolant temperature, air conditioning ON/OFF, etc.). Sensors transmit signals to the ECU which
control the flow of air through the throttle valve bypass and adjust idle speed to the target value.
4. Diagnosis
The ECU detects any malfunctions and abnormalities in the sensor network and lights a check
engine warning light in the combination meter. At the same time, trouble is identified and a
diagnostic code is recorded by the ECU. The diagnostic code can be read by the number of blinks
of the check engine warnig light when terminals TE1 and E1 of the check connector are
connected. The diagnostic codes are referred to in a later page. (See page EG-1 18)
5. Self—Correction Function
If any sensor malfunctions. an average value recorded in the back—up circuit is substituted to
make driving possible. If danger is predicted, the engine is stopped and the check engine warning
light will light up.
6. Fail—Safe Function
In the event of the sensor malfunctioning, a back—up circuit will take over to provide minimal
driveability, and the check engine warning light will illuminate.
E6412 ENGINE — EFI SYSTEM
OPERATION M
FUEL SYSTEM
::;:-' 5 ;;3>;-
Fuel Pressure Regulator Fuel Tank
.. QA Tl
§/ l > /> J //'
\‘IQ Q\k( Fuel Pump

\\\
Delivery Pipe
'_r §»‘//
Iniectgr FUBI FIIIGT
Y Pl6='J<i>
Fuel pumped up by the fuel pump, flows through the fuel filter and is distributed to each injector
at a set pressure maintained by the fuel pressure regulator.
The fuel pressure regulator adjusts the pressure of the fuel from the fuel line (high pressure side)
to a pressure 250 kPa (2.55 kgf/cm’, 36 psi) higher than the pressure inside the intake manifold
and excess fuel is returned to the fuel tank through the return pipe.
Fuel is injected into the intake manifold according to signals from the ECU.
ENGINE - EFI SYSTEM E6413
I\IK—l1
AIR INDUCTION SYSTEM
Throttle Body
|me,c°°|er Intake Manifold
(Air Intake Chamber)
. st! “"1; 5 ->
U. //\
U
in\\ 11$
2 W’
Ed
Turbocharger Air Cleaner
Y H8335
Air is filtered through the air cleaner and the amount flowing to the air intake chamber is
determined according to the throttle valve opening in the throttle body and the engine speed.
Intake air controlled by the throttle valve opening is distributed from the air intake chamber to the
manifold of each cylinder and is drawn into the combustion chamber.
At low temperatures the ISC valve opens and air flows through the ISC valve and the throttle
body, into the air intake chamber. During engine warming up, even if the throttle valve is
completely closed, air flows to the air intake chamber, thereby increasing the idle speed (first idle
operation). The air intake chamber prevents pulsation of the intake air. It also prevents intake air
interference in each cylinder.
EG-114
I531.-‘I11
ELECTRONIC CONTROL SYSTEM
Vacuum Sensor
VSV for EGR

Intake Air Temperature Sensor
(tor Intake Manifold) Circuit Opening Relay
Knock Sensor
gs;
' ‘ _ ECU
1
Oxygen Sensor f .
I O
r’
Fuel Pump Relay
i A/C Idle-Up Valve
Water Temperature Sensor

I Solenoid Resistor
Fuel Pump Resistor EFI Main Relay
l
Intake Air Temperature Sensor
(for Air Cleaner Case)
Y F'lB45Z
The control system consists of sensors which detect various engine conditions, and an ECU
which determines the injection volume (timing) based on the signals from the sensors.
The various sensors detect the intake air pressure, engine speed, oxygen density in the exhaust
gas, engine coolant temperature. intake air temperature and atmospheric pressure etc. and
convert the information into an electrical signal which is sent to the ECU. Based on these signals,
the ECU calculates the optimum ignition timing for the current conditions and operates the
injectors. The ECU not only controls the fuel injection timing, but also the self—diagnostic
function which records the occurrence of a malfunction, ignition timing control, idle speed
control and EGR control.
EG-1 15
PREPARATION fiflfi-01

-5
.435 at 09209 -41045 Injection Measuring Tool Set
~=-="-;-~:§.r
W
GI
éée
(0926ls'-41090) No.6 Union

f:§§§§:=1¢t=:'45i‘§l‘¢§i§iE.'
'-iii3E51§%s§iil4£=i5;1;»3
I
1 All 'i9'0ki0'5'-1090151 0.; 051°;
0 09842 —30060 Wire ‘E’ EFI Inspection Injector
)1 09843-18020 Diagnosis Check Wire
RECOMMENDED TOOLS
09002-00050 TOYOTA Electrical Tester Sat
09200-00010 Engine Adjust Kit '

% % ”=__.
I
09258-00030 Hose Plug Set Plug for vacuum hose, fuel hose
y <92 QQC.
<§ °’
EOUIPMEMT
Carburetor cleaner Throttle body
Graduated cylinder Injector
Soft brush Throttle body
Sound scope Injector
Tachometer
Thermometer
E6416 ENGINE - EFI SYSTEM
‘ Torque wrench i r
KCG—l\
SSM (SERVICE SPECIAL MATERIALS)

08826-00080 Seal Packing Black or equivalent Cylinder head cover
(FIPG)
,5 _\ Q 5»?
-.- :»}Z°¢j
DIAGNOSIS SYSTEM W
DESCRIPTION
The ECU contains a bui|t—in self—diagnosis system by which troubles with the engine signal
network are detected and the check engine warning light on the combination meter light up.
By analyzing various signals as shown in the later table (See page EG-1 18) the ECU detects
system malfunctions relating to the sensors or actuators.
The self—diagnosis system has 2 modes, a normal mode and a test mode.
If a malfunction is detected when in the normal mode, the ECU lights the check engine warning
light to inform the driver of the occurrence of a malfunction. (For some codes the light does not
come on.) The light goes OFF automatically when the malfunction has been repaired. But the
diagnostic code(s) remains stored in the ECU memory. The ECU stores the code(s) until it is
cleared by removing the EFI fuse with the ignition switch OFF.
The diagnostic code can be read by the number of blinks of the check engine warning light when
TE1 and E1 terminals on the check connector are connected. When 2 or more codes are
indicated, the lowest number (code) will appear first.
If a malfunction is detected when in the test mode, the ECU lights up the check engine warning
light to inform the technician of the occurrence of malfunction (except for code Nos. 42, 43 and
51). In this case, TE2 and E1 terminals on the check connector should be connected.
In the test mode, even if the malfunction is corrected, the malfunction code is stored in the ECU
memory even when the ignition switch is OFF (except code Nos. 42, 43 and 51). This also applies
in the normal mode. The diagnostic mode (normal or test) and the output of the check engine
warning light can be selected by connecting the TE1, TE2 and E1 terminals on the check
COFITIBCTOT.
A test mode function has been added to the functions of the self—diagnosis 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 self—diagnosis system. The technician can
start the test mode by following the appropriate check terminal connection procedure.
DIAGNOSTIC CODES
HINT:
If a malfunction is detected during the diagnostic code check, refer to the circuit indicated in the
table, and turn to the corresponding page.
Your readings may vary from the parameters listed in the table, depending on the instruments used.
is:';>”.<.\.'.1sr'-:>.-mat
'l-{>1-I/"<2,. " mu we
?t:*;;;‘::,>.y Chock Engine"
-<:~:.>.. :.<>:~-'- 11*
Coda Number ol blinks of Check Warning Light
System Diagnosis Trouble Area Memory " Sea Page
No. Engine Warning Light Normal Test
Mode Mods
Normal No trouble coda is recorded.
H1401
l Open or short in NE, G
I No G1, G2 or NE signal is
circuit
12
__iL'Il_ RPM Signal ON N.A.
input to the ECU for 2 sacs.
or more after STA turns ON.
0 Open in G - circuit
Distributor
Open or short in STA circuit
O Ee-193
ECU
NE signal is not input to ECU
Open or ahon in NE circuit
13 __l'l_'Jlll_ RPM Signal ON ON
for 0.05 sec. or more when
engine speed is 1,000 rpm Distributor
ECU
O
Of 711078.
Open or short in IGF or IGT

lG signal from igniter is not
14
__ll_'_lllllL Ignition Signal ON N .5. input to ECU for B consecutive
ignitiona.
circuit from igniter to ECU
igniter O EG-134
ECU
Sub-CPU Sub-CPU
15
__lU.1JlJllllL ON N.A.
Malrunction ECU X
Open or short in heater

Open or short in heater circuit
circuit or oxygen sensor
N.A of oxygen sensor for 0.5 sec. or
Oxygen sensor heater
more. lH'l'l
ECU
At normal driving speed lbelow
Oxygen Sensor Open or short in oxygen
71 ON ‘I00 ltmlh I60 mph] and engine O EG-137
Signal sensor circuit
speed is above 1,500 rpml.
Oxygen sensor
amplitude of oxygen sensor
ON Open or short in vacuum
signal lOX‘ll is reduced to
sensor circuit
between 0.35 - 0.70 V
Vacuum sensor
continuously for 00 secs. or more.
ECU
H1609 l2 trip detection logic)
Open or short in water

Water Temp.
Open or short in water temp.
temp. sensor circuit
22 ON ON sensor circuit for 0.5 sec. or O EG-132
Sensor Signal W810! temp. $611301‘
more. ITHWI
Fl‘I6‘l0 ECU
Intake Air Open or short in intake

Temp. Sensor
Open or short in intake air
air temp. sensor circuit
24
Signal (tor air
ON ON temp. sensor circuit for 0.5 O EG-130
Intake air temp. sensor
sac. or more. {THAI
cleaner case) ECU
H1811
Engine ground bolt loose
Open in El circuit
Open In injector circuit
Oxygen sensor output in less Fuel line pressure
Air-Fuel than 0.45 V for at least 90 secs. llniector blockage. etc.)
25 Radio Lean ON ON when oxygen $InI0r is warmed Open or short in oxygen O EG-137
Malfunction up (racing at 1,500 rpm). sensor circuit
(2 trip detection logic) Oxygen sensor
Ignition system
Water temp. sensor
FI2562 ECU
l
Open or snort detected Open or short in vacuum

Vacuum Sensor continuously for 500 msec. sensor circuit
31 ON ON O EG-128
Signal or more in vacuum sensor Vacuum sensor
sensor circuit. lPlMl ECU
H1512
WE-{I57
EG-119
DIAGNOSTIC CODES lCont'dl

Check Engine“
Coda Number of blinlta ollfiheclt swum Warning Light mlgnohh
No Engine Warning Light Mum.‘ 7eat Trouble Ana Memory" Sea Page
Made Mode
Open or ahort in vecu um

lonaor circuit
Turbocharging Abnormal over charge during Vacuum eenaor
34
_ll.7.T__'J U Ll L Pressure Signal
ON NA.
high load driving. Open or short in IG SW or
EFI rnain relay circuit
BE3933 ECU
Open or short in throttle

Throttle Position
Open or short detectd in
position lensor circuit
ll
47_'JT_| \_ Sensor Signal
ON ON throttle position censor signal
ll/TA! for 0.5 sac. or more.
Throttle position sensor EG426
ECU
SPD signal is not input to the
Open or short ln vehicle
Vehicle Speed ECU for at lust 8 aeconoa
speed senor circuit
42
_'.'.lL'_J U l_ Pulse Generator
Signal
OFF OFF during high load driving with
engine lpeed between 2.000
Vehicle apaad aanaor
rpm and 5.000 rpm. ECU
I Open or short in starter

Starter signal (STA) ia not signal circuit
43
_T.'JULl ll U L Starter Signal N.A. OFF Input to ECU until TE1 and E1
are connected.
I Open or short in IG SW or
EFl main relsv circuit
EG-133
Q ECU
With engine speed between Open or short in ltnocl: sensor
2,850 rpm and 7,300 rpm. signal circuit
Knock Sensor
52 ON N.A. from knock aensor is not input Knock sensor
Signal
to ECU for 2 revoiutiona. llooaeneaa, etc.)
H1618 IKNKI ECU
Engine speed is between 700
Knock Control rpm and 7,300 rpm and ECU
53 ON NA. ECU
Sig nel lfor lrnocl: control) malfunction
H1619 il detected.
lntercooler water pump

lntercooler relay
lntercooler lntercooler water pump motor lntercooler water ourn p circ uit
54 System ON N.A. is locked or intercooler coolant lntercooler coolant level EG-96
Malfunction level is low. sensor
lntercooler coolant level
P036130 level senior circuit
1
A/C switch circuit
Displayed when A/C is ON or Throttle position Qtllllbf IDL
Switch
51 NA. OFF IDL contact OFF with the check circuit EG~'l26
Condition Signal
terminals E1 and TE1 connected. Accelerator pedal, cable
F|l6‘l7 ECU
REMARKS:
*1
"0N “ displayed in the diagnosis mode column indicates that the check engine warning light is lighted
up when a malfunction is detected. "OFF" indicates that the check engine warning light 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.
-it-2
"O" in the memory column indicates that a diagnostic code is recorded in the ECU memory when a
malfunction occurs. "X" indicates that a diagnostic code is not recorded in the ECU memory even if a
malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is performed
with the ignition switch ON.
\/05458
E6420 ENGINE ~ EFI SYSTEM
TROUBLESHOOTING w/ VOLT. OHMMETER
HINT: E6-ll‘T"Ol
I The following troubleshooting procedures are designed for inspection of each separate system,
and therefore the actual procedure may vary somewhat. However. troubleshooting should be
performed while referring to the inspection methods described in this manual.
I Before beginning inspection, it is best to first make a simple check of the fuses, fusible link and
g-“>3.
E the condition of the connectors.
0 The following troubleshooting procedures are based on the supposition that the trouble lies in
either a short or open circuit within the computer.
0 If engine trouble occurs even though proper operating voltage is detected in the computer
connector, then it can be assumed that the ECU is faulty and should be replaced.
IQQU -OI
FUSES AND FUSIBLE LINK LOCATION
IGN Fuse
GAUGE Fuse
[l
I I
ST Fuse
U5 ‘ AM2 Fuse
U0
T|
A13
' xv;
elites/. 4Q U 1:1
N
Z1
Z1
Z1
Z
Z
MAIN FL
IU
[1
El] MAIN H - Fuse
Y P1833?
IIAII
EFI SYSTEM CHECK PROCEDURE
_i“
P /'_' g Lock PREPARATION
Disconnect the connectors from the ECU.
‘5' v,
=-
KI I "V l(bia) Remove the locks as shown in the illustration so that
the tester probe(s) can easily come in.
Lock
§
'
»/7L-
n n
T‘
NOTICE: Pay attention to sections ‘A’ and "B" in the
illustration which can be easily broken.
B H2944 (cl Reconnect the connectors to the ECU. ,
HINT:
0 Perform all voltage measurements with the con-
ecu U nectors connected.
- . . . . . . . . . . . . 0 Verify that the battery voltage is 11 V or more
DUDDDUUUDOD UDDDDIJ I
unuouunnnuoo , uouooo uouunnuee. when the ignition switch is in the "ON" position.
_{ ._g 1 . . '
voltmeter V +5
E1 Using a voltmeter with high impedance (10 kQ/V
minimum), measure the voltage at each terminal of
the wiring connectors.
M8294
EG-122
ECU Terminals
Symbol Terminal name é Symbol Terminal name Symbol Terminal name

TURBOCHARGING
E01 POWER GROUND TPC AC1 A/C AMPLIFIER
PRESSURE VSV
E02 POWER GROUND / ACT A/C AMPLIFIER
#10
#30
INJECTOR
INJECTOR 4 ENGINE GROUND
TD _\ SPEED sewson I
\
\U,
#20 INJECTOR VF CHECK CONNECTOR ATS A/C AMPLIFIER

#40
RSO
INJECTOR
ISC VALVE /
I FPR FUEL PUMP RELAY
\
\
VISC
RSC
INT
A/C IDLE-UP VALVE
ISC VALVE
INTERCOOLER RELAY I TE2
TE1
OX
CHECK CON NECTOR
CHECK CONNECTOR
CHECK CONNECTOR
\
\
HT
OXYGEN SENSOR
HEATER / W WARNING LIGHT
/
MTT
INTERCOOLER WATER
PUMP l
l
KNK
THW
KNOCK SENSOR
WATER TEMP. SENSOR

\ STP I STOP LIGHT SWTICH
THROTTLE POSITION INTERCOOLER COOLANT
IGT IGNITER IDL
SENSOR I-EV LEVEL SENSOR
INTAKE AIR TEMP.
SENSOR
EGR EGR VSV THA
FOR AIR CLEANER
CASE
INTERCOOLER WATER THROTTLE POSITION FC CIRCUIT OPENING
M+ VTA
PUMP SENSOR RE LAY
G2 DISTRIBUTOR PIM
TURBO PRESSURE ‘ TAILLIGHT RELAY,
SENSOR EL5 DEFOGGER RELAY
I
INTAKE AIR TEMP.
SENSOR
G1 DISTRIBUTOR THAM
(FOR INTAKE)
MANIFOLD
NE DISTRIBUTOR VC SENSOR POWER SOURCE BATT BATTERY
G- DISTRIBUTOR E2 SENSOR GROUND +B EFI MAIN RELAY
IGF IGNITER STA STARTER SWTICH
M_
INTERCOOLER WATER
PUMP
ECU Terminals
l E01
E0?
IIO
I30
I20
I60
RSO RSC
VISC INT
HT
MTT IGT
EGR
M»
GI
G1
NE
G~
IGF
M»
TPC
El
VF
FPR TEI
OX
TE2 KNK
THW TNA
IDL
PIM
VTA IMAM
VC
E2
STA AC1
ACT
SP1 ATS W STP
LEV FC
ELS MP1‘
-B
F l2796
IAISAEQ
ECU Wiring Connectors Voltage
No. Terminals Condition STD voltage IVI See page

1 +B—E1 IG SW ON 9-14 EG-‘I24
2 I BATT-E1 9-14 EG-I25
lDL—E2 I Throttle valve open 9-14
VC—E2 4.5 — 5.5
3 -A IG SW ON EG-126
Throttle valve fully closed 0.3 - 0.8
VTA-E2
Throttle valve fully open 3.2 - 4.9
PIM -E2 2.2 -2.8
4 Al l
t EG-128
VC-E2 4.5- 5.5
IG SW ON
#10. #30 E01
9-14 EG-129
5 #20. #40 ' E02
6 THA— E2 EG—130
-——i—-i‘ Intake air temp. 20°C (68°Fl 0.5 — 3.4
7 THAM -E2 I IG SW ON EG-131
8 THW—E2 Coolant temp. 80°C l176°Fl 0.2 -1.0 EG-132
We STA - E1 I Cranking 6 or more EG—133
10 |GT—E1 Cranking or idling Pulse generation EG-‘I34
RSC
11 RSO—E1 * IG SW ON ECU connectors disconnected 9-14 EG-135
No trouble (Check engine warning light off) and engine

12 W—E1 9-14 EG-136
running
ECU Terminals
H . . . l . . _ .._
cow I10 no nso esc HT sen oz we IGF we vr ox mw ‘IRA PIM vc sn m1 SP1 ATS w st? [T5 “-1
E02 no I40 VISC mt mt IGT an cn 5- u- :1 FPR 1-£1 TE: not It-it vra mm ea T |_5v H; .5
H2796
\/05460
EG 124
Terminals
+B — E1 I
Trouble
No voltage I Condition
IG SW ON I
STD Voltage
9 -14 V
EFI Main Relay /-..'5_‘?_‘!é

Q/'-Q ___.W~ O e a O +B
Ignition Switch 'I'

' - Q .
0 5 o I 0 Q 0' IG2 I
MAIN GOA AM2 3OA ° . ' '
MAIN FL \\
Battery
0
.F;. T Pl8321
® There is no voltage between ECU terminals +B and E1.

EW . I G) IIG sw om
V It tel,
Ill DO B3 DDDODD
-"""——'-I
"W i_?_
DD DD
|
I
O me 51 Check that there is voltage between ECU termin al +8 and body
' I +8 I® ground. IIG sw om
IE‘ + N0 I o|<
Check wiring between ECU terminal E1 and body
mam ® ground.
OK BAD
.
ECU ®
D8
u DOCID DC! DO SC OD
DD DCICICIDU ODD
OODO DD ODODDO
‘I
I Repair or replace
IL
Voltmeter i
Checkfuses, fusible links and ignition BAD
Repair or replace
I switch
.! ' ll OK
Check EFI main relay. Replace.

% P18295
Check wiring between EFI main relay ‘ BAD I

Repair or replace
ECU
T HIE;-‘:51!
%"i'i‘!‘a‘a‘: u nuo0Ibe:a|'|
Ohmmeter ~ I Law‘ H '
5,1 ?“<:E1 I
-1 ' H2755 I
VC546
EG-1 25
No Terminals Trouble Condition STD Voltage

BATT — E1 No voltage - 9-14V
ECU
EFl15A
e/<> QBATT
MNNFL:
Battery
E1
\____/
PW814
Voltmeter
ECU
.. III
.¥HflFL"4"".
IVE‘ qt - a o a n | n I ‘if-‘n'afu'a‘=
— L1. I —
'e‘a'o‘n'¢'a'e'|‘a‘ I
— '‘
® I @ There is no voltage between ECU terminals BATT and E1.
Y
Check that there is voltage between ECU terminal BATT and
Ed “I II >~ ® body ground.
\§
NO Iok
ground.
FI2753 OK
® Try another ECU. Repair or replace.

ECU 7 7 __
Voltmeter ‘
W
A
<III
::':§"::""' _::i:::"i
.___ F
I
I Check fuse and fusible link.
Y
OK
_
Check wiring between ECU terminal
5A9
H Replace.
, BAD I .
err;-xa I and battery. Repair or replace.
FI2754
©
Ecu_
1.“. . . . L . . ._ If. .'.'.‘
(5-1 I -1 u ‘ ¢‘|’v 'a'c'a' '1' ‘I In‘-‘I uu‘n‘n' I‘
Ohmmeter ' I I AH" I W‘
MEI I
H2755
VC5462
EG-126
No. Terminals I Trouble Condition STD Voltage

IDL — E2 Throttle valve open 9-14V
VC -E2 — 4.5 — 5.5 V
3 No voltage IG SW ON
Throttle valve fully closed I ea-eav
VTA - E2
I Throttle valve fully open I 3.2-4.9 v
ECU
+B
Throttle Position Sensor
E2
E2
IDL IDL
VTA VTA
VC VC
El
7-T ‘H368
(DI . IDL-E2
ECU ‘ There is no voltage between ECU terminals IDL and E2.
Vonmeterl _I_lIlLIllII_‘ IIIIIIQ
.....:‘;‘..:._._._..:
‘ . . . ";
. . . . T. -
® IIG SW ON) lThrottle valve open)
% \ . 7 -.
IIIIIIIIIII u ur-
l—.
Check that there is voltage between ECU terminal +8 and body

i® ground. IIG SW ONI
r-xgr-1 IDL E/2
NO I OK
F I2782 Check wiring between ECU terminal E1 and body
ground.
ecu ® OK BAD
- - - - a a - .
DCIU I‘ CIOOODD 1 IJDDGDCIDDD
ga DD DD DD DD CIDOD DO OD DOD I I DOCIOCID I I CIDDDDGDOD I Try another ECU. Repair or replace.
I
Refer to +B - E1 ‘troubleshooting BAD
WV +8 section (No.1l. (See page EG~124)

‘I
Rep“ °' 'e°'a°"'
\\_ P1B295
Check throttle position sensor.
® (See page EG-161) BAD
Ohmmeter © BAD
O
Repair or replace I Check wiring between ECU and I
throttle position sensor. throttle position sensor.
Throttle Position Sensor Egl
OK
VC ll‘
VTA I T‘ _
Pm
. ' Try another ECU.
IDL _
E2
I
III
_ FI4-757
VC5463
EG-127
G) 0 VC-E2
Ecu No voltage between ECU terminals VC and E2.
(D "G SW °""
Voltrrlieter C
/,5 X
E2~ 1
A‘ 7 Check that there is voltage between ECU terminal +B and body
Z21 ground. IIG SW ON)

I Q|( i 1 N0
. . B — E1
Hm“ Check throttle positron sensor. Refer to + . "°§“"°
@ troubleshooting section (No.1)
(See page EG-161)
Ohmmeter ® (See page EG-124)
I
1 BAD 1 OK
Throttle Position Sensor Repair 0, ,ep|ace_ b Check wiring between ECU and throttle
to position sensor.
VC ,. I OK BAD
VTA
r’ I1-1] i Try another ECU. I Flepair or replace.
|;|q\
IDL ip
E2 V
|l
H4757
0 VTA-E2
®
Voltmeter
ECU
‘ i
WeE “ 7'
No specified voltage at ECU terminals VTA and E2.
® “G SW °"’
1 7
I
' Check that there is voltage between ECU terminals VC and E2. I
E5. @ no sw om
IE-3
NO OK
FIZ763 Refer to VC - E2
troubleshooting section.
2
O OK
ECU'- ' _'_,_ I ___ _ _ __ Ch 6C k th YOttl 8 pOSl‘t’ION SBHSOT. BAD _
$+:+:+:<:-:-:-:::~::'=:;:»:~:~:¢A;-:':~:-:-:-:»:‘J i @ (see page E9151) R806" 0' replace-
Voltmeter ' —T-
' ion
/ /
l Check wiring between ECU and throttle BAD
Repair or replace
COO‘
position sensor
l I I
ox
H2784
Try another ECU.
Ohmmeter ®
VC
VTA
IDL
,. ll‘l
E2 ‘ I‘;
' 1 Fl-1757
VOSIG4
E6428 euerne - EFI SYSTEM
No. Terminals Trouble Condition STD voltage

HM-E2 Z CD 22-zav
4 No voltage IGSWON
VC - E2 as-ssv
Vacuum Sensor ECU

rim
M a I1 | d Absolute
Pressure Sensor
*.-:;,>;.;:11-‘;;1t1;<:,:,‘.;;
iE2
PIM PIM
VC
oVC
TFE1
_ ii-l
_ mm
C) There is no voltage between ECU terminals PIM or VC and E2.

ecu i® us sw om
;:-:-:-:-:-:~:-:-:-:-:-:~: :-:¢:-:-:-: ~ ~:-:-:-:-:-:-:~:-:-:
v%%%§r Pwfléfiggéf/. I
Check that there is voltage between ECU terminal +8 and body
gt. ’® ground. IIG SW ON}

OK NO
l
Refer to +8 — E1
troubleshooting section
(N0-ll (See page EG-124)
ecu (3
Q Q I Q Q Q . Q Q Q . Q u\
I
DDDDDDDDDDD CIODDDO
UDCIDDUO IILlI!"L"
@ Check wiring between ECU terminal E1 and body ground.‘
Voltmeter —--— ml
ii
OK K BAD
U, M U +8 1'
Check vacuum sensor. | Repair or replace.
BAD
Y
Replace vacuum Check wiring between ECU and vacuum
/, mazes
sensor. sensor.
10K BAD
C) Try another ECU. I Repair or replace.
ecu
r1':':':'::::':'=':':,5 *,: ~::'n-on------------
on mn- ...:l
Ohmmeter l ‘l'_”'*
/—l_
W1_
D
" H2756
V05465
EG-129
ENGINE — EFl SYSTEM
s Q2: fig - E3; No voltage IG sw on 9 - 14 v
Ignition Switch ECU

AM2 30A AM9 we
l
Solenoid A ,~
MAIN BOA “‘ Resistor
0 o 0 0 ‘
#10 #20 #30 #40
MAIN FL
Injector
O
No.10 No.20 No.30 #40
Battery #30
#20
#10
I E01
E02
T
P18322
0 In
#20 ® There is no voltage between ECU terminals #10, #20, #30 andl or
|\ i® #40 and E01 and/or E02. IIG SW ON)
#30 u 1
voltmeter
l v r I
R.‘\.:~;.~.s~.—m>i-x t.'r'::
5°)’ ll
___ l '":--.~.-.-1.-~ E l
‘
Ch ec k t h att h ere -IS spec -ifi e d v olt age b etween s ol eno -Id resistor
® terminal +B and body ground. STD voltage: 9 - 14 V
. 7
-
i<'>l°‘J51 .?°2 °" i“°

Check fusible links, wiring BAD K Repair
7 or
H5314 and ignition switch. replace.
Voltmeter ®
Solenoid Resistor Check that there is specified voltage between resistor terminals
@ (#10, #20, #30 or #40) and body ground.
E STD voltage: 9 - 14 V
II‘
\\§‘-9.1‘-=
-- -> a.
Oo_e
O
\§\§i\:l;/0 .1-= OK NO
Replace resistor.
§"!1fi" #20 #30 |
‘ti-Fl‘ #10 #4-0 :
+B 7 mm Cergglrovviring between ECU and solenoid V BAD ‘ Repair or replaw
>\,
(3) l ox
Oh mmeter
Check resistance of each injector. BAD . . .
IQ) STD resistance: 2 - 4 Q i i Reps" Imecton
\\\\
k I I I
lot
i.\ ;\.
-,_
“ ‘,
r:_"\i I Try another ecu. |
\ iz
P1845?
VU5466
EG-130
Terminals Trouble Condition STD voltage

THA - ez i No voltage i to sw on | Intake air temperature zo~c isa°|=1 i 0.5 - 3.4 v
ECU
K-“M
Intake Air Temp. Sensor J3+B
(for Air Cleaner Case)
-\ ¢=~'.'a'~';: "
THA oTHA
E2 0 e2
E1
1
-: ki;
msn
G) There is no voltae between ECU terminals THA and E2.

@ no sw om
y ECU
;:§.¢.....-.-.‘..~.»;.....é‘L =l r
Voltmeter i
_ —'"""
THA. p E2. ® Check that there is voltage between ECU terminal +B and body
I _ I } ground. ilG SW ONl '
OK NO
Refer to +8 - E1
H2767 troubleshooting section
lNo.1l- (See page EG-124)
ECU ®
<
'0' '0' '0'
I _
DDIJDCIDDUDUD DCIDUDD DD DDDDDUD
DDOODDDUDDD DODODD CIDDDDDD Check wiring between ECU terminal E1 and body ground.
Voltmeter
‘OK BAD
. @ Check intake air temp. sensor.

V BAD
Repair intake air
temp. sensor.
N
L OK
Check wiring between ECU and intake
air temp. sensor.
BAD
® Try another ECU. I Repair or replace.
I: Ohmmeter
§,4fl'
,
§¢‘5‘§_
l i K);
POIGSB
ENGINE —- EFI SYSTEM EG4 31
No. I Terminals Trouble Condition STD voltage

7 ] THAM — E2 No voltage IG SW ON | Intake air temperature 20°C l68°Fl 0.5 - 3.4 V \
ECU
F?
Intake Air Temp. Sensor
(for Intake Manifold) O +3
THAM 0 ’=- -$
E2 0 E2
E1
-: \-Q
Fl3572
(D E There is no voltage between ECU terminals THAM and E2. W

ECU ® IIG SW ONl
Vonmeter iii]
L 177-7?-I_r:t;‘ ,
THAME Check that there is voltage between ECU terminal +B and body
'1 @ ground. us sw om
Refer to +B - E1
mazo troubleshooting section
(No.1). (See page EG-124)
ecu ®
. . _.. Y
of-ql-Ilnnr-!;iiiiiiF --III-I-|
Check wiring between ECU terminal E1 and body ground.
Voltmeter |
+8 BAD
e. @(S§;p;';;;_';6;§"P
Ch k‘ t k ' t . .
Repairorreplace.
.
| BAD 10K
Y
F mm Repair intake air Check wiring between ECU and intake
A
T temp. sensor. air temp. sensor.
@ BAD
‘V Try another ECU. I Repair or replace.
0 h mmeter
‘:I
on-.»
!f'.—'
!
'I'I'I"I"I‘I‘I‘I‘
5i:%':.'J
F1831!
WEN
EG-132
Terminals Trouble Condition STD voltage

THW - E2 No voltage f I eswon | c oolant temperature 80°C l‘l16°Fl 0.2- 1.0V
ECU
Water Temp. Sensor O +B
»- OTHW
E2
O E2
E1
\______J
F1351-'2
® I There 'IS no voltage between ECU terminals THW and E2. .

@ (IG SW ONI
ECU
uJIH_uH" ""
Voltmeter
fi nu an on
"' —--*
%i§%;i
t " t 1-*-t=t%.i*j3t:t5.‘ r1:!r3rl'T-.l_t!;?;‘ *1-1 no II no - II 1‘
Ch eck that there is voltage between ECU te rminal +B and body
{ 1.21 i O
WTHWC
I 1 _ E2 I ® ground. (IG SW ON l
():e
l_v __o
OK NO
Flefer to +8 - E1
H2766 troubleshooting section
iNo.1l- (See page EG-124)
ECU
I
Voltmeter
DDDODDDODDO
DCIDUDD _
D I -- DD
ODDDOD ‘JODDCI onOD ]
Check wiring between ECU terminal E1 and bod y ground. I
‘-on
4- W OK BAD
_—
ta Y
@ Check water temp . sensor. I Repair or replace.
+ _
F%%%!
00 BAD lox
Replace water Check wiring between ECU and water
I temp. sensor. tBmp. sensor.
A P182535
1 OK BAD
(D Tr
Y“"°""=' E°“- I
T II
" Ohmmeter
, '—5*"
X § .
gunllnma @
-an
P0162?
W51‘-16'?
ENGINE - EFI svsrsm E6433
No. I Ter minale Trouble I Condition I STQ voltage
9 I STA - E1 I No voltage Cranking 6 V or more
Ignition Switch ECU
AM2 30A
.
‘£3 2 S
MAIN 60A \\
MAIN FL :\ e e
Starter Relay
' Starter '
Battery I °'
.| ':
' —‘
Z f ‘= Z T
P18323
Voltmeter
If ‘W1
ECU
I
l-
I
Titl-
I
.1... .11"._-‘e_-'.
(E1 W 321/
(D
§»:7:»:':~:r:-:~:7:~§‘
Y
CD There is no voltage between ECU terminals STA and E1.
(IG SW START)
Check starter
operation.
ox Check wiring between ECU terminal STA
and ignition switch terminal ST2.
BAD OK BAD
I 0
Repair or replace.
F1218!
@ Check wiring between ECU terminal E1 and body

a. ECU I ® ground.
Ohmmeter I
».=f=.=.=.e-=.=»=r=i=-Q‘-=.=r=:=.=.=;.r-—~ IQK BAD
l_§'iT_']
_ ?|4rE1 E 5 I Try another ECU. I Repair or replace.
I
I Check fusible links, battery, and ignition BAD Re air or re lace
switch. p p '
"' rmss QK
l
® ® Check that there is voltage at terminal 50 of starter.
(IG SW START) STD voltage: 6 V or more
Voltmeter
QB I
Terminal 50 Starter V OK I N0
|, Checlt wiring between 1). ST2 and starter
r_ \_ i,--— _" ; Check starter. relay, and 2). battery and starterterminal
lw 5».
I
’ man
\|'U5470
E6434 enema - EFI SYSTEM
Terminals I Trouble I Condition STD voltage
IGT - E1 No voltage Idling Pulse generation
Ignition Switch Ignition Coil ECU
AM2.
IG
0 O
.
AM2 son ' O . O
MAIN 60A \\
O
O
igniter
MAIN FL k\ O
.
I IGT
I O
Battery --I 0 IGF
To Tachometer ~ E1
= \_i/
r
P I B333
®.
There is no voltage between ECU terminals IGT and E1.
ECU _ __ @ ildlingl
3
I€‘1%,‘I-%Z-i‘é7I‘:~i~Z:lt;i._,i_7iIi lti : _;»:7:~::":7I I I _
Vmmeter \ VIA A i Check that there is volta 9 e between ECU terminal IGT and bod v
Iii.
.v . IGT I E1 t I @ ground _ Ildlingl
-
5-0 ' NO IOK
III
U Check wiring between ECU BAD Repair or

H2770 ® terminal El and body ground. » replace.
OK
®
ECU H IW Try another ECU.
v0%
It t 8|’ ‘
_v_
> _ _._L.._.A..
IGT \
I
>1
V1
_ _.., _.A
" I r
Check fusible links and ignition switch. I?-IBAD Repair or replace.
O 1» 00 I V OK
Check distributor. I Ii-IBAD Repair or replace.
OK
F|TI1'| y
Check wiring between ECU and battery. I—————-I Repair or replace.
ECU ® 1°“
Check igniter. HAD_ Repair or replace-
Ohmmeter '
5
I c
IE1
FI2755
VO54'r'l
EG-135
No. Terminals I Trouble Condition STD voltage
11 RSC — E1 I No voltage IG SW ON I ECU connectors disconnected 9 - 14 V

RSO
ISC Valve ECU

EFI Main Relay f ‘t
EFI t5A ~~i 0 0 RSC
O./U I e I O O " AHA
lqnltlon Switch Hi ' RSC’ 3%”
. .
e e AM2‘ |G2
§. z\i 80> AM2 30A 1 I e e +B
IGN 7.5A
MAIN FL \\
I
Battery
E1
= I: ‘ ,
P183241
l ECU
® There is no voltage between ECU terminals RSC or RSO and E1.
I @ IIG sw ONI
|
FISO 53¢
zi i__
Check that there is voltage between E CU terminal +B and body
Voltmeter ” "Q ® ground. IIG SW ON)
1/E1
E|I
NO
Reier to +8 - E1
P03472 troubleshooting section
lNo.‘ll. (See page EG-124)
EC U
EIODDOUDDDDDDCIDDDCIDOOCI
DDDCDDGDDDD DDDODO EIDDDOODDD
Ki-. Liitl
Check resistance between ISC valve
Voltmeter terminals +8 and RSC or RSO. Replace ISC
ii
ll ‘I! *5 ' ® STD resistance: BAD valve.
Aprox. 19.3 - 22.3 Q
I0i<
Check wiring between ECU and ISC BAD .
Repair or replace.
valve
4 P5225
In
Try another ECU.
Ohmmeter ®
I
\‘/.
.
if:
RSO—-— -
Y mass
V054?2
EG436 ENGINE - EFI SYSTEM
No trouble l"CHECl(" engine warning light olfl 9 _ 14 V
12 W - E1 No voltage and engine running.
ECU
rim
..... .. .. .,; GAUGE 10A

. . . h i_ Q . QW
2;%l1g)nition Switc o -do "CHECK" Engine I
Warning Light
Combination Meter I E1 -4 '
Q4
H0728
@ G) There is no voltage between ECU terminals w and E1.

_ __ é Z_ Ildlingl
Voltmeter
Iii
I62
“
ill ‘ “
eiii
’l7:':<:¢:%.:1:~:.+':+'1>12::-:l:;:~:' -‘:1-Iri lti’-Z:': -2‘-_1I
"
_J V
® Check thatthere is voltage between ECU terminal Wand body
ground. .
e
ii ‘er N0 IOK
FI2772 ground.
OK BAD
®
ECU Try another ECU. Repair or replace.
A _ _ _ Y
Voltmeter
V WI cn e ckGAUGE fLlSBi1U A) and "CHECK" I
O
engine warning light.
‘i
O
OK I BAD
I I Repair or replace. I
rmrzi V [Fuse blows again
Check wiring between ECU terminal BAD .
® W and fuse‘ Repair or replace.
ECU
_
.....
Ohmmeter
E;
IIgl-
I H2755
V054i'3
EG-137
ECU
To EFI Main Relay -4 I)+B .

ox
Oxygen
Sensor n M
OE1
ChecltConnector VF
iiii
l .- .el
W31 E1
OX1
YHT
PI 3838
(D I @ There is no voltage between ECU terminals VF and E1.

I
ECU Check that there is voltage between ECU terminal VF and body
ground.
no I OK
I Check wiring between ECU terminal E1 and body ground. I
I oi< BAD
vr- Flvi I? @020
e
H3575
I Try another ECU. BAD Repair or replace.
1
ls air leaking into air induction
Ii-IBAD Repair or replace.
(9 system?
SST ‘OK
l Check spark plugs. Ii—-IBAD Repair or replace.
/I“,
I 13
IOK
IiIl‘,I \ Check Connector Check distributor and ignition system. Ii-IBAD Repair or replace.
.W IOK
._a.N.-'l»t_‘.'=-43.1.;
wt’ | @E TE1 Check fuel pressure. I—?-IBAD Repair or replace.
I,0i<
iiL%ii E I CIIGCK IHIBCIZOTS. (See page EG-148) Ii>IBAD Repair or replace.
Voltmeter
l_I I oi<
Check vacuum sensor. I——HD Repair or replace.
: SST
l°'<
@ Check operation of oxygen sensor. I 0. C-J: System normal.
I BAD
Check Connector fg '5'_|'
-5"-"i
| ll e I"-‘ \/F1 Check wiring between oxygen sensor BAD
and ECU Ii-I Repair wiring.
II n || IOK
gm E1 " Replace oxygen sensor. I
P06331
P06326 T
VO54TlI
FUEL PUMP
Ignition Switch
A 2'
AM2 30A ‘ ‘ ST 7.5A
1-,_,-g
+B
@
I CD D T.
0 it‘ ii
I
Fuel Pump
e e
E
iii
EIEIIB
Check Connector
I e e
F IPU
: ' : . C_ _t Fuel Pump Relay Rggistormp
EFI Main Starter ~ WCUI
I I
Relay “°"Y - Fp 82$?“ To ecu (FPR)
e e 0 I O FC
0 To ECU iFCl
STA
Negative (—) Terminal Cable ON —VEHlCLE INSPECTION

_I_I _I FUEL PUMP INSPECTION
an
S”
/
O ;Q ~:!~ _
121
1. DISCONNECT NEGATIVE (—) TE RMINAL CABLE
FROM BATTERY
2. DISCONNECT FUEL PUMP CONNECTOR
gt“/%;~\
(a) Remove the wire protector.
(b) Disconnect the fuel pump protector
9
iti /
ENGINE — EFI SYSTEM E6439
3. INSPECT FUEL PUMP
2 -_. 1 '
1. Q .-/ _ _
‘"; !?"" \\
\
A. Inspect fuel pump resistance
Using an ohmmeter, measure the resistance between
l‘,\‘*§a. \< the terminals ‘I and 2.

Resistance:
5%;
113 5, pump.
0.2 — 3.0 Q at 20°C (68°F)
If the resistance is not as specified, replace the fuel
€€‘~"E
.\
,,..
\ / /V’/-I;-IE5-3‘1lD
B. Inspect fuel pump operation _

2 __ v=-
,/
)_/_
..-__ Connect the positive (+) lead from the battery to
/Z
terminal 1 of the connector. and the negative (—) lead
//_. to terminal 2. Check that the fuel pump operates.
&§\.
- If operation is not as specified. replace the fuel pump.
‘—I—
NOTICE:
__,_..-
0 These tests must be performed quickly (within 10
Battery seconds) to prevent the coil from burning out.
mi I Keep the fuel pump as fer away from the battery as
possible.
I Always perform switching at the battery side.
4. RECONNECT FUEL PUMP CONNECTOR

(a) Reconnect the fuel pump protector.
(b) Install the wire protector.
fie
0
-.4
____,i
Pl333‘53
5. CONNECT NEGATIVE (—) TERMINAL CABLE TO

BATTERY
EG-140 ENGINE — EFI SYSTEM
ilfif-OI

INSTALLATION
/ Q Gasket
Cut Off Valve ,,
Evaporation Tube
.1 --"-3”’
.1 I’, >
/ii AV 71¢
/
Fuel Pump Bracket

Assembly
¥I
IIn‘:
Q5?
§Gasket A A A Q
@ »*T @ 5' Q
i
N-m (kgf-cm. it-Ibf) : Specified torque
O Non-reusable part
Negative (—) Terminal Cable

\\§
FUEL PUMP REMOVAL
Y P18-453
IGIl—lII
__l ,_ <5 (See Components for Removal and Installation)

- .'*_ -“ CAUTION: Do not smoke or work near an open flame
. ‘,2 1.
when working on the fuel pump.
DISCONNECT NEGATIVE (—) TERMINAL CABLE
FROM BATTERY
2. DRAIN GASOLINE FROM FUEL TANK
3. REMOVE FUEL TANK
4. REMOVE FUEL PUMP BRACKET FROM FUEL TANK

la) Remove the 4 screws and 7 bolts.
§\< (b) Pull out the evaporation tube. fuel pump bracket and 2
gaskets.
AO9902
iéé 2132111
ENGINE — EFI SYSTEM E6441
comromznrrs FOR DISASSEMBLY AN|5""'°'
ASSEMBLY
Fuel Pump Bracket
W "1-_
€§v
~=-\¢-fQ"
‘I l“‘ \\
-¢’
+ ,-'
Fuel Pump
@o‘Q-)
~ Fuel Pump Filter
@-——i 0 crap
— Rubber Cushion
Y
Q Non-reusable part P181154
FUEL PUMP DISASSEMBLY

1. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Disconnect the lead wire connector from the fuel
pump.
As904
»;_.;:,;+"y-4 é§_ Zl$D7
(bl Pull out the lower side of the fuel pump from the
bracket.
(c) Disconnect the fuel hose from the fuel p u mp; and
remove the fuel pump.
(dl Remove the rubber cushion.
?/
Y Pl?-197
EG-142
ENGINE -— EFI SYSTEM
2. REMOVE FUEL PUMP FILTER FROM FUEL PUMP

r /""\
/ §\ \\, Remove the clip and pull out the pump filter.
ll
lt R.‘ \
L; _
//L11?/i R
/M
(A
EG I Y P184155
[G171 -DI
FUEL PUMP ASSEMBLY
//> Q New Clip (See Components for Disassembly and Assembly)

1. INSTALL FUEL PUMP FILTER TO FUEL PUMP
/’ Install the pump filter with a new clip.
P181155 Y Liqltg
2. INSTALL FUEL PUMP T0 FUEL PUMP BRACKET

(8) Insert the outlet port of the fuel pump into the fuel
hose.
(b) Install the rubber cushion to the lower side of the fuel
pump.
(cl Push the lower side of the fuel pump, together with
the rubber cushion, into the fuel pump bracket.
(d) Connect the lead wire connector to the fuel pump.
~?“aIr_,<~
.r 1-5 \
A9904 \ 212201
EG-143
/ FUEL PUMP INSTALLATION

1. INSTALL FUEL PUMP BRACKET
[B47]-DI
\
/T;/
//9
/
A
,(\©st
(a) Place the fuel pump bracket and evaporation tube
with 2 new gaskets on the fuel tank.
(b) Install and torque the 7 bolts and 4 screws.
Torque:
Bracket: 2.9 N-m (30 kgf-cm. 26 in.-lbf) '
Bent tube: 3.4 N-m (35 kgf-cm. 30 in.-lbf)
2. INSTALL FUEL TANK
3. REFILL GASOLINE
4. CONNECT NEGATIVE (—) TERMINAL CABLE TO
BATTERY
5. CHECK FOR FUEL LEAKAGE
EG-144
PRESSURE REGULATOR
ml14~qi__
Vacuum Sensing Hose Fuel Pressure Regulator
\¢~§
I I /
Fuel inlet Hose
{M l;l_x1;_ ta" e4» r 2‘/is T
I
l
7\<%\ ‘
Delivery Pipg Fuel Return Hose
Y P1809’;
EG-145

INSTALLATION
ii
. Gaske‘ Vacuum Hose
.
v .1’ /--—'~ __ _,-—'\ Throttle Positron
L __,/' Q Sensor Connector
axis
~' -§‘// I——i:
HIE!
Yo Alr Connector Stay
ISC Valve Connector Intake Air Connector
Throttle Body \~ lntercooler
Clamp Air Connector
Gasket 1
‘<2-
/*\
Cool Air Inlet

._- , '1
.-ell}-L
!
‘1
Accelerator Cable Bracket
\_ €!_.
\\\ ?Pl
:5
\';5“
High-Tension Cord LJ .
,. " Gasket CIBITIP sis-.‘|
4
1"“ '::;\\‘
~ _--e
I 0"?
Spacer fl’\ -A Seal Washer
1‘ ‘ tame
Cylinder Head Cover u t
Fuel Hose
Gasket Delivery Pipe \ . Gasket
No. 1 PCV H
Fuel Pressure Regulator
\S _ =" '
‘» _ V $‘\§‘
-‘< No 1 Air H ose
N03 water Bypass Hose
Engine Wire
O O - Ring
'
Q Insulator
‘A'0.
Spacer \¢'i*t\§.,. No 1 PCV Case
e3 a
-F5‘
fqwlt
EGR Vacuum Modulator
EGR VSV Connector
.6
= Specified torque /\\\

O Non-reusable part Y
M8498
EG-146
I0flI—0I
FUEL PRESSURE REGULATOR REMOVAL
1. REMOVE DELIVERY PIPE
(See steps 1 to 11 pages EG—15O to EG~—152)
2. REMOVE FUEL PRESSURE REGULATOR

(a) Disconnect the fuel return hose from the fuel pressure
regulator.
(bl Loosen the lock nut, and remove the fuel pressure
'\\.;- Q
regulator.
{J
'9
S
A099l6 7
Q
"/ ZISZH
New Ming FUEL PRESSURE REGULATOR IflIW1—5I
© INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR
la) Fully loosen the lock nut of the pressure regulator.
\_,/ lb) Apply a light coat of gasoline to a new O—ring. and
install it to the pressure regulator.
A08579 ZIKHO
(cl Thrust the pressure regulator completely into the de-

livery pipe by hand.
_ __ (d) Turn the pressure regulator counterclockwise until

\:/ the fuel return pipe faces in the direction indicated in
the illustration.
O
I M8W%
(B) Tighten the lock nut

K (fl Connect the fuel return hose to the fuel pressure
&
*./Mir
'>\»'70
~"\\/ §
regulator.
2. INSTALL DELIVERY PIPE
(See steps 1 to 12 pages EG—-157 to EG—159)
\
AO591S F / Z1339
ENGINE —- EFI SYSTEM
EG-1 47
INJECTOR
EO4TI—Q|
injector Fuel Inlet Hose

Fuel Pressure R89U|6't0r 1'."-Fmzr <.
i
a /‘fay’
r
.3?» /
~o ‘\\o
Q-..\\\§‘
Delivery Pipe
t
t
\
¢ ~ .\ Fuel Return.Hose
Ignition Switch ECU

AM2 30A AM2
' ' £-‘G2 +8
I Solenoid
MAIN 60A ll Resistor
I
#10 #20 #30 ' #40

MAIN Fl.
I
Injector
Nofto No.20 No.30 .4

Battery E
P‘l83BZ
P18322
213203
EG-148
ENGINE —~ EFI SYSTEM
ROI" ~01
ON—VEHlCLE INSPECTION
_.§
1. INSPECT INJECTOR OPERATION
\\
Sound Scope 3%
\l\ la)
Check operation sound from each injector.
With the engine running or cranking, use a sound
scope to check that there is normal operating noise in
proportion to engine rpm.
EG
_ Y mes-or
(Q (bl If you have no sound scope, you can check the injec-
\\ tor transmission operation with a screwdriver.
If no sound or unusual sound is heard. check the
T \§ wiring connector, injector or injection signal from the
‘\l
5%» ECU.
Y F1350?
2. INSPECT INJECTOR RESISTANCE

la) Remove the throttle body.
(See page EG—l63)
(bl Disconnect the 4 injector connectors.
\..
cr,-
.7) -
A09738 4132i?
\
To
\ 1|; L (C)
Ohmmeter ' ‘
~.__{1_. the terminals.
(2%-
¥)»: "--_
r Resistance:
Approx. 2 — 4 Q at 20°C (68°F)
V $5»
/4;... j
.¢'-.-.-.-iféfi» If the resistance is not as specified, replace the injec-
33*‘
Ni
21"‘ ‘IIOF.
\_. V P1345?
id) Reconnect the 4 injector connectors.

is) Reinstall the throttle body.
(See page EG—166)
EG-149
ENGINE —- EFI SYSTEM
I-D41.-OI

INSTALLATION
Vacuum Hose —
/i- asrrrrwr
(3 k1 ..\ _,,-~*- _,-»" Throttle Position
T as 6 ‘§y.-*3; ___-/' Sensor Connector
I 5 ‘ad t——-1
ISC Valve Connector —-7Q Pk‘
‘QC Arr Connector Stay
" \_ ? Intake Air Connector
Throttle Body
.
‘iS
Gasket
~. M
Clamp
'
9. P~r.
.5
Q
Air Connector
Accelerator Cable Bracket 6

Cool Air inlet
i
High-Tension Cord J
5
r1,__) S gger -v
_n
p Clamp
\
i
ti»
0"”
."9
I o"‘wI//it
“’!‘\_
-\'
- ‘- 4»-—SeaIWasher
I t
lntercooler
No.1 PCV Case
Cylinder Head Cover \ J

Z Gasket
No.1 PCV Hose

Fuel Hose No.1 Air Hose
w é
No.3 Fuel Tube
No.3 Water Bypass Hose
‘A . s
‘ Injector Cover
r,
m\
Fuel Hose Q0-Fling
O Insulator
9-.
\at
\\\
\\ t
tr t '1
Fuel Hose
O Gasket
O Insulator
K
Delivery Pipe
/_:\§
’
Spa8'A
si
Q Insulator
Engine Wire
EGR Vacuum Modulator
%
Q -‘< /gqkthtie
6,
-5‘
J %—- EGR VSV Connector
‘J
= Specified torque \\
Q Non-reusable pan
Y P185110
EG-150
00471-01
INJECTORS REMOVAL
(See Page EG—163)
2. REMOVE NO.1 PCV CASE

,
la) Disconnect the No.2 PCV hose from the cylinder head
// coven
(bl Disconnect the No.3 water bypass hose from the
No.1 PCV case.
(0) Remove the No.1 PCV case from the bracket.
l§=F\i\
§\ ,y /-\/\,\_>/it/f"
k"M\_\ <'i’J)\)/y
/*
‘rl
‘J.
r/I . ~{5"*~
/’ \‘$z“§?4-‘-ea“ ‘
Y P185-03
,-f 3. REMOVE VSV AND EGR VACUUM MODULATOR

/I
,__
ta) Disconnect the VSV connector.
(bi Remove the following hoses from the EGR vacuum
modulator:
~i‘t\\
(I) Vacuum hose (from EGR valve)
I / (2) EGR hose (from EGR valve)
.‘
JT T (2)
\ \
§€
L/1’ Y Pl845S
(c) Remove the 2 bolts, VSV and EGR vacuum modulator

,--—-""T\/
i assembly.
_-~’ 1
kt.-
.>
-4&1
-Re.
_)
.V I ~
_/T7‘ i‘l§_:_3@
% \ \ '~'=“ i
REMOVE HlGH—TENSlON CORDS
Remove the 3 bolts, and pull out the high—tension
cords from the cylinder head.
/ "\_./ "
II
A A 7,!-"\.»\.;-_
1 \ " \\
A09749 ' Zi32l4
6. REMOVE NO.3 WATER BYPASS HOSE AND NO.1
AIR HOSE
Remove the following hoses:
(1) No.1 air hose (from No.1 air tube)
W
o
‘Q,
fit
>>\
'1‘/I
of aw
3?
A0975O
‘X H335
145
(2) 2 water bypass hoses (from No.1 air tube)
. _ '§‘~\~‘/‘
,J 4
AO97..»l 213216
7. REMOVE NO.1 PCV HOSE
risP I -
3./I \l{ I i 5;
l
j
r
.r if
/ filo
k ‘W F‘l8-‘$73
8. DISCONNECT ENGINE WIRE

Disconnect th e 2 bolts. an d d|'sconnect th e engine
\-o
' (B wire from the No.4 timing belt cover.
r 9. DISCONNECT VACUUM SENSING HOSE FROM
PRESSURE REGULATOR
t/‘ii’
ea?
\k\
5"‘.5
A09752
nn*‘Q“\
,__
Zl32l
10. REMOVE CYLINDER HEAD COVER WITH NO. 4

TIMING BELT COVER
~41 (a) Remove the gasket and spacer

(b) Remove the 10 bolts. cylinder head cover with No.4
\\
/ timing belt cover. and gasket.
g
/ /
/\
'Q,
5‘ *\ \%
/
NOTICE: Cover the cylinder head with a clean shop rag to
ll .’l_ l I
itt "i
prevent damage to the cylinder head and camshafts.
\'-\|'|‘”'
r ill
o ~‘\ f .
i ,7, J
F\/ "‘\' as
REMOVE DELIVERY PIPE ASSEMBLY
Disconnect the 4 injector connectors.
/ ..\\,,
i'!-"=-.-’
»
.“ (Ms-~
AO9912
Q-Z cu?
in
Q
{Q
=-sg‘
%.* J1¢l32l9
.
Remove the union bolt and 2 gaskets, and disconnect

the fuel inlet hose from the delivery pipe.
/N
Qfi
is4; * s 9
A09915
its
\@\O\“e
o -»g
.
\
4 ‘£9’
7' ah
‘
\ 2
$7;
r
ZI322l
Loosen the 3 bolts holding the delivery pipe to the
cylinder head.
Remove the delivery pipe and 3 spacers.
ENGINE — EFI SYSTEM EG-153
BOT"-0!
INJECTORS INSPECTION
E
Pressure
Regulator
\t':\\
SST
J.)
we :
E
?\
1. INSPECT INJECTOR INJECTION
CAUTION: Keep injector clean of sparks during the test.
5,; (I
. I1-F’ <1",
" ‘F SST
La.
~ “ H
©
ssr -Y-—%__
@ _
\
Fuel Filter .
(on Vehicle)
Y P185313
X (a) Remove the union bolt and 2 gaskets, and disconnect

K the fuel inlet hose from the fuel filter outlet.
\ 90 NOTICE: When removing or installing the union bolt fix
the fuel filter in place using a spanner.
fit
(b) Connect SST (union and hose) to the fuel filter outlet
?—umon Bolt
SST
‘ with 2 new gaskets and union bolt.
SST Wnronlfi New SST 09268-41045 (90405—0901 5)
(Hose) Gasket Torque: 29 N-m (300 kgf-cm. 22 ft-Ibf)
-__
Fuel Filter
\-_-.-/
P151523
(cl Connect the fuel return hose to the fuel outlet of the
Union Bolt W SST No.3 fuel tube on the delivery pipe.
New Gasket / (Union) id) Connect SST (union and hose) to the delivery pipe
I 31o with 2 new gaskets and the union bolt.
Pressure K
Re 91ulator Fuel Return SST 09268-41045 (O9268—41080)
. » /" ' Hose Torque: 32 N-m (325 kgf-cm. 24 ft-Ibf)
(Bl Put the injector into the graduated cylinder.
SST(Hose)
Y F‘l853I
4
__ (fl Using SST, connect terminals +B and FP of the check

B connector.
L / SST 09843-18020
41/ Reconnect the negative (—) terminal cable to the
battery.
g)- mi
Check Connector
PISIOO Zigmu
Turn the ignition switch ON.

NOTICE: Do not start the engine.
Z1
“M5
1*‘
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 09842— 30060
I
Z Volume:
120 — 150 cm‘ (7.3 — 9.2 cu in.) per 15 seconds
Difference between each injector:

5 cm’ (0.3 cu in.) or less
If the injection volume is not as specified, replace the
injector.
/ ‘ INSPECT LEAKAGE
In the condition above, disconnect the tester probes
of SST (wire) from the battery and check for fuel
leakage from the injector.
_?._‘ vi ‘\-
SST 09842 — 30060

Fuel drop:
One drop or less per minute
P185134
Turn the ignition switch to LOCK.

\9 xaz pl-/8
Disconnect the negative (—) terminal cable to the
battery.
Remove the SST.
SST 09268-41045, 09843-18020
'5
.
:10
“fir;
'\___\_\
(e) Reinstall the fuel inlet hose to the fuel filter outlet with
§ Ar 2 new gaskets and the union bolt.
NOTICE: When removing or installing the union bolt fix
the fuel filter in place using e spanner.
qr
" _'_i;?;i°_‘€‘%‘;’T"
PISZSQ
iiac
INJECTORS REPLACEMENT ‘°"“°'

‘ (See Components for Removal and Installation)
Q ’ i 1. REMOVE INJECTOR COVER
e!',__
_ (a) Disco nnect the fuel hose from the fuel pressure regu-
4&5’ W. lator.
~' (b) Remove the 4 bolts, N o .3 fuel tube and injector
' ' cover.
(c) Remove the 4 insulators from th e injectors.
' '
P1&-ui
;__ 2. REMOVEINJECTORS
pi
Gasoline (a) Apply gasoline bet ween the delivery pipe and injec-
'—l; tors.
_’
vxewwwfign
\\\\\“‘
\\\\\
ES‘
’ \ \ \ \ \ ~\ \ \ \ \ \ \ K
\\\
'
SW\-\ 2_
I Gasoline
F I 54%
I (bi Using SST, lift up the 4 in'jectors.

E SST O926B— 74010 (O9268— 04020)
,_--
/ /'
i \ ;-r C
,_ -
,-»—-‘<
/\
J/'
1
er ssr
IQ. / F ISZ33
i (c) Pull out the 4 injectors f rom the delivery pipe.

(d) Remove the insulator and 2 O—rin g s f rom each injec-
C‘ tor.
‘<14
J
F1535“
3. INSTALL INJECTORS
(a) Apply a light coat of gasoline to 2 new O—rings.
9 (b) Install the 2 O—rings and new insulator to each injec-

IIO|'.
New insulator
01111131?
FI5383
(c) Push in the 4 injectors so that the injector connectors

are positioned as shown in the illustration.
O e
1//R /S of
“re f%'~ F C:
.A-T I Q‘ Q‘
I . ' . ‘f .
‘
_§;q_
H5092
P18505 2335.5
4. INSTALL INJECTOR COVER

(a) Install a new insulator on each injector.
X
i L» ,
' 5'
v
_¢
.
é
W‘ W
New Insulator &
Y P185416
(b) Install the injector cover and No.3 fuel tube with the 4
bolts.
Torque: 7.8 N-m (80 kgf-cm. 69 in.-Ibf)
I I 4 \ _
(c) Connect the fuel hose to the fuel pressure regulator.
O
_ i or
r’Piie
- “fir
Pl$?5Ul
10415-01
INJECTORS INSTALLATION
\/fv (See Components for Removal and Installation)
& 1; 1. INSTALL oauveav PIPE ASSEMBLY
(a) Install 4 new insulators to the delivery pipe.
P18730
ii New lsulato F A
€#fi¥%?“”
Z1315
(b) Install the 3 spacers to the cylinder head.

NOTICE: Install the spacers with the metal side toward
k
hi __ C
. the cylinder head.
@
der
2 T
3 it _~—””“
(Q 1323
(c) Install the delivery pipe assembly with the 3 bolts.

_\
\ 1
\t:~\* ‘\§Z;}\
7
e4»
AO9915 Z1332
id) Connect the fuel inlet hose to the delivery pipe with 2
/7‘ new gaskets and union bolt.
/. -\ l (Bl Connect the 4 injector connectors.
/2% // Km HINT: No.1 and No.3 injector connectors are brown,
No.2 and No.4 injector connectors are black.
t
AO99l3
/“ \~"-11” >> \\)fi5§$j;
/// Zlifla
£f~s i 2. INSTALL CYLINDER HEAD COVER WITH NO. 4

p_/~1L_/Mn/\_r
.r;>aTyjo1*]_ nine-Inn TIMING BELT COVER
:_ Ky; _-i IIIIIIIIIIEIIIIIEI la) Apply seal packing to the cylinder head as shown in
“J';_._jo ‘O . ~ 0 the illustration.
i.i;ilo_ 0 <><;
YT;
($33, (*0
'5‘
"U .-l ‘.:.,
-<5
:Sea| Packing
‘Ill
. 0
llillllalillllil
‘
o
I Seal packing:
FIR /H
EG-158
(bl Install the gasket to the cylinder head cover.

(C) Install the cylinder head cover with the No.4 timing
I /’
belt cover. 10 seal washers and bolts. Uniformly tight-
en the bolts in several passes.
Torque: 16 N'm (60 kgf-cm. 12 ft-Ibf)
Id) Install the spacer and gasket.
3. CONNECT VACUUM SENSING HOSE TO FUEL
K\ PRESSURE REGULATOR
AO9753 ZI32l8
4. INSTALL ENGINE WIRE

Install the 2 bolts, and connect the engine wire to the
"F
ab? No.4 timing belt cover.
AO9752
Z7.5
J
/one\<)m\‘Q“\ Zl'*"l?
E%‘/
5. INSTALL NO.1 PCV HOSE
TI;
-9-as K
'\\@
fla-
/ F Pl84T3
V ( 6. INSTALL no.3 WATER BYPASS HOSE AND NO.1

>4‘ \
»\ ” 1" X AIR HOSE
b Q Install the following hoses:
\ (1) 2 water bypass hoses (to No.1 air tube)
A0975I
~>‘ 213216
.,
\
l (2) No.1 air hose (to No.1 air tube)
In
sq’
E!’
9*’
?
K‘_/ ,9’
M19750 H3215
ENGINE - EFI SYSTEM E645?
K4‘, _ 'i-
‘ 7. INSTALL HIGH—TENSlON CORDS
la) Insert the high—tension cords to the cylinder head.
“t
lb) Install the high—tension cords to the cylinder head
cover with the 3 bolts.
8. INSTALL COOL AIR INLET
Install the cool air Inlet with the 2 bolts.
3 ~.\
A09“-F49
yu \\:\;
ZI32l4
9. INSTALL VSV AND EGR VACUUM MODULATOR

‘T
. = T,-/'
_-
>/
/
H?
5K la) Install the VSV and vacuum modulator assembly with
"t
./—_\ ll,-, the 2 bolts.
' I
.-
ff" /KL
’v>’
\
“‘\7\ %f
-.:_—_f;.
(CI)
’\ ‘E-sis
D?W \ "-11
-\
of») Q ~ I
lb) Install the following hoses to the vacuum modulator:
'1’
(1) EGR hose (from EGR valve)
K
,\\v
5 (C)
(2) Vacuum hose (from EGR valve)
Connect the VSV connector.
-. I
figs» \
.-
C-5
g
it}
.4
\_.f‘
-
/
\t
1'_4,/
/ //
) -
E /Z
P181158
10. INSTALL NO.1 PCV CASE

la) Install the PCV case to the backet.
_,/
1'. /
/
lb) Connect the No.3 water bypass hose to the No.1 PCV
case.
(<=) Connect the No.2 PCV hose to the cylinder head
coven
\
‘D
\4‘nil
.-l\, 0
‘
‘\
_. “L
ti Y PN3503
11. INSTALL THROTTLE BODY

(See page EG— 166)
12. START ENGINE AND CHECK FOR FUEL LEAKS
EG-160
ENGINE -— EFI SYSTEM
THROTTLE BODY
pun-an
Thmme Body Throttle Position Sensor
r‘ )
k 0 _
($0
0
A ._____
/Ll:
, \7"’7W\’ //
Throttle Opener ISC Valve
ECU
+B
E2 E2
IDL IDL
VTA VTA
_ vc. VC
E1
P181383
FH356
213204
EG-161
EIIFOI
ON—VEHlCLE INPSECTION
\
1. mseecr THROTTLE eopv
(a) Check that the throttle linkage moves smoothly.
/L (‘EN
‘Q!ii‘
/’\
s__ If‘ /Q
>3
\ iii
(b) Check the vacuum at each port.
0 Start the engine.
0 Check the vacuum with the vacuum hoses pick
P¢// I/N your finger.
/7 Port name At idle Other than idle
P No vacuum Vacuum
E No vacuum Vacuum
tr//I ti‘ \
"/ \\\“»
W840}
2. INSPECT THROTTLE POSITION SENSOR

I (a) Disconnect the throttle position sensor connector.
.-..?‘» _ ( (b) Disconnect the vacuum hose from the throttle opener.
(<>) Apply vacuum to the throttle opener.
(d) Insert a feeler gauge between the throttle stop screw
Gauge 4*/~ and stop lever.
Vacuum MM
(e) Using an ohmmeter, measure the resistance between

»k—“?_t§
\ fiwzx each terminal.
\
if}
(
§ 0
Clearance between
\_| ‘\ Z‘ Between terminals Resistance
lever and stop screw
__ ~ \‘\‘F;:y \
0 mm (D in.) VTA — E2 0.2 —- 5.7 RQ
0.50 mm (0.020 in.) IDL — E2 2.3 k0 or less
0.90 mm (0.035 in.) IDL — E2 Infinity
Throttle valve fully
VTA — E2 2.0 — lO.2 kQ
open
— VC—E2 2.5 — 5.9 kQ
(f) Reconnect the vacuum hose to the throttle opener.

(g) Reconnect the throttle position sensor connector.
EG-1 62
3. INSPECT THROTTLE OPENER

700 i 50 rpm A. Warm up engine
Allow the engine to warm up to normal operating
temperature.
I Check idle speed
Idle speed:
ORPM 700 i 50 rpm
Tachometer
P021163 31315?
, /
/A5,»/ //
/Z _ it
. \
C.
la)
Check and adjust throttle opener setting speed
Disconnect the vacuum hose from the throttle opener,
and plug the hose end.
/I Plug
/
‘<31. fig ‘) I(
Disconnect Y W66
(bl Check the throttle opener setting speed.

900 ~1,900 rpm Throttle opener setting speed:
900 — 1.900 rpm (w/ Cooling fen OFF)
If the throttle opener setting is not as specified,
replace the throttle body assembly.
0 (C) Stop the engine.
R PM
Tachometer
P021160 1;;-7g;
.~’ 1' Z
(d) Reconnect the vacuum hose to the throttle opener.
/7 /’a /
V.
,\ X/‘
~_\
/
rl
\\
- /\;
CORHB
/if
Y P181167
(e) Start the engine, and check that the idle rpm returns
700 i 50 rpm to the correct speed.
Idle speed:
700 i" 50 rpm
,.-oil
ORPM
Tachometer
P02463 tl E57
EG-163
!G41e—o\
INSTALLATION
O Gasket Vacuum Hose

EIEEIEI
[552 __'_
-.~\I ii; _,/"IL ~=.
',.- Throttle Position
Sensor Connector
e>s.§§@i’l E
-
-.,;-
".1' 1.
at
ISC Valve
Connector
L‘;
@——»
‘ ‘~.
. \
Air Connector St
i Intake Air Connector
at |fll9r¢00|Br
Air Connector
Throttle Body
4
ii Accelerator Cable Bracket
Gasket !
\("
h
:3
No.1 Air Hose I
No.3 Water Bypass Hose
N-m (kgl-cm. ft-Ibf) : Specified torque

O Non-reusable part
l/\
Y PIBSOT
IGT!!!-0|
THROTTLE BODY REMOVAL

(See Components for Removal Installation)
1. DISCONNECT NEGATIVE (—) TERMINAL CABLE
FROM BATTERY
‘-3 . 3. REMOVE INTERCOOLER

i ‘ /ii? _
(a) Loosen the 3 clamps.
(b) Remove the 3 bolts and intercooler.
4 A
\\ 1.;P
.-
-
W
/’\ /(Q P_ . _
.
Y
't
H3202
E6" 64 ENGINE — EFI SYSTEM
4. REMOVE INTAKE AIR CONNECTOR

&\
Remove the 4 bolts, accelerator cable bracket and
4i
as "Q/~}a
4
la) Disconnect the throttle position sensor connector.
V; ' Q I
lb) Disconnect the following hoses:
(1) Vacuum hose (from port 'P" of throttle body)
(2) Vacuum hose (from port "E" of throttle body)
_ \ \ Q /. (3) Vacuum hose (from throttle opener)
‘Q. L \~;r._,_\§
- alt 5!
('3'
V/
T*<"7
(0) Remove the 6 bolts and air connector stay, and dis-
connect the throttle body from the intake manifold.
id) Remove the throttle body gasket.
(B) Remove the No.3 cylinder head gasket.
e
weal
1-’/I__ (f) Disconnect the following hoses and connector from
/. the throttle body. and remove the throttle body:
st.5SQso
‘_
(I) No.3 water bypass hose

(2) No.1 air hose
v-1' '-
(3)? ‘ ~lr»i-:3»-56"
I Q
\'”~<;>»l L‘ \\" ll‘-ln'£!jE:

I
‘-
I2)
AO9?39 D3226 l
SO11-I-0!
THROTTLE BODY INSPECTION
~ an-is
'3 fl‘
1.
(a)
CLEAN THROTTLE BODY
Using a soft brush and carburetor cleaner. clean the
f-1'3 L cast parts.
\g.a)5bq l U or)
lb) Using compressed air, clean all the passages and
\‘
apertures.
NOTICE: To prevent deterioration. do not clean the
‘ Y P184?!) . throttle position sensor.
EG-165
2. INSPECT THROTTLE VALVE

Throttle (a) Apply vacuum to th e thr o ttle o p ener.
Slop Screw (b) Check that there is no clearance between the throttle
miThrows stop screw and throttle lever when the throttle valve
/7M xi.1‘Ee, \/awe is fully closed.

o
?I
e.
Vacuum ( gblged)
‘H J
\‘€;¢§$_
_ Throttle
(é%~t;:
No Clearance Lever
V H3453
Ohmmeter 3. INSPECT THROTTLE POSITION SENSOR

VC
In DUE,_vTA la) Apply vacuum to the throttle opener -
I
DL (b) Insert a feeler gauge between the throttle stop screw
E2 and stop lever.
(c) Using an ohmmeter, measure the resistance between
. Q each terminal.
Vacuum .-
4 Clearance between _
Between terminals Resistance
/ U lever and stop screw
Feeler Gaug G Y Pl845‘9 0 mm (O in.) VTA-E2 0.2 — 5.7 kQ
0.50 mm (0.020 in.) IDL — E2 2.3 kQ or lass
Throttle valve fully
VTA-E2 2.0 — 10.2 kQ
open
- VC—E2 2.5 — 5.9 kQ
4. IF NECESSARY. ADJUST THROTTLE POSITION

I I
SENSOR
Loosen the 2 set screws of the sensor.
sire;-’
,5 ! Y P181170
Ohmmeyer ‘ 7 (b) Apply vacuum to the throttle opener.

’\ 3 (c) Insert a 0.70 mm (0.028 in.) feeler gauge between the
K, Qt IDL
, throttle stop screw and stop lever
.\
(d) Connect the tester probe of an ohmmeter to the termi-
_, ' ‘) ' nals IDL and E2 of the sensor.
Ir /_9-‘, *
Vacuum
Feeler Gauge
w").
Pia-169 Y43l
E6 166 ENGINE — EFI SYSTEM
(e) Gradually turn the sensor clockwise until the ohmme-

ter deflects. and secure it with the 2 set screws.
:
(:5 Gradually
Turn
mi
Recheck the continuity between terminals IDL and E2

Clearance between _ _
'3‘; &E2 Continuity (IDL — E2)
lever and stop screw
v? 0.50 mm (0.020 in.) Continuity
\ 0
&
0.90 mm (0.035 in.) | No continuity
Q @iT
I001!-BI
-_ TH ROTTLE BODY INSTALLATION
Q e Components for Removal and Installation)

INSTALL THROTTLE BODY
‘\'¢.
1’
fl"
"
/‘I! lb!’
Connect the following connector and hoses to the
throttle body:
(I) ISC valve connector
(2) No.3 water bypass hose
AD9739 _ (3) No.1 air hose
Install the No.3 cylinder head gasket to the spacer.
Install a new gasket on the throttle body, facing the
protrusion upward.
E13?! l“1%
‘*"“*’“ P1847
Install the throttle body and air connector stay with

the 6 bolts.
Torque: 21 N-m (210 kgf-cm. ‘I5 ft-Ibf)
"X Different bolt lengths A. B and C.
Bolt length:
A: 45 mm (1.77 in.)
1‘-J B: 70 mm (2.76 in.)
N4 A MW’/ll‘ C: 80 mm (3.15 in.)

ENGINE — EFI SYSTEM E6-167
(e) Connect the following hoses:

"-3-Tilfe----\:\~ (1) Vacuum hose (to port ‘P’ of throttle body)
(2) Vacuum hose (to port ‘E of throttle body)
> i’1/
at.-".";_\.\
‘ (3) Vacuum hose (to throttle opener)
!/"T. l » (f) Connect the throttle position sensor connector
-§Q/‘T29. ~§
“org .
\'.».
.125}? ‘H
l
_.
*4
I» .
B29." 5',-ill!
~l‘ iasoz
/
/ //
K \
2. INSTALL INTAKE AIR CONNECTOR
Install the intake air connector and accelerator cable
bracket with the 4 bolts.
*‘1€=“§; Torque: 21 N-m (210 kgf-cm. 15 ft-Ibf)
7,
\__ 3. INSTALL INTERCOOLER
" a
--
ii J1 .3
/- a
(a) Install the intercooler with the 3 bolts.
,2 L ~ I A0
+1-\ lb) Connect the air connector to the intercooler, and
T tighten the 3 clamps.
»\ \ as .-its
\’\~'91l;i.,
rt
X P1320?
4. CONNECT NEGATIVE (—) TERMINAL CABLE Tl

BATTERY
5. REFILL WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR ENGINE
COOLANT
EG-168
INTAKE AIR TEMPERATURE SENSOR
ECU
. ' T
Intake Air Temp. Sensor g+B
(for Intake Manifold)
THAM ta THAM
E2 OE2
E1
'=' LS
FI3572 ZKQQQ
INTAKE AIR TEMPERATURE SENSOR

INSPECTION (for INTAKE MANIFOLD)
$.- 1. REMOVE INTAKE AIR TEMPERATURE SENSOR
: Ohmmeter 2. INSPECT INTAKE AIR TEMPERATURE SENSOR
l) eg-
ll i
12:’:
-II
_ o
the terminals.
Resistance:
Refer to the graph
If the resistance is not as specified, replace the intake
air temperature sensor.
3. REINSTALL INTAKE AIR TEMPERATURE SENSOR
30
20
10
Acceptable
k§2
tance
Res
s
i—~‘r-' i—r-ti—r'r1 i— '1"—rT

O .0.0
.0
Q(,1
K)OJ(J1
N)
-3
—\
u
—20 0 20 40 60 B0 I00
l—4l I32) l68ll104Il140Il176I(212l
Temperature °C ("Fl
PI83l9
H4741 Z1325’-3
SOLENOID RESISTOR
Ignition Switch ECU

A .
A2 3 AM2 ."'.
lG2
I '
- Solenoid
MAIN BOA (( Resistor
O
#10 #20 #30 #40
MAIN FL
' Injector
No.10 No.20 No.30 .4 #40

I30
Battery ' #20
#10
E01
E02
' i>m22
SOLENOID RESISTOR INSPECTION """"

1. DISCONNECT SOLENOID RESISTOR CONNECTOR
2. INSPECT SOLENOID RESISTOR
Using an ohmmeter. measure the resistance between
r No. 20 N0. 30 terminals +B and other terminals.
Z,/il lml’
I No.10+8 No§4g83]_
Resistance:
4 — 6 Q at 20°C (68°F)
If the resistance is not as specified. replace the resis-
tor.
3. RECONNECT SOLENOID RESISTOR CONNECTOR
EG-170
FUEL PUMP RELAY AND RESISTOR

B.flB.:.2I_
Fuel Pump Flelay

4 we 0 > To Check Connector
To Circuit Opening Relay ~ - F“°' p“'"p R°”'s'°' (PP)
E6 r... . 5 .
3 1
> To ECU (FPFI)
Fuel Pump ®
T P123475
MIT!-Ill
FUEL PUMP RELAY INSPECTION

1. REMOVE FUEL PUMP RELAY
No Continuity
2. INSPECT FUEL PUMP RELAY
A. Inspect relay continuity
§El* la) Using an ohmmeter, check that there is continuity
o 4 =\l \
lb) Check that there is continuity between terminals 2
1-=3 1 Y PIBELB
lc)
and 4.
Check that there is no continuity between terminals 4
and 5.
If continuity is not as specified, replace the relay.
Continuity B. Inspect relay operation

la) Apply battery voltage across terminals 1 and 3.
lb) Using an ohmmeter. check that there is no continuity
NcConiinuity
itiri5 I lc)
between the 2 and 4.
Check that there is continuity between terminals 4
and 5.
El SQ-
_ \:""?i'L-El;
If operation is not as specified, replace the relay.

Is. REINSTALL FUEL PUMP RELAY
Batlery T mam
IIIlI'l—OI
Ohmmeter
FUEL PUMP RESISTOR INSPECTION
1. DISCONNECT FUEL PUMP RESISTOR CONNECTOR
INSPECT FUEL PUMP RESISTOR
Using an ohmmeter. measure the resistance between
the terminal.
- .‘§
Resistance:
<.~/v I Approx. 0.73 Q at 20°C (68°F)
T PIS510 If the resistance is not as specified, replace the resis-
tor.
3. RECONNECT FUEL PUMP RESISTOR CONNECTOR
SERVICE SPECIFICATIONS Ml"-el
SERVICE DATA
Fuel pressure Fuel pressure 81 DO VBCUUITI 231 — 270 kPa (2.35 — 2.75 kgf/cm’, 33 — 39 psi)
regulator
Fuel pump Resistance at 20°C (68° F) 0.2 — 3.0 Q
Injector Resistance at 20°C (6B° F) 2-4Q
Injection volume 120 — 150 cm‘ (7.3 - 9.2 cu in.) per 15 sec.
Difference between each cylinder 5 cm‘ (0.3 cu in.) or less
Fuel leakage One drop or less per minute
6:
Throttle body Throttle body fully closed angle
Throttle opener setting speed 900 — 1.900 rpm (w/ Cooling fan OFF)
Throttle Clearance between stop screw and lever
position 0 mm (O in.) VTA — E2 0.2 — 5.7 RQ
sensor 0.50 mm (0.020 in.) IDL — E2 2.3 kQ or less
Throttle valve fully open VTA — E2 2.0 — 10.2 kQ
VC —- E2 2.5 — 5.9 ItQ
ISC valve Resistance (+B — RSC or RSO) 81 2030 (68°Fl 19.3 — 22.3 Q
VSV for EG R Resistance 33—39Q
A/C idle— up Resistance et 20°C (68° F) 30-349
valve
Water Temp. Resistance at -2o°c (—4°F) IO — 20 llQ
sensor at o°c (32’F) 4 — 7kQ
at 2o"c (68°F) 2 — 3kQ
at 4o°c (104'F) 0.9 -1.3kQ
at eo°c (140°F) 0.4 — 0.7 kQ
at eo°c (176°F) 0.2 - 0.4 ltQ
Intake Resistance at —2o°c i—4°i=) I0 — 20 l<Q
Air Temp. at o°c (:i2° F) 4 —- 7kQ
sensor at 2o°c (68°F) 2 — 3kQ
(for Air at 4o°c (104°F) 0.9 — 1.3 kQ
Cleaner case] at eo°c (l40’F) 0.4 — 0.7 kQ
at eo°c (176°F) 0.2 — 0.4 kQ
Intake Resistance at —2o"c (—4°F) I0 — 20 kQ
Air Temp. at o°c (32°F) 4 — 7kQ
sensor at 2o°c (6B°F) 2 — 3kQ
(for Intake at 4o°c (I 04° F) 0.9 —1.3kQ
Manifold) at so°c (I40"F) 0.4 — 0.7 kQ
at so°c (176°F) 0.2 — 0.4 kQ
Solenoid
Resistance at 20°C (68° F) 4—6Q
resistor
Fuel pump
Resistance at 20°C (68° F) Approx. 7.3 Q
Resistor
Oxygen sensor Heater coil resistance 5.1 — 6.3 Q
Fuel cut rpm Fuel return rpm 1.700 rpm
SERVICE DATA (Cont'd)

‘ ecu
Voltage
+B — E1 lG SW ON 9-14V
BATT — E1 9- 14V
IDL — E2 IG SW ON (Throttle valve open) 9- 14V
VTA -— E2 IG SW ON (Throttle valve fully closed) 0.3-0.8V
IG SW ON (Throttle valve fully open) ?-Q"?-*3_<~'+.'§‘&~\_*\
3.2—4.9V
PIM — E2 IG SW ON
~ EG
2.2-—2.8V
VC — E2 IG SW ON 4.5—5.5V
#10, #20, #30 or #40 — E01 IG SW ON 9- 14V
#10, #20, #30 or #40 - E02 IG SW .ON 9-14V
THA — E2 IG SW ON (Intake air temp. 20°C O.5—3.4V
(6B°F])
THAM — E2 IG SW ON (lntaka air temp. 20°C 0.5 — 3.4-V
(6B° F))
THW — E2 IG SW ON (Coolant temp. 80"C 0.2 — 1.0 V
(1 76° Fl)
STA — El Cranking 6 V or more
IGT — El Idling Pulse generation
RSC — E1 IG SW ON 9 — 14 V
RSO — El IG SW ON 9 — 14 V
W — El No trouble (Check engine warning 9 — 14 V
light off) and engine running
TE1 — El IG SW ON (Check connector terminals 9 — 14 V
TE1 — E1 not connected)
IG SW ON (Check connector terminals 0 -— 3 V
TE1 — E1 connected]
Resistance
IDL — E2 at throttle valve open Infinity
at throttle valve fully closed 2,300 Q or less
VTA — E2 at throttle valve fully open 2.000 —— 10.200 Q
at throttle valve fully closed 200 - 5.700 Q
VC — E2 2.500 — 5.900 Q
THA — E2 at intake air temp. 20’C (68°F) 2.000 — 3.000 Q
THW — E2 at coolant temp. 80°C (176°F) 200 — 400 Q
G1 or G2 — G— at cold(—I0°C(14°F) to I25 — 200 Q
50°C (1 22° F))
at hot (50°C (1 22° F) to 160 — 235 Q
100°C (21 2’ Fl}
NE+ — G— at cold(—l0°C(I4°F) to 155 — 250 Q
50°C (122°F))
at hot (50°C (122°F) to 190 — 290 Q
100°C (212°Fl)
+B — RSC or RSO 19.3 — 22.3 Q
EG-174
IBIIII-O1
Fuelfine
Union bolt type 29 300 22
Flare nut type Fuel pump side 38 385 28
Others 30 310 22
Fuel pump x Fuel tank 2.9 30 26 in.-lbf
Fuel pressure regulator x Delivery pipe 29 300 22
Fuel return pipe x Fuel pressure regulator 29 300 22
Delivery pipe x Cylinder head 29 300 22
Fuel inlet hose x Delivery pipe 32 325 24
Cylinder head cover x Cylinder head 16 60 12
Throttle body x Intake manifold 21 210 I5
I Air connector stay x Cylinder head 21 210 15
Air connector x Throttle body 21 210 15
Knock sensor x Cylinder block 44 450 33
Oxygen sensor x Exhaust manifold 20 200 14
ENGINE - coo|_|~c-; SYSTEM EG 115
COOLING SYSTEM
OPERATION
Throttle Body
Water Outlet
lSC Valve
TO HEATER
W,F’
RADlATOR
FROM HEATE
KPi\‘Qt\
N)-- ~
x,/fir
,/ i~% 51?/’}?$7
':»—//Q //,
\*¢%O/
>599’;
,_
1 E ‘ I @119
/t’
nL Oil Cooler
~d
Water Pum p '3 I*t§§
on 1 hermostat
Water Bypass Pipe

Turbooharger
FROM F1ADlATOR
Water lnlet
Pissez l_
EG-176
ENGINE —- COOLING SYSTEM
WATER PUMP
INSTALLATION
-nming Be“ RH Front Engine Hanger

Gasket Alternator Bracket
No.2 'l'iming Belt Cover
:""""”‘ , "9
16 1‘
‘E2
W \ Alternator Wire
’k’>)-’
\ ‘ X
RH Engine \ _ ___T
“‘“\ \ (((§\I
E
Mounting II
Bracket I \
.-
Alternator vs‘ 5.l§.~“i=__r

1]; ~/
No.1‘fiming Belt Cover ' £1
QI (O BeltGuide $4 ‘la
Crankshaft '/ ' T Gasket
Pulley ' W» _/
lie
\ _____5'___\A \-i
$15 /'
/
/I 1“_,)
LUTI
0._ /XJe. e_ _ _ _J‘
/,'’ Oxygen Sensor ’~\\\
10711 090 79) /,'’ C

°"ne° t °'
Exhaust Camshaft Timing Pulley
Intake Camshaft Timing Pulley Engine Wire Protector
/ \\
Knock Pin /I
,/ Alternator
=/1* 5% ~’ onriector
\ ,»,-<-K»/re /
Ground Strap
59lG00 43) W“ {§i’/4
‘T
' II ‘Y?
Hr
'-$11420 30l 1
1"
.
\
._/
Timing Belt Tensioner

Plate Washer
V-_-_ _._ _ .\
I
\
‘l
\¥\..- I
\
4-
I_fl
O /5[\4" w 7‘
\_.___)
, ‘"1110.
* \ ----to
@
No.1 Idler Pulley /1'
.;_\\\\____
No 2 Idler Pulley K’
\
\\:- I
\
K“
i,_._,,."\%\I\‘
_/
/ S \\\
N
\\
Y\__\\
'
\\
\\
\\K
I“
aeie
Q. Z‘
, 1
,/
\
\ \\
N~m (kgf-cm, ft-lbf) : Specified torque

it Precoated part
* For use with SST
F'l
EG-177
ENGINE — COOLING SYSTEM
No.3 Timing Belt Cover
_,'\
,,/ i
,,/ /’ \i %
\ I
IL\’1_\ \
W’ 1/\):q\ \
1 \
\ (CR?-_'\\
H O \ ‘
%/
(
\\ T-'\:‘-Z
ix‘ I,
O O-Ring ‘K16 __\ H@IIlJ
W»-=.
6 Gasket \\°r5,°
¢
O O-Fling
Oil Dipstick Guide
K]
Tq
WI» (*.-.Z'V )""
A \//_
I WY;vpfl 1
L77
/ I
I
\ Q / f-P/
‘I
\;g3‘
Water Pump and “\,
1-.
";I1.\_)
f_J’\‘o)
\' tflfb I»
\_-_.-_ /A
I
0
Water Pump Cover
Assembly "\\
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~
.\ I 1
/.‘J/T’
/
’\
K/2)
/I
P
//
E
I‘ I
Idler Pulley /_l___
@
Bracket Q =' e~" °@ /‘ \.
0 oTRing//
"5 \|
ti.‘
Water Pump Cover
~i K
" 61”-
O Gasket . . .”(3\
/
Oil Dipstick
WasherPum “cl-
.' ° ". ‘
"3/Q“
P w'I'l(;§\%Il=’
<@ Q0 . a,_-
Q» 0
w /’
/J} r O
O Non-reusable part
Pl>3f\?9
E6478 ENGINE - COOLING SYSTEM
SERVICE SPECIFICATIONS mII'|L—0I
SERVICE DATA
Thermostat Valve opening temperature 80 ~ 84°C (176 —183“F)
Valve lift at 95" C (203' F] 10 mm (0.39 in.) or more

Radiator cap Relief valve opening pressure STD 74 — 103 kPa (0.75 — 1.05 kgf/cm’, 10.7 — 14.9 psi)
Limit 59 kPa (0.6 kgf/cm’. 8.5 psi)
Electric Rotating amperage 5.7 — 7.7 A
cooling fan
EGIITN -on
Part tightened N-m kgt-cm It-lbf
Cylinder block x Drain plug 25 250 18
Water pump x Water pump cover 8.8 90 78 in.-lbf
Water pump x Cylinder block 7.5 76 66 in.-lbf

Water bypass pipe x Water pump cover I0 100 7
Idler pulley bracket for alternator drive belt Water pump aide 23 230 17
x Cylinder block Cylinder block side 19 190 14
No.3 timing belt cover x Cylinder head 8.0 82 71 in.-lbf

No.2 idler pulley x Cylinder block 4-4 450 32
Timing belt tensioner x Cylinder head 21 210 15
No.1 idler pulley x Cylinder head 52 530 38
Camshaft timing pulley x Camshaft 59 600 43

for SST 41 420 30
Water inlet x Water pump cover 9.0 92 B0 in.-lbf

EG-179
ENGINE — LUBRICATION SYSTEM
LUBRICATION SYSTEM
OPERATION
Z . ,6 ‘$23?
. ‘- R‘
'3
5r"/~
‘O
i
is Q-_. \.i
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i
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1‘l ‘
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‘Ila
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PI8583
VALVE LIFTERS _ _
at VALVE stems 1 1
.-- PISTONS CAMS -1
1 CONNECTING CAMSHAFT
r ' ' noos JOURNALS
1- - - CRANKSHAFT OIL NOZZLES CYLINDER HEAD - -1
l MAIN OIL HOLE

, l r " " - " " "'1
- lruneoci-mac-.isi=i| | RELIEFVALVE | | OILCOOLER i
RELIEFVALVE | I OILFILTER I
P
| nzuer VALVE
I
OIL STFIAINER I
I! I i
OIL PAN
*1
Zl""l‘
EG-180
OIL PUMP
COMPONENTS FOR REMOVAL AND "'"*"
INSTALLATION
-rming Be" RH Front Engine Hanger

Gasket Alternator Bracket
No.2 Timing Belt Cover
1'v'IvVf'\\
7* \ xi W I5Q
we \ (\'§a(\1_.T\'\‘1 g
\\\
Alternator Wire
RH Engine /\ I
Mounting
Bracket
,4’
I "'1 Alternator ,
M “ \ \ '<6_\i
iti ‘I i\\Y‘\ ‘“"'i@ /
r
No.1 Timing Belt Cover / Timing

Belt Guide "Yii.iiit‘*‘\
.
Q ._ Gasket
Crankshaft Pulley J
Ox V9 en Sensor _
_____eu
5
“\3\\\1'i // \__
lam __/-"’ Connector I \..__
/
_.- /
, ,
,
-_--
-.,1
/ ,
101 i1.oso.7sl ,»”
I’
Alternator
Engine Wire Protector Connector
Ground Strap
ll
Intake Camshaft 'I'iming Pulley
Knock Pin \\
.\ \\\
l
/an Q!
59 I600 43]
"41 I420 30] La \O
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2/_i
\
'.\““"'
No2 Idler Pulley ,~;" y
7
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i==-i ?/P'@‘
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_,.-»-ii J \ -
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, ‘ "--\\/_‘;'
{flag
’ /
1 /f
4‘
Oil Pump Pulley p’ ///, Q \ Q
is ,, - /’
,
C”
, 1
Crankshaft Pulley , ..
I ’/,
N-m lkgf-cm, ft-Ibf) : Specified torque

* For use with SST
Pl€'591'J
ENGINE — LUBRICATION SYSTEM EG-181
as\
I 1/1
; 2%???
i<°1€'~§ J l
. Gaske ‘ (T /O/\\\‘\ \ Oil Dipstick
on Pump ) 1“ l_ 4 \\\
V0 &(1 M“ \ ti i \\\ I
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O Gasket
Turbo Oil Outlet Pipe
zs m Length Bolt 2.. /.1 Oil Pan Baffle Plate
9.31192, so ii-i.-ibti - Z4;/F’
35 mm Length Bolt /I
a.o (a2. 11 inulbll Q _ _ I," / 10mmHeadBoIt
“(*1 1, / _ \ 12 121150.315 It
O Gasket %6'" ’
21 1210, 151 O
l'|'I|l'l OI
_ _ _I
i -
Oil Strainer /I e -/
_
-
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' , I
'1 '
7‘ T 1
¢
'1'-i
/I '
Oil Pressure
Regulator
/_4€ -—\ ’ / ’ 1 ‘i
. :\~-1 _. . - -
O O-Ring ’ 45¢; \ Engine Wire
X ';:“‘">“r<?; '=, i @l CI C Bracket
'1.-‘;;’ TKQ /_/' \;\\_ - Q _:
No.10i|Pan* A _ ié-=f '
- O Gasket 35
+0-Ring
~
, / - ~-~__ L Oil Level
Sensor
:7
Y..- at %'3"l iril.&
_ _/ “ _\
/__ ti Connector q“""/
No.2 Oil Pan— 1 (lg? ,..-~il _. / J in p|ug
is \-—» easier
N-m (kgf-cm. ft-Ibf) : Specified torque

O Non-reusable part
PIBSBI
E6482 ENGINE — LUBRICATION SYSTEM
OIL COOLER
COMPONENTS FOR REMOVAL AND "”'"
INSTALLATION
Fe.
‘ “\
is“
-0
in
\\\\\\\ I I I I
I I I
gt . Water Bypass Hose
Relief Valve
Oil Cooler
S
Alternator
\ ‘ Ti“
Alternator Wife
®
Q)
i
Q0 Ring T
__-- -
7- - - _- _- _- _ _I
e il.tt'.I"I(‘\_-_.
O Seal Washer
@fi‘>%' T" \ water Bypass Hose

119 riV § I“~~
@W Oil Dlpstick Guide

Alternator
I
Connector
E
I 1 I
Oxygen Sensor _,- 1 I
I
‘\
\ -1.
Connector
T“°"“°s“‘“ Oil Dipstick

Q Gasket
s—PK II
O O-Ring
Water Inlet G
Nim (kgf-cm. ft-Ibf) : Specified torque
0 Non-reusable part Y
Pl£r'i;R<i
EG-183
SERVICE DATA
Oil pressure ’ at idle speed 29 kPa (0.3 kgf/cm‘, 43 psi] or more

at 5,000 rpm 245 — 490 kPa (2.5 — 5.0 kgf/cm’, 36 — 71 psi)
Oil pump Body clearance STD 0.10 — 0.16 mm (0.0039 — 0.0063 in.)
Limit 0.20 mm (0.0079 in.) gwfiw Y‘
Tip clearance STD 0.04 —- 0.16 mm (0.0016 — 0.0063 in.) iam ,
Limit 0.20 mm (0.0079 in.)
IGIOC-001
Oil pan x Drain plug 37 380 27
Oil pump body cover x Oil pump body 8.8 90 78 in.-lbf
Oil pump x Cylinder block 25 mm long bolt 9.0 92 80 in.-lbf
35 mm long bolt 8.0 82 71 in.-lbf
Oil strainer x Oil pump 9.0 92 80 in.-lbf
Oil strainer x Cylinder block 6.5 66 58 in.-lbf
Oil pan baffle plate x Cylinder block 6.5 66 58 in.-lbf
No.1 oil pan x Oil pump 9.0 92 80 in.-lbf
No.1 oil pan x Rear oil seal retainer 9.0 92 80 in.-lbf
No.1 oil pan x Cylinder block
20 mm (0.79 in.) long bolt for 10 mm head 12 120 9
25 mm (0.98 in.) long bolt for I2 mm head 21 210 15
Nut 14 I40 I0
No.1 oil pan x No.2 oil pan 6.5 66 58 in.-lbf
Turbo oil outlet pipe x No.1 oil pan 20 200 15
Oil pressure regulator x No.1 oil pan 18 180 13
Oil pump pulley x Oil pump drive shaft 35 360 26
No.2 idler pulley x Cylinder block 44 450 32
Oil cooler x Oil cooler bracket (Relief valve) 59 600 44
Oil nozzle x Cylinder block 9.0 92 80 in.-lbf
ST-1
STARTING SYSTEM
SERVICE SPECIFICATIONS ---------------------- -- ST— Z
REFER TO 3S—GE ENGINE REPAIR MANUAL

(Pub. No. RM396EI
NOTE: The above pages contain only the points
which differ from the above listed manual.
ST-2 STARTING SYSTEM — SERVICE SPECIFICATIONS
SERVICE DATA
Starter Rated voltage and output power 12 V 1.2 kW
No—Ioad characteristics Current 90AorIeseat11.5V
rpm 3.000 rpm or more
Brush length STD 15.0 mm (0.591 in.)
Limit 8.0 mm (0.315 in.)
Spring installed load 10 — I6 N (1.0 - 1.6 kgf. 2.2 — 3.6
Commutetor
LE; - .;
=' Ii ;E' .t;=; =;=E

Diameter STD 30 mm (1.18 in.)
Limit 29 mm (1.14 in.)
Undercut depth STD 0.6 mm (0.024 in.)
Limit 0.2 mm (0.008 in.)
Circle runout Limit 0.05 mm 10.0020 in.)
I101. -N
I
Part tightened N-m kgf-cm ft- Ibf
End cover x Brush holder 1.5 15 13 in.-lbf

Starter housing x Magnetic switch 5.9 60 52 in.-lbf
End cover x Starter housing 5.9 60 52 in.-lbf
Lead wire of field frame x Magnetic switch 7.9 81 70 in.-lbf
CH-1
CHARGING SYSTEM
ALTERNATOR ..................................... .. CH_ 2

SERWCE $pEC|p|CAT|0N3 ...................... .. CH_ 3
REFER TO 3S-GE ENGINE REPAIR MANUAL

(Pub. No. nmassei
NOTE: The above pages contain only the points
which differ from the above listed manual.
CH-2
CHARGING SYSTEM — ALTERNATOR
ALTERNATOR
COMPONENTS FOR DISASSEMBLY AME?“
ASSEMBLY
Drive End Frame (Stator)
Pulley
Bearing Retainer
"j ROtU|'
CH @ \ /Q Rear Bearing
§ 5"--J?" . Alternator Washer
r \. Wt cf,’
w 5 .-*
-‘)§r‘11“
\\ Front Bearing q%$$"" f T
__\\\ J L A
I
\\ J_
C Rubber Insulator Bearing CW9’

,_ ._ _ _ _7 \‘ ® IC Regulator “\\
‘\
Bearing Cover
L-\
-.4
Rectifier End Frame
arm
(ff Ae§>J_§’ ;é‘>\»*<>:’“
f Brush Holder \‘\\ \-J
-4?
l if-gr “°'o
\ \ ‘ Rectifier Holder ‘*%
T‘\t @ t. -_ \
Cord Cup \ __ x Seal Plate
Terminal Insulator ‘ - \ Brush Home, Cove

I
*0
I /'
/ /
r‘ I
D I / .____q______I
L ‘J
~__
Lead Wire
Rear End Coverhr -
fi/ ‘ fir@
®
*4, 1»
We
G’ ET‘ Air Duct
Plate Terminal
* “ ~e
I: T T ‘ ‘w
F4857?
CH-3
CHARGING SYSTEM — SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS G¥HlA—0G
SERVICE DATA
Battery Specific gravity at 20°C (6B° F) 1.25 — 1.27
Drive belt Deflection w/ A/C New belt 10 — 11 mm (0.39 — 0.43 in.)
Used belt 13 — 16 mm (0.51 — 0.63 in.)
w/0 A/C New belt 11 — 14 mm (0.43 — 0.55 in.)

Used belt 12 — 18 mm (0.47 — 0.71 in.)
Tension w/ A/C New belt 686 —— 785 N (70 — BO kgf)
Used belt 294 — 441 N (30 -— 45 kgf)
W/D A/C New belt 461 — 706 N (47 — 72 kgf)
Used belt 353 — 610 N (36 -— 62 kgf)
Alternator Rated output I2 V 80 A
Rotor coil resistance 2.8 — 3.0 Q

Slip ring diameter STD 14.2 — 14.4 mm (0.559 — 0.567 in.)
Limit 12.8 mm (0.504 in.)
Brush exposed length STD 10.5 mm (0.413 in.)
Limit 1.5 mm (0.059 in.)
IC regulator Regulating voltage at 25°C (77°F] 13.9 — 15.1 V
at 115°C (239°F] 13.5 —14.3V
GJIIIO-I.
Part tightened N-m kgf-cm ft-Ibf
Bearing retainer x Drive end frame 2.6 27 23 in.-lbf
Rectifier end frame x Drive end frame 4.5 46 40 in.-lbf
Cord clip x Rectifier end frame 5.4 55 47 in.-lbf

I Alternator pulley x Rotor 110 1.125 81
1 Rectifier holder x Coil lead on rectifier and frame 2 .9 30 26 in.-lbf
1 Rear end cover x Rectifier holder 4.4 45 39 in.-lbf
I Plate terminal x Rectifier holder Nut 4.4 45 39 in.- Ibf
Bolt 3.8 39 34 in.- lbf
Terminal insulator x Rectifier holder 4.1 42 36 in.- lbf
Air duct x Rear end cover 4.4 45 39 in.- lbf

Air duct x Rectifier end frame 3.4 35 30 in.- lbf
TOYOTA

Toyota Celica - ST205 - Engine Repair Manual Supplement (RM398E)

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Toyota Celica - ST205 - Engine Repair Manual Supplement (RM398E)

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® TOYOTA

FIEPMR MANUAL SUPPLEMENT

INTRODUCTION I_L -Ir

CHARGING SYSTEM _'J|II'-:

HOW TC USE THIS MANUAL ---------------- -- IN

ABE-REVIATICN5 USED IN THIS

Oil Pump Body

Oil Pump Oil Seal

N-m (kgf-cm, ft-lbf) 1 Specified torque

The procedures are presented in a step—by—step format:

Task heading: what to do

. 5. INSTALL CRANKSHAFT PULLEY

CAUTIONS. NOTICES. HINTS:

IDENTIFICATION INFORMATION IIWO-01‘

ENGINE SERIAL NUMBER

Negative (—) Terminal Cable GENERAL REPAIR INSTRUCTIONS

9. Use of special service tools (SST) and special service

Illustration Symbol Part Name Abbreviation

é%—— MEDIUM CURRENT FUSE M~FUSE

_.,@.,_ HIGH CURRENT FUSE H-FUSE

11. Care must be taken when jacking up and supporting

After the vehicle is jacked up, be sure to support it on

Do not open the cover or case of the ECU unless

To disconnect vacuum hoses, pull on the end. not the

Never use an impact wrench to remove or install

Example Tag hoses before disconnecting them:

Unless otherwise stated, all resistance is measured at

2. Avoid prolonged idling.

3. Avoid spark jump test.

4. Avoid prolonged engine compression measurement.

5. Do not run engine when fuel tank is nearly empty.

6. Avoid coasting with ignition turned off and prolonged braking.

IF VEHICLE IS EOUIPPED WITH MOBILE COMMUNICATION SYSTEM “H

ABBREVIATIONS USED IN THIS MANUAL mu

A/C Air conditioner

STANDARD BOLT TORQUE SPECIFICATIONS

HOW TO DETERMINE BOLT STRENGTH

\ Mark Class Mark Class

Hexagon 4- 4T Stud bOII

SPECIFIED TORQUE FOR STANDARD BOLTS

6 1 5 55 48 in.'Ibf 6 60 52 |l'1. lbf ;- w

6 1 6.5 65 56 in.-Ibf 7.5 75 65 in.-lbf

8 1.25 29 300 22 33 330 24

a 1.25 34 340 25 37 380 27

, a 1.25 38 390 28 42 430 31

8 1.25 42 430 31 47 480 35

ENG|NE MECHAN|CA|_ ......................... .. EG — . . . . . . . . . . . . . . . - . . . . . . . . . ..

. . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EG - SERVICE SPECIFICATIONS ---------------------- '- EG— I83

INTAKE AIR TEMPERATURE SENSOR ---- -- EG—I68

FUEL PUMP RELAY AND RESISTOR ------- -- EG—1TU

SERVICE SPECIFICATIONS ---------------------- -- EG—IT3

plugs are located in the center of the combustion chambers.

SST (SPECIAL SERVICE TOOLS)

X 09155-16100 Spark Plug Wrench

09216-00021 Belt Tension Gauge

09216-00030 Belt Tension Gauge Cable

Torque Wrench Adaptor

Verieble Pin Wrench Set

Engine tune— up tester

Precision straight edge

SSM (SERVICE SPECIAL MATERIALS)

08833-00080 Adhesive 1344. No.1 idler pulley pivot bolt

H5424 the "FULL" line.

CHECK ENGINE COOLANT QUALITY

C‘ 4’ Q. T 5" “RI I _