JMO OB1 3t
 

Mazda CONTENTS
Tirle Sect
121 General nformation
Workshop Pre-Delivery nspectionand
ScheduledMaintenanceService

Manual Engine
LubricationSystem
Vofume 1 of 2 Cooling System
Fuel ndEmission,onttolystem EGI-S
FOREWORD
EngineElectricalSystem
Thisworkshopmanual s intended or us e
bv servicetechniciansof AuthorizedMazda Clutch
D-ealers help them serviceMazdavehicles.
It can also be uselul o ownersand operators ManualTransaxle
of Mazda vehicles in diagnosing some
problemsand performing imited epairan d Automatic Transaxle
maintenanceon Mazda vehicles. Front and Rear Axles
For proper repair and maintenance, Steering System
thoroughamiliarizationith hismanual s m-
portant,and it shouldalwaysbe kept n a han- Braking Syslem
dy place or quick and easy reterence.
All the contentsof this manual, ncluding Wheelsand Tires
drawingsand specifications,re he atest vail-
able at the time of printing.As modifications Suspension
affecting epairor maintenance ccur, elevant
information upplementaryo thisvolumewill Body
be made available at Authorized Mazda Body Electrical System
Dealers.This manual should be kept up-
to-date. Heaterand AarConditionerSystems
MazdaMotorCorporation eserveshe right TechnicalD ata
to alter he specifications nd contentsof this
manualw ithoutobligation r advancenotice. SpecialTools
All rights eserved.No part of this bookmay
be reproducedor used in any form or by any wiringDiasram Sili:.|Tj|:'"''""'0"''
means,electronic r mechanical-including
photocopyingand recording and the use of The section Z is publishedseparate rom this manual.
any kind oJ nformationstorage and retrieval
system-without permission n writing.
o 1990MazdaMotorCorporation
Mazda Motor Corporation ocT. '90 @)
HIROSHIMA. APAN 1249-10-90J
APPLICATION:
Thismanual s applicableo vehicles eginning
with the Vehicle dentificationNumbers (VlN)
shown on the following page.
 

vEHlcLE DENTIFICATIONUMBERSVlN)
JMoD81031 0 100001
 

GI

GENERALNFORMATION
TMPORTANT N FORMATION ....................l- 2
BAS|C SSUMPT|ONS........ .................... l- 2
sAFEryH1SK............... ... Gl- 2
POSSIBLEOSS FWARRANry.....,,......I- 2
WARNINGN LUBRICANTS
ANDGREASES. ............. l- 2
HOWTO USETH|SMANUAL.................... t- 3
PREPARATTON ................ l- 3
REpAtR ROCEDURE............................. l- 3
SYMBOLS........ ............... l- 4
NOTES.AUTIONS.NDWARNINGS....... I- 4
FUNDAMENTALR OCEDURES................. I- 4
PROTECTION FTHEVEHICLE.,........... I- 4
A WORD BOUT AFETY................... .... l- 5
PREPARATION FTOOLS
ANDMEASURINGQUIPMENT............. I_ 5
SPEC|ALOO1S............ .. Gl- 5
REMOVALFPARTS.............................s l-
DTSASSEMBLY ................ l- 5
REASSEMBLY .................I- 6
ADJUSTMENTS ..,....,..,,... I- 7
RUBBER ARTS NDTUBING.............,.. I_ 7
JACKANDSAFETY TANDPOSITIONS....I- 8
VEHICLE IFT 2.SUPPORTYPE)
postTtoNs..... ................. l- I
TOW|NG......... ...................l- 9
IDENTIFICATIONUMBER OCATIONS.,...I-10
uNtTs............. . . . . . . . . . . . . . . . . .l.- l 0
ABBREVTATTONS .................................... l-l0
CAUT|ON .... Gl-ll
INSTALLATIONFA MOBILE
TWO-WAYAD|O YSTEM.................... l-l1
REMOVAL F GNITIONEYON
AUTOMATICRANSAXLEODE1.......... I-11
ELECTRICAL R OUBLESHOOTING OOLS I-12
CAUTION ITHELECTRICALARTS........I-13
03uGtx-001
 

GI IMPORTANTNFORMATION
IMPORTANTNFORMATION
BASICASSUMPTIONS
Thisworkshopmanual ssumeshatyou havecertain pecialools hatarenecessaryor he safeandetfi-
cientperlormancef service perationsn Mazda ehicles nd hatyou knowhow o use hemproperly.
Italsoassumeshatyouare amiliar ithautomobileystems ndbasic ervice nd repair rocedures.ou
should otattempto use hismanual nlesshese ssumptionsrecorrecl nd you understandheconse-
quences escribedelow.

SAFETYRISK
Thismanual ontains ertain otes,w arnings,ndotherprecautionary nformationhatyoushould arefully
readand ollow o reduce he riskof personaln jury o yourself r others nd he riskof improper ervice
thatmaydamage hevehicle r render t unsafe.f there s no such nformationn regardo anyspectfic
servicemethod, hisdoes not mean here s no possibilityhat personal afetyor vehicle afetywillbe
jeopardized y the useoJ ncorrectm ethods r tools.

POSSIBLE OSSOF WARRANTY

Themanufacturer'sarranty n Mazda ehicles ndengines anbe voided f mproper ervice r repairs
M azdaDealer.
are performed y persons ther han hoseat an Authorized
WARNING N LUBRICANTSND GREASES
Avoidall prolonged nd repeated ontactw ithmineral ils,especially sedoils.Usedoilscontaminated
during ervicee.g., ngine ump ils) remore rritatingndmore ikelyo cause eriousffects,n cluding
skincancer, n the eventof grossand prolonged kincontact.
Washskin horoughly fterwork nvolving il.
Protectiveandcleanersmaybe of valueprovidedheycan be removedrom he skinwithwater.D o not
usegasoline, araffin, r othersolventso remove il from he skin.
Lubricants nd greasesmay be slightlyrritatingo the eyes.
Bepeated r prolonged kincontact hould e avoided ywearing rotectivelothingf necessary.articu-
larcareshould e takenwithusedoilsand greases ontainingead.Do notallowworkclothingo be con-
taminated ithoil. Dry cleanor launder uchclothing t regularntervals.
sMuGrx_oo

Gl-z
 

HOWTO USETHISMANUAL GI
HOWTO USETHISMANUAL

F[rtFf#rtifiirointsout heneededpeciatervice ool ssT) or he erviceperationatt pro-

ceeds.G ather ll necessary ST beforebeginning ork.

Example:
MANUAL TEERING
PREPARATION SST NUMBER
ssT

49 0118 50C
Pullef, all oinl

SST NAME SST ILLUSTRATION

03uGtx-@6

REPAIB ROCEDURE
1. Most epair perations eginwithan overviewllustration. t identifieshe components,howshow he
parts it together, nd visualparts nspections.f a damaged r wornpart s found, epairor replacet
as necessary.
2. Expendablearts,ighteningorques,ndsymbolsoroil,grease,ndsealantreshownn heoverview
illustration.
3. Pages elatedo service rocedures reshownunderhe llustration.efero this nformationhen er-
vicing he related art.

Example:

SHOWSTIGHTENING
TOROUE UNIT

sHows 17 Spacer
RELATED 18 Drive pinion
PAGEFOR Bemoval page M-2'l
SERVICE rpecl splines and leelh fot weat or damage

9MUGIX.O34
" 1 : Thenumberingex.@) hows ervice rocedure.
Units hown n Nm (m-kg, tJb)unless therwisepecified.
Gt-3
 

GI R OCEDURES
HOWTO USETHIS MANUAL/FUNDAMENTAL
SYMBOLS
if,er" uresi* symbolsndicating il,grease, ndsealant. hese ymbols howhe points f applying uch
materialsuring ervice.

Symbol Meaning Kind

g Apply oil New engineoil or gear oil as appropriate

@ Apply brake luid Only brake luid

E Apply automatic ransmissionluid OnlyATF

Applygrease Appropriate rease

€

(@[ Apply sealant Appropriate ealant

e Apply petroleum elly Appropriatepetroleum ellY

osuctx 05

Note
. Whenspecialoil or grease s needed, his is shown in the illustration.

NOTES, AUTIONS, NDWARNINGS

As you ead hroughhe procedures,o uwillcomeacross OTES, AUTIONS,n dWARNINGS.a ch
one s therefore ipecific purpose.N OTESgiveyou added nformation hatwill helpyou o complete
a particularrocedrire. AUTIbNSaregiven o pri:vent ou rommaking n error hatcoulddamage he
vdhicle.WARNINGSemind ou o beespeciallyarefuln hose reaswhere arelessnessancausePer'
sonat niury.The ollowingilt containsome eneral WARNINGSoushouldollowwhen ouworkon
a vehicle
olA.,x-oo2

FUNDAMENTALROCEDURES
PROTECTIONF THEVEHICLE
Always esure o cover enders, eats, nd loorareasbe-
forestartino ork.

9MUGIX.O37
Gt-4
 

FUNDAMENTALROCEDURES GI
A WORDABOUTSAFETY
The ollowing recautionsustbe ollowed hen acking p
thevehicle.
1 Blockhe wheels.
2. Useonly he specifiedacking ositions.
3. Supporthe vehiclewith safety tands.
Startheengine nlyaftermaking ertainheengine ompart-
ment s clearof ools nd people.

9MUGtX-003
PREPARATIONF TOOLSANDMEASURING
EOUTPMENT
Besurehatallnecessary o olsandmeasuringquipmentre
available efore tarting ny work.

9[,{UGtX-038
SPECIALTOOLS
Use special oolswhen hey are required.

47UOGX-005
REMOVALOF PARTS
While orrecting problem, ry also o determinets cause.
Beginworkonlyafter irst earningwhich partsand subassem-
b es mustbe removedand disassembledor replacement r
repair.

47U0GX-006
DISASSEMBLY
lf the disassembly rocedures complex, equiringmanyparts
to be disassembled,ll partsshouldbe disassembledn a way
that will not affect heir performance r externala ppearance
and dentified o hat eassembly anbe performed asily nd
efficiently.

SMUGIX,O39
Gr-5
 

GI FUNDAMENTALROCEDURES
1. nsoectlonof Parts
Whbn emoved,-each a rtshould ecarefullynspectedor
etormation,a mage, ndother roblems'
malfunctioning,

9MUGtX-040
2. Arrangementof Parts
AlldisJssembledarts hould ecarefully rrangedor re-
assembly.
Be sureio separate r otherwisedentifyhe parts o be
reolacedrom hose hatwill be reused

9MUGIX.O41
3. Cleaningparts tor reuse
All oarts'iobe reused houldbe carefully nd horoughly
cleaned n the appropriate ethod.

REASSEMBLY
Standard alues, uchas torquesand certain d.iustments'
mustbe strictlv bservedn the reassemblyf all parts'
NEIErOSTNUONRDOLTANDNUTTIGHTENINGORQUE
inSection D or ighteningorques otmentionedn hemain
text.
lf removed,heseparts houldbe replacedwithnewones:
'1. Oilseals 2. Gaskets
3. O-rings 4. Lockwashers
5. Cotterpins 6. Nylon uts

9MUGIX-OM
Depending n location:

)ffi
1 Sealant houldbe appliedo gaskets.
2. Oilshould e appliedothe moving omponentsf parts'
3. Specified ilor giease hould eapplied t he prescribed
locationssuchas oil seals) efore eassembly'

9MUGIX{42
t-6
 

FUNDAMENTAL ROCEDURES GI
ADJUSTMENTS
Usesuitableauges nd/oresters henmaking diustments.
E

57UoGX-002
RUBBER ARTSANDTUBING
Prevent asoliner oil romgetting nrubber arts r ubing.

9MUGIX.OOs

Gt-7
 

Gl ,oo AND AFEw srANDFosmoNsyvEHplEUFT 25UPP6RTYPE) osmoNs

JACKAND SAFETYSTANDPOSITIONS
FRONT N
Jack positioni Satetystand positions:
At the rontcrossmember Side ills

REAREN D
Jack position: Safetystand positions:
At hecenter f the ear rossmember Side ills

03uGlx'oog

vEHlcLE LIFT (2-SUPPORTYPE)POSITIONS

FRONT ND REAREND
Frame Frame
Side ills Side ills

9ltlUGlX-010
Gt-8
 

TOWING GI
TOWING
Properowing quipments necessaryo prevent amageo p
thevehicle.
Lawsand regulationspplicableo vehiclesn tow mustal
WHEELDOLLIES
waysbe observed.
As a generalule,owed ehicleshould e pulledwith he
driving heels ff he ground.f excessiveamage r other
conditionsrevento winghevehicle ith hedriving heels
off he ground. sewheel ollies.

03uGlx002 Witheitherautomatic r manualransaxle:

1.Set he gnitionwitchn theACCposition:
2. Place he selectoreveror shift ever n N (Neutral);
3. Releasehe parking rake.
Caution
. Do not ow he vehiclebackwardwithdrivingwheels
on the ground.This may cause nternaldamage o
the transaxles.
. Do not use he hook oops under he front and rear
ol the vehicle tor towing purposes. These hook
loops aredesignedONLY or transport ie-down. t
tie.down hook loops are used for towing, the
front/rear bumperwill be damaged.

Gt-9
 

Gl U MBERocATroNs/uNtrs/ABBREVtATtoNS
rDENTIFrcATroN
IDENTIFICATIONUMBER OCATIONS
VEHICLE DENTIFICATIONNUMBER (VIN) AUTOMATIC RANSAXLEIODEL AND NUMBER

,'%
r(g
  /tYl
.,,/Pk

ENGINEMODELAND NUMBER

UNITS
N.m m-kgor cm-kg, EC-AT....... . .... ...Electronically-controlled
ftlb or in-lb).. ...... orque automatic ransmission
rpm....... . ... . ........ evolutionser minute E C U . . . . . . . . . . . . . . . . . . .n g i n e o n t r o l n i t
A . . . . . . . . . . . . . . . . . . . . . . . . .m p e r e ( s ) EGI . ............. ...Electronicasoline
V . . . . . . . . . . . . . . . . . . . . .V o l t ( s ) injection
o. . . ....... ........... hm(s) resistance) E I L . . . . . . . . . . . . . . . .. . . .E l e c t r i c aola d
kPa kg/cm2, si)..... . Pressure EX.. .. . Exhaust
(usuallyPositive) lC........ ..... .. Integratedircuit
mmHg(inHg).... Pressure lGN..... .. ... .. .lgnition
(usuallY egative) l N . . . . . . . . . . . . . . . . . . . . . .n. .t .a.k. e
W.......... ... . . . . . .W. att 1 N T . . . . . . . .. . . . . . . . . . . . . . n
. .t.e. r m f t e n t
liters US qt, lmp qt) . . Volume ISC ....... ..... ldle speed ontrol
mm (in) ..... ....... .. Length L H . . . . . . . . . . . . . . . . . . . . . .e. f.t a n d
M....................... tvlotor
89U0GX.006 M I L . . . . . . . . . . . . . . . . . . . . \. r. a l f u n c t i o n i n d i c a t o r
lamp
ABBREVIATIONS MTX.......... Manualransaxle
OD ....... . Overdrive
O F F . . . . . . . . . .. . . . . . . . . . . . .w. .i t c h f f
ABDC....... Atterbottom ead O N . . . . . . . . . . . . . . . . . . . . .w . .i t c h n
center PCV....... Positive rankcase
A/C ...... ........ .... Airconditioner ventilatlon
A C C . . . . . .. . . . . . . . . . . . . . c c e s s o r i e s P R C . . . . . . . .. . . . . . . . . . P r e s s u r e r e g u l a t o r
ATX. ...... Automaticransaxle control
ATDC ..... After op dead center P/S.-..... ............ Power teering
ATF Automatrcransmrssion P / V . . . . . . . . . . .. ........ . . . P o w e r i n d o w
fluid R H . . . . .. . . . . . . . . . . . . . . . .i g h t a n d
BAC......... Bypass ir control SST.,... . Specialservice ool
BBDC... Before ottomdead S T . . . . . ... . . . . . . . . . . . . . t. a r t
center S W . . . . . . . . . . . . . . . . . . .w . .i t c h
BTDC .. .... ...... ...Beforeop deadcenter TDC.......... ....... ... Top deadcenter
CPU........ Centralprocessingunit

03uGtx.004
Gt-l0
 

CAUTION GI
CAUTION
INSTALLATION F MOBILETWO.WAYRADIOSYSTEM
lf a mobilewo-wayadio ystems nstalledmproperlyr f a high-poweredype s used,heEGI ystem
and othersystems maybe affected.
When he vehicle s to be equippedwitha mobile wo-wayadio,observehe ollowlng recaulions:
1. nstallheantenna l theJarthestoint romcontrol nits.
2. nstallh eantennaeeder s aras possiblerom hecontrol nitharnessesat east30 cm [11.8 n]).
3. Ensurehat he antenna nd feederare properly djusted.
4. Do not nstall high-powered obile wo-way adiosystem.

MOBILETWO.WAYRADIO

EGAT CONTFOL UNIT

ENGINECONTROLUNIT

"'o'"*'*J
Ll lZ'""-rRoLUN,r
r/rl
AT LEAST 30 cm (11.8 n)
FARTHESTPOINT

05uGlx'013
REMOVAL F IGNITION EYONAUTOMATIC
TRANSAXLEMODEL
Theselectorevermustb e n P (PARK)o urn he gnition ey
to the OFFposition.f theswitch eemso be off but hekey
cannot e removed,h eswitchmaystillbe n he ACCposi-
R tion,or heselectore vermaynotbe n P (PARK). hifthe
N selectore ver o P (PARK),nd urn he gnitioney o the
D LOCK osition.hekeyshould owbe ree or removal.
s
L
03UGIX.OOs
Gl-11
 

GI CAUTION
ELECTRICAL ROUBLESHOOTINGOOLS
Test Light
The est-light,s shownn he igure, ses 12Vbulb.T he
two eadwiresshouldbe connectedo probes.
The est ight s used orsimple oltage hecks nd orcheck-
ing or short ircuits.
Caution
. Whenchecking he control unit, neveruse a bulb
over 3,4W.

9MUGIX.O19
JumperWire
The umperw ire s used or esting y shorting cross witch
terminalsnd ground onnections.
Caution
. Donotconnecta umperwire rom he powersource
line to a body ground;this may cause burning or
other damage to harnessesor electronic com'
ponents.

9MUGIXO2O
Voltmeter
VOLTMETER TheDCvoltmeters used o measure fcircuit oltage. volt-
meterw itha rangeof 15Vor more s usedby connectinghe
positive+) probe red eadwire) o the pointwhere oltage
is to be mi;asured nd the negative -) probe black ead
wire)o a bodyground.

GFOUNO

9MUGIX.O21
DiagnosisConnector
Inserth eprobentoheservice olewhen onnecting um-
perwire o the diagnosis onnector.

Caution
. Do not insert the jumper wire probe nto the diag'
nosis connector erminal,which may damage he
terminal.

05uGtx-021
Ohmmeter
Theohmmetersusedo measurehe esistanceetweenwo
oointsna circuit ndalsoocheckorcontinuitynddiagno-
sis of shortcircuits.
Caution
. Do not attempt o connect he ohmmeter o anycir-
cuit to which voltage s applied; his may burn or
otherwisedamage he ohmmeter.

9MUGIX04 5
Gl-12
 

CAUTION GI
CAUTIONWITHELECTRICALARTS
BatteryCable
Before isconnectingonnectorsrreplacinglectricalarts,
disconnecth e negative attery able.

9MUGIX-022
connectors
Removal f connector
Never pull on the wiringharnesswhen disconnectingon -
nectors.

9MUGIX.O23
Connectors an be removed y pressing r pulling he oc k
leveras shown.

9MUGIX.O24
Lockingof connector
Whenocking onnectors,ake ureo istenora click hat
will ndicateheyaresecurelyocked.

9MUGIX-025
lnspection
1 When estersusedocheckorcontinuityr o measure
voltage,n serthe ester roberom hewire arnesside.

03uGtx,011
Gr-l3
 

GI CAUTION
2. Checkhe erminalsfwaterproofonnectorsr om hecon-
nector ide,as hey annot e accessedrom hewirehar-
ness ide.
Caution
. Use ine wire to prevent damage o the terminal.
. Do not damage he terminal when inserting the
tester lead.

Terminals
lnsoection
putitigntlyn ndividualireso checkhat heyaresecured
in he erminal.

9MUGIX.O27
ReDlacement f terminals
Us6 heappropriate o olso removehe erminals shown'
h e erminal,e sure o nsertt untilt ocks
When nstailind
securery.
<Female)
lnsert thin pieceofmetairom he erminal ideof he con-
nector, nd hen,w ith he erminalo ckingab pressed own,
pull erminalut rom heconnector.
<Male>
9MUGIX-028 Sameas the emaleYPe.

Sensors,Switches,and RelaYs
Handle ensors, witches,nd relays arefully. o not drop
themor strike hemagainst therparts.

9MUGIX-O3O
Gt-l4
 

CAUTION GI
Fuse
Replacement
1 When eplacing fuse,be sure o replacet withone of
specified apacity.
lf a fuseagain ailsafter t has been eplaced,he circuit
probablyhas a short circuitand the wiringshouldbe
checked.
2. Be sure he negative atteryerminals disconnectede-
forereplacing main use 80A).

9MUGIX.O31
3. Wheneplacingpulloutu se, se he use uller upplied
in the useboxcover.

M*m
ffifi,.".
BR/Y
MUGIX,O32
Wiring Harness
Wiring color codes
Two-color iresare ndicated y a two-colorode symbol.
The irst ode ndicateshebase olorof hewireand hesec-
ond the colorof the strioe.

CODE COLOR CODE COLOF

B Black o Orange

BR Brown P Pink

olAGtX-001 LJ Green R Red

GY Gray Violet

L Blue White

LB LightBlue Y Yellow

LG Light Green

Gl-15
 

 
PRE-DELIVERY
N SPECTION
AND
SCHEDULED AINTENANCE
SERVICES

PRE-DEL|VERY .........,..........- 2
N SPECTION
PRE-DELIVERY
NSPECTION A 81E..........- 2
SCHEDULED AINTENANCEERVICES..... - 3
 

PRE.DELIVEBYNSPECTION
PFE-DELIVERYNSPECTION ABLE

INSPECT ndADJUST, necessary,he olowing lemso   Headisht leaneril equipped)

  Horn,wipers nd washer
  Glass€xterorbight melaland paint or damage tr Antennai equipped)
. Wheelug nuls tr cigareneighter ndclock ifequLpp€d)
tr Heateranddefrosteral variousmode seleclions
C Al weathelslfs or darnage r detachrnenl D Canvasop (il equipped)
  Operationl bonnel elease nd ock CHECKhe olow ng tems:
D Operalion l tiJnk id and ue lid open€r   Presence l spare use
(l equipped)   upholslerynd nterlorinish
tr Dooroperaiion nd ahgnmenl CHECK ndADJUST,l necessary,he ollowing ems
tr Headlghl imlng   Operallonnd it ol wi ndows
INSTALLhe o owrng arls I Pedal eighl nd ree playol blakeandclutchpedal
  Wheel apsor ngs equPPed) I Parklng rake
  outsidemrro(s) UNDER ONNET-ENGINEUNNING T
- Front lap il equrppeo)
OPEFATTNGEMPEBATUBE
UNDERBONNET.ENGINEFF CHECK he lollowing lems:
INSPECTand ADJUST. r necessary.he lolowlng items o C Operaton ol idle_up )€tem or air cond toner or powerseer'
ing (it equ pped)
  Fuel,coolantand hydraulc nd D Aulornal transaxleluid level
componentsor leaks I lnitial gnton tmrng
  Englneol evel - ldle speed
  Brakemastercylnder lluid evels   Operallon l ihroltlesensor
  ClutchmastercyLnder luid levels if equrpped)   Operatonof dashpot
- Windshiedwasher eservo lluid evel
  Radiator oolanl eveland spec ic graviiy
tr Tlghtness i waler hose clamps CHECKhe ollowingems.
  Tghhessol baliery elminals, ectro ,'le evelandspecillc   u nders e ue coolarl ndhydrallicines itlings' onnec'
graviry tons andcomponentsor eaks
I llanuallransaxe l eve   Tiresor clts or bruises
  Dflv€ belt(s) enson D Sleeing nkage,uspension,xhauslyslem ndalrunder
tr Acceeratorcable and linkage or iree movemeni sde hardwareor loosenessr oamage
tl Headlght ceaner and lluld level if equipped) ROADTEST
CLEAN he spark plugs
CHECKhe ollowing nrs:
  Brake peral n
INSTALL he lo lowing parls   Clulch perauon
C Fubber slopper or nside ear vew mifror (ii equ pped)   Steeringontro
tr Fuse or accessones tr op€mtion l meters ndgauges
CHECK he operationoi lhe lolowing tems
tr Squeaks,a ltesor unusuanoses
- Seatconlrols slidng and reclning)and head rest   Engine eneral eriormance
I Seal belts   Emerge^cy cking eiiaclors
I lgntion switchand steerng lock AFTERROADTEST
  Powerwindow it equipp€d)
REMOVE the seat and lloor mat proled ve covers
  Door ocks ncluding hid prool door locks
  nhibitor wllch ATXonly) CHECK or the necessary wner nformallonmaterias ools
n A l l g l L s T l u o , n g w a r 1 1 9a l d . n dL a l o r g h t s and spare ire n vehicle
  lgfiton key rem nder buzzer f equlpped)

A-2
 

SCHEDULEDMAINTENANCEERVICES
SCHEDULED AINTENANCEERVICES
-\.\_{e :Inc€ ilumber ot months or km. whlchever comcs lla3l
inrerval
llonths 1 2 1 8 24 30 42 48 54 60 6€
llaintenance item------\ x 1000km t.5 1 5 22.5 30 {5 60 67.5 42.5 so
ENGINE
Enoine alve learance I
Ex. manifoldbolls and nuls T T T T
Enoine iminq bell" Replaco very105,000kilometels
Dfive belts'" I
Enoine il' R R R B R B B R R R
Oil ille'" R R R B R R

COOLING YSTEM
Cooiingsystem I
Enqine oolanl With eservon) R F R

FUELSYSTEM

Arrcleaner lemsnt" R R I R
R B R
I

IGNITIONSYSTEM
Initial qnition iminq I I
Spark lugs I

EVAPOFATIVE MISSION ONTROL YSTET'

EXHAUST MISSION ONTROL YSTEM

oashpot I
I

ELECTRICALYSTEM
level and sp€crllc qravfy

CHASSIS ND BODY
Clulch eda I
Brake llnes. hoses and connections I
Brakel'rid" B I I

Power reennglud and ines ll oquippeo

Sleerngoporalionand gear housing
Steerinainkaoesackqude and ie rodends
I R I
Automaticransaxleluid evel I I
Front uspensionall oir(s
Fronlwheel bearlnggreases R
Driveshaftdust boots I
8olls, nuls on chassis and body 1 T T T T T T
Exhaugsystemheal shields I

A-3
 

SCHEDULEDMAINTENANCE ERVICES
Chartsymbols: performance)
|: lsoecl : V|sua| xam|nalon I iunclona|m easurementf system's peration
A: ,ljust
R: aedaceor change
T: Tighten
L: Lubricate
Note:
. f -the resuhot visual examination l tunctlonalmeasurement l a system's operation per-
lolmance),correct,clgan or leplaceas required'

Remarks: t ems nd nter-

. After 0,OOOmor 72 months, onllnueo ollow hedescribedcheduled aintenance
valsperiodically. ollts - -
. n"lJ-- maite'o tems n this maintenancehart'please ay attentiono the ollowing
ii' iiin" ".tri"i" i" op"rated nder hsiollowingonditions't s suggestedhat heengine ilandoil ilter
OeCnanged m oieoften han at usual ecommended n tervals'
a) Driving n duslyconditions
Oi extenaeO eriods f idlingor lowspeedoperation' egularly'
ij Oriuinglor'"prolonged lrrod n cold emoeraturer drivingonlyshortdistance iming beltmay
.2: ieolacerientof he timingbelt s Auned;t;very 1o5,ooo m' Failureo replace
resultn damageo the engine.
's, ir-fr;u.hi"l i;;p;rated in-very usty r sandy reas,nspect nd' f necessary'e placemoreoften
thanat usual ecommendedn tervals.
'a, AJlust iinip""t alternatorndwaGi pumpdrivebelt'andpower teering ndairconditionerrive
beft, f equipped.
'5:  Replace very wo Years
r
iiiti"i ta" o6en ontinuous arddflving,m ountain rivrng, r it the brakes re usedextensively
nnually'
the vehicles operatedn extremely uriid climates,he brake luidshouldbe changed

EmlsgionConirol and RelaledSystems:

il;;;;" t;Jl; "i"temJ"* uitdrrvm pottanttotheroper perationttheemissionontrolandelated
svste-ms,s wellas tor etflcient ngine perations' "oi,?"*fl.
ift;;;'g[,"r;;;;JtnJ eraedo hesevstemsedone vvour uthorized
dt se"rvicing

A-4
 

SCHEDULEDMAINTENANCE ERVICES
ADJUSTIIENTOF ENGINE ALVECLEARANCE
Note
. Whenvalveclearancenspection ndcylindefiead r
bolts retightening service are ai the same nterval, E
tlEhten he cylinder head bolts tlrst. I

1.Warmup the engineo normal peratingemperature.

2. Withhepiston ftheNo.1 ylinderat DC fcompression,
adjusthe valve learancesllustrated.
valve clearance (at valve)
lntake : 0.30mm 0.012 n)
ADJUSTINGCFEW Exhaust:0.30mm 0.012 n)

LOCKNUT 3. Turn he crankshaftne ull urnso that he piston f the

No.4cylindersatTDCol compression,ndadjuslheclear-
ances f the remainingalves.

TIGHTENINGNTAKEMANIFOLD OLTSANDNUTS
Tightening orque:
19-25 N.m 1,9-2.6 m-kg, 14-19 ttlb)

TIGHTENING XHAUSTMANIFOLD UTS

Tightening orque:
16-23 Nm (1.6-2.3 m-kg, 12-17 ftlb)

REPLACEMENTIMINGBELT
Refero Section ot theWorkshop anualor he replace-
mentprocedure f the imingbelt.

A-5
 

SCHEDULEDMAINTENANCE ERVICES
INSPECTION ND ADJUSTI'ENTOF DRIVEBELTS
aAlternalot nd water pump drive bell' Powersteering
iump and alr condilionelcompressordrive belt)
i cfieck he belt or cracks r any otherdamage.
2. Adiustor rePlace,l necessary.
3. Ch;ckthedrivebelt ension ith humbpressuref about
98 N (10 kg, 22 lb) at eacharrowpoints

Belt detlection
Altemator drive belt
New belt : 5'5-7.0mm (0.21-0.27 in)
Usedbell: 6.0-7.5mm (0.23-0'29 in)

ALTEFINATOR P/ S

Air conditionerdrive belt (if eqipped)

New bell : 8-9mm (0.31-0.35 in)
Used belt: 9-l0mm (0.35-0.39 in)

COMPFESSOFI

Power steeringoil pumPdrive belt (if equipped)

Newbelt: 8-9mm (0.31-0'35 n)
Usedbelt: 9-1omm (0.35-0.39 in)

Air condltionel compressorand powel steedng oil

pump
- drive belt (it equiPPed)
New belt : 8-9mm (0'31-0.35 in)
Usedbelt: 9-10mm (0.35-0.39 in)
)X \euuevi
j
,a'z \ \\
CFANKSHAFT/ \
PUTLEY 1",^ |
\ -zcoMPREssoF

A-6
 

SCHEDULEDMAINTENANCEERVICES
REPLACEMENTF ENGINEOIL
'l.Warm p heengine.
2. Drain he oilby removinghe drainplugand oilfiller ap.
Warning
. Walt a while fo. the engine s too hot,
And be caretul o drain.
3. Reinstallhe drainplugsecurely.
Tightening orque:
29-41 Nm (3.0-4.2 m-kg,22-30 ft-lb)
F" levelmarked
4. Refillthengine ith hespecifiediltothe
on he evel auge.
5. Refithe oil illercap securely.
Oil pan capacity:3.0 iters (3.2 US qt, 2.6 lmp qt)

Recommended AE viscosily numbers

-30 -m -10 0 10 20 30 40 50
(.c)
eF)

5W.30 v 30 '

5w-rd-> :
Engine il 10w-30

Typicalspecitication:API serviceSD, SE or SF

REPLACEMENTF ENGINEOIL FILTER

1. Removeheoil ilterwith he SSTa suitable rench.
2. lJsea clean ag o wipeoff he mounting udace n the
engine.
3. Apply small mount fclean ngine ilio he ubber eal
ol the new ilter.
4. Installhe oil ilterand ighten t by handuntil he rubber
sealcontactshe base.
5. Tightenhe llter1 and 1/6 urnswitha filterwrench.
6. Starthe engine nd check or leaks.
7. Check heoil evela ndadd oil f necessary.
Oil filler capaclty
83: 0.17 iter 0.18US ql, 0.15lmpqt)

A-7
 

SCHEDULED AINTENANCEERVICES
INSPECTION F COOLING YSTEiI
Warning
. Nevei remove he radialorcap while he engine s
hot.
. Wraoa thick cloth around he cap when removing t.
. Whdnremoving he radiatorcap, loosen t slowly
to the fitst stop until he pressure n the radialor s
released. nd remove t.

CoolantLevel (Engine old)

1.Verifvhat hecoolanlevel s near he adiator llel neck
2. Verilv hat he coolantevel n the coolant eserviors be'
tween he FULLand LOWmarks
3. Add coolantf necessary.

CoolantOuallty
1.Verffyhat heie s no buildup f rustor scale round he
radiator ao or radiatorillerneck
2. Verily hat coolants free of oi Replacehe coolant f
necessarv,

CoolantLeakage
1.Connect radiatore ster commerciallyv ailable)nd he
SST o the radiatorillerneck.
2. Apply 03 kPa 1.05kg/cmz. 5 psi) pressureo the
system.
3. Verifyhat he pressures held.
It not,check or coolanieakage

?_---z'- .- l,'1,/ '

CoolanlProtection
Caution
. Do not use alcohol-or methanol-based oolant'
. Useonly soft (deminerallzed) ater n the coolant
mixlure.

1. Measurehecoolante mperaturendspecific ravitywith

a thermometernd a hydrometer'
2. Determinehe coolant rotectiony referringo hegraph
snotproper' ddwater rcoolant
lrthecoolant rotectaon

Antitreeze olution mixturepercentage

Gravilyai
coolant 20"c (68"F)
Above -16"C (3oF) 65 35 1.054
Above 26oC (-1soF) 55
Above a0'C (-40"D 55 1.078
COOLANT EMPEFATUFE C (.F)

A-8
 

SCHEDULEDMAINTENANCE ERVICES
REPLACEi'ENT F ENGINE OOLANT
Warning
. Never pen he radiator apwhile he engine s hot.
. Wrapa thick clotharound he cap when oosening.
. Use caution when draininghqt coolanl.

THEDFAINHOSE
Caution
. Do nol use alcghol.or methanol-basedoolant.
. Useonly soft (demineralized) ater n the coolanl
mixture.
'1.Removehe radiator apand oosenhe drainplug.
2. Drain he coolantntoa suitable ontarner.
3. Flushhecooling ystem ithwater ntil ll races f color
are gone; hen et he system raincompletely.
4. Installhe drainplug.
5. Fillwith he proper mount nd mixture f ethylene lycol
based oolant y referringo the ableabove.
Coolanlcapacity
MTX:5.0 liters (5.3 US qt, 4.4 lmp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 lmp qt)

6. Run heenginewith he adiator ap emoved ntilthe p-

radiator ose s hot.
7.With he enginedling, dd coolanto the radiator ntil t
reacheshe bottom l the illerneck.
8. Installhe radialor ap.

A-9
 

SCHEDULEDMAINTENANCE ERVICES
ADJUSTMENT F IDLESPEED
Preparalion
'1.Warmup the engineo normal peratlngemperaure.
2. Verityhat he wat rod e)dends utwardullyand he dle
camseparatesrom he roller'
3. Turnall electricoadsOFF.
. Blower an
. Headlight
. Rear Delroster
4. Makesure hat he engine peeddoesnotchangewnen
disconnecting healrbtpasssolenoidalve@ connector.

Note
. lf lhe engine Peed ecleases.he engine s still un-
der the warm-upcondition'

5. ftheelectfic oolingan soperating, ait illthefan lops

6. Verifyhat he engines running t dle n goodcondition-
7. Connecthe SST o the diagnosisonnector'
8. Connect tachometer o thediagnosisonnectorG- ter-
minala s shown.

L Selswitch6) to Position .
10 SetTESTSW10SELF-TEST.

Note
. lf the SST s not used, ump across he TEN elmi'
nal and the GND telminal ot the diagnosiscon'
nector.

ldle Speed
1. Check he idle speed with a tachometer.
t-\*l
ldle speed:MTX Neutral) 750 T rpm
ATX P range) ,100 't rpm

djusthe dleby urninghe

2. f notwithinhespecifacalion,
throttle djusting crewOAS).

A-10
 

SCHEDULEDMAINTENANCEERVICES
REPLACEMENTF AIF CLEANEF LEMENT
Visuallyheckthe ircleanerlementforxcessiveirt,dam,
age or oil,replacef necessary.

REPLACEMENTF FUELFILTER
Warning
. Keepsparksand open lamesaway rom lhe tuel
area.
. After replacing he tuel filter, check hat the filler
ioints are nol leaking.
To reolacehe uel ilter, roceed s ollows:
1. Disconnecthe uelhoses.
2. Removehe uel i/ter irh hebrackel
3. lnstall new ilter n the reverse rderol removal.
Note
. When nstalling he fillter makesure he hosesare
pushedgn as tal as possiblg.Secure he hoseswith
clips.

INSPECTION F FUELLINESANOHOSES
Checkhe uel ine ittings, onnectionsndcomponents
or

There hould e nowetness r stalned reashatmioht ndi-

cate eaks-
Replace ny detective oses r clips.

A-1 1
 

SCHEDULEDMAINTENANCE ERVICES
ATUUSTMENT F IGNITION IMING
Preparation
1.Warmup the engine o normal peratingemperature.
2. Verily hat hewax odextends utwardullyand he dle
cam separatesrom he roller.
3. Turnall electricoadsOFF.
. Blower an
. Headlight
. RearWindowDefroster
4. lvlake ure hat he engine peeddoesnotchangewhen
disconnecting heairbypass olenoidalve@ connector'

Note
. I the engine peeddecreases,h e engine s still u]}
der the warm-upcondition.
ACHOMETEF
5. lf heelectric oolingan soperating,aittilltheanstops.
6. Verifyhal he engines running t dle n goodcondition.
7. Connecthe SST o the diagnosisonnector.
.-- 8. Connect timing ight.
|N 9. Connect tachometero hediagnosisonnectorG- ter'
re
G- GNO
_--\
minalas shown.

10.Setswitch@ to Position .
11.SetTEST W o SELF EST.

Note
. lf the SST s not used, ump across he TEN ermi'
G ND
nal and the GND erminal gl the diagnosiscon'
nector.

lgnition Timing
.?-.:f- \r:1 \ Inspeclion Adiustment
1. Check hat he dlespeed s within he specification.
-=\,('__',
ldle speed: MTX Neutral) ?50 :l rPm
ATX (P range)1,100 ' rpm

2. Check he gnjtionimingwitha timing ight

lgnition timing: BTDC16 + | "
oosen
3. lf the gnitioniming s notwithinhe specification,
/1.,"_(V the distributoro ckboltsand urn he distributoro make
.:TS the adiustment-
4. Tiqhtenhe distributoro ckbolts o thespeciliedorque.
r ,<-- Tiohteninq oloue:
ie-zsI{m (i.6-2.3 m-kg,12-16 ftlb)

5. Puta sealon thedistributoro ck bolt

A-12
 

SCHEDULEDMAINTENANCEEFVICES
INSPECTION F SPARKPLUGS
'1.Checkhe plugs or burned r eroded lectrodes,ouling
or cracked orcelain.
heelectrodeap. f necessary,d justhegap o
2. lvleasure
specificationsr replacehe sparkplugs.
Pluggap:1.0-l.1mm (0.039-0.043n)
(0.75-0.85mm10.029-0.033 nl)
-Bl Carburetor
ENGINE B1 B3
NGK B PB sE S, P Bo ES B K R s E . 1 1K
, N6E.]
NIPPONDENSO W16EXF.U, 2OEXR.U K16PR-U11,2 OPR-IJ11

Cauiion
. when nslalling newplug or reinstalling ld plugs,
use a small amount of anti-seizecgmDoundor
Bolybdenum-bas€dhread lubricar on the filst few
threads.
. Do not pull the spark plug cables lo remove them,
pull on the spark plug boots.

INSPECTION F THROTTLE ENSOR

USECONNECTOR
1.Warm p theengineo normal peralingemperature.
2. Verifyhat hewax odexpands utwardullyand hecam
separatesrom he roller.
3. Stop he engine nd urn he gnition witchON.
4. Connectthe STS EngineSignalMonilorandAdapter
Harness)o the ECUas shown.
5. Set he SST (EnglneSignelMonitor) o terminal M.

6. Rotatehe hrottleinkby handandverifyhat he voltage

is within hespecification.
Speciticalion
Throtle valvecondilion
ECUTerminal

2M 0. 41-062V

7. It nol as specilied, 4ust the throttlesensor.

A-13
 

SCHEDULED'AINTENANCE ERVICES
INSPECTION F DASHPOT
Inapection
1. ODenhe hrottle alve ully.Push hedashpot od witha
fingerandverity hat t goes nto he dashpot lowly.
2. Releasehe rodand check hat t comesout quickly
3. Replacehe dashpotf notas specified.

4. Warmup the engine nd run t at idle.

5. Connect tachometero the diagnosis onnectorG-
terminal nd ncreasengine peed.
6. Slowly ecreasehe engine peedandcheck hat he e-
ver oucheshe dashpotod at the specified peed.
Specitication: ,500 + 100 rpm

7. f notasspecilied,oosenhe ocknut nd urn hedashpot

to adjust.

ADJUSTINGCFEW

A-14
 

SCHEDULED AINTENANCE ERVICES

INSPECTION F EVAPORATIVE YSTEM
emperaturend
.un t at idle.
2. Disconneclhe vacuum ose rom he solenoid alveas
shownn he igure, ndverityhatnovacuums eltatthe
solenoid alve.
3. f notas specified,heck he solenoid alve.

INSPECTIONF BATTERY
Check he electrolyteevel.
The evelshoulde betweenhe upper nd owerines.l the
level s low.add distilled ater.
Check he specific ravity.
Speciticgravity: 1.27 1.29

INSPECTION F ALL ELECTRICAL YSTEM

Check he all electricalystems.
lf he mulfunctons found,eieroSection or wiring iagrams
tor reparr.

A-15
 

SCHEDULED ATNTENANCEERVICES
INSPECTION F CLUTCHPEDAL
'1.Check he pedal or smooth peration
2. Checkthe edal eight.f necessary'd judthe edalheight
by ooseningocknut@ and urningheclutch wltch q).
retighlenhe ocknut 4).
3. Ch;ck he pedal ree play. f necessary,diusthe pedal
freeplay.Refer o H-4.

Pedalheiqht: 196-207mm (7.72-8.15 in)

Pedal reCplay: 0.7-3.3mm (0.03-0.13 In)
Diaenqagement eight:
4lmm (1.61 n) mlnimum With carPet)

INSPECTION F BFAKELINES,HOSESAND
CONNECTIONS
Check he points elow, eplace arts f necessary.
1.Crackind, amage r corrosion l the brakehose
2. Damaoeo the brakehose hreads.
3.Scars.lracks r swelling f the lexible ose.
4. All ines or luid eakage.

INSPECTION F BRAKEFLUID
Checklluidevelnreservoir.he evelshouldebetweenhe
lvax.and Min. ineson the reservoir.
lf the luid evels extremelvow,check he brake ystemor
€aKs.

A-16
 

SCHEDULED AINTENANCE ERVICES

REPLACEMENTF BRAKEFLUID
AIR BLEEDING
1. Removehe brakeluidkom he reservoiry using suc-
lon pump.
2. Fill he reservoir ithnewbrake luid.
Fluid apecllication:FMVSS116: DOT-3
SAE:J1703

3. Attach vinyltubetohebleeder crew ndplace heoth-

er endol the vinyl ube n a containel.
4. Pumpout he old brake luidby looseningachbleeder
screw oneby one)and pumpinghe brakepedal.

5. Bleed ir as described elow.

Cautlon
. The tluid in the reservolr must be maintalnedal the
Z4 l€vel or higherdurlng air bleeding.
. Be caretul nol to spill brake lluid onto Painted
surtaces.

'1.
Jackup thevehicle nd supportt withsalety tands
2. Removehe bleeder ap and attach vinylhose o the
bleeder lug.
3. Place he otherendof the vinyl ube n a container.
4. Slowly ump he brakepedals everalimes.
5. Whilethe rake edals pressed,o osenthe leedercrew
to let luidand a'r escape.
6. Repeat teps and5 until here re no air bubblesn he
fluid.
7. Check or cotrectbrakeoperation.
8. Checko be sure hat here s no luid eakage. esure o
cleanawayanyspilledluidwith ags.
9. Afterbleedinghe air,add brake luid o he reservoirp
to the sDeciiiedevel.

INSPECTION F PARKING RAKE

1. Pullthebrake everwith98 N (10 kg, 22 b) ol forceand
measurehe everstroke.
2. f necessary,djusthe ever troke y urninghe adjust-
Ingnut.
Stroke: 6-8 noiches

INSPECTION F POWER RAKEUNITAND HOSES

1.Check hevacuum ose, onnectorsndcheck-valve or

@ @ cracks, hafing, eteriorationtc.

2. With he engine topped, epresshe pedala few imes

ww
3. With he pedald epressed,tart he engine.
4. lf, mmediatelyfter heengine tarts,hepedalmoves own
slightly,he unit s good.

A-17
 

SCHEDULED'AINTENANCESERVICES
INSPECTION F DISCBRAKE
Check he ollowing iscbrake omponents.
1. Check he caliper perationnd nspector eaks
2. Check he Pads ot wear.
3 Check he condition nd hickness l the discplate

Minimum:BrakePad2.0mm (0.08 n)
Dlsc plate thicknesa
l6.0mm (0.63 models
lomm (0.39 n) MTXmod€ls

INSPECTION F DRUMBBAKE
'1. Check hewheel ylinder perationnd nspector eaks.
2. Check he in'ngsor wearor damage
3. Checkhe condition f he nner urface nd he nner l-
ameter f the drum.
Limli:
Brake1in1n9........... l.omm (0.04 n)
lnnerdlamater f drum ..'.,.... 81.smm 7.15 n)

INSPECTION FSTEERING NDFRONTSUSPENSION

1. Check he steering heel ree play

Free play: 0-30mm (0-1.18 in)

2. Checkthe teeringor proper perationnd or ooseness
of the steering ouslng.
3. Check he steering ear housing or lluid leakageor
seepage.

4. Checkor exoessivelayon he ie rodendsandrackguide

5. Check or damage l the dust boots.
6. Checkloroosenessr greaseeakage fthetie odends

INSPECTION F POWER TEERING LUIDANDLINES

(if equipped)
i- Check he fluidhoses,inesand connections o r cracks,
chaf tc.
ng,deterioration,
2. Check he luid evelon he reservolr.
"F" and "L" level Add
The evel hould e betweenhe
fluid f necessary.
Fluld soecificalion:
ATF Dexronoll or M-m

A-18
 

SCHEDULEDMAINTENANCEERVICES
REPLACEi'ENT F MANUAL RANSAXLE IL
1. Visuallyheck he manualransaxleor oil eakage.
lf leakages found, heck or he cause, nd repair.
2. Removehe speedometera bleand drivengear.
3. Removehe drainplugand drain he oil.
4. Reinstallhe drainplugsecurely.
Tlghtening orque:
24-35 Nm (2.4-3.6 m-kg, 17-26 ftJb)

5. Fillw ith hespecifiedil rom hespeedometerr iven ear

hoie o theF markon he speedometerriven ear.

Specilledoil
Grade:APIserviceGL-4
Viscoslly:All-seasonDexron@tr l M2C33F
Above -l8cc (0"F) SAE 75W'80

Capacity:
2.5 litets (2.64US qt, 2.2 lmp qt)

INSPECTION FAUTOMATIC MNSAXLE FLUIDLEVEL

Caulion
. Place he vehlcleon a flat, level surtace.

1 Apply he parking rake nd position heel hocks ecurely

lo preventhe vehicleromrolling.
2. Warm-uphe engineuntil he ATF .eaches 0-70oC
(140-rs8oq.

3. While epressinghebrakepedal, hift he selectorever

to each ange P-L) nd eave t a iew secondsn each
HOTBANGE
range.
4. Shiftback o P.
Nole
. Only use the COOL (20oC) range as a rough
tetetence.

5. EnsurehattheATF evels n heHOT 65oC)ange. dd

ATF o soecffication,f necessary.

ATF ype: oexron@tr r M-Itr

Capacity:6 .3 literc(6.7 US qt, 5'5 lmp qt)

BEPLACEMENTF FRONTWHEEL EARING REASES

i ll heshaded reashown n he igurewith ithi'
Completely
um grease.
Note
. Reler to page M-8 for disassembly assembly
procedure.

A-19
 

SCHEDULEDMAINTENANCE ERVICES
INSPECTION F DRIVESHAFTDUSTBOOTS
Check he dustbooton he driveshaft or cracks, amage,
greaseeakage, nd a loosebootband.

TIGHTENING FBOLTSANDNUTSON CHASSIS ND

BODY
'1.Tighten ll seatmounting olts.
2. Retightenny oose uts ndbofts n hechassisandody
to the specifiedorque. Refero Section D.)

TNSPECTIONF EXHAUST YSTEMHEATSHIELD

Check heclearance etweenhe nsulator nd bodyandalso
betweenhe nsulatornd he exhaust ystem.

A-20
 

ENGINE
tNDEX.............,..... B-2 tNSPECT|ONREPA|R..................... -48
ourLrNE............... B-3 pREpARATtON .....,...................,.. -48
SPECTFTCATIONS ... B-3 cYLtNDER EAD.......................... -48
TROUBLESHOOTING U IDE..,........, B-3 VALVEVIECHANtSM ....................-49
ENGINE UNE-UP ROCEDURE . ....,B - 5 cAt\,4sHAFT.................................. -52
PtrFPAHATI.)I\I B-5 cYLtNDEB 1OCK........................ -54
E N G T N Er 1 . . . . . - . . . . . B-5 PISTON,ISTON ING, ND
ENGINE OOLANT B-5 PtsToNPrN................................ -56
B-5 coNNECT|NG OD....................... -57
VALVECLEARANCE B-7 CRANKSHAFT ............................. -s8
IGNITIONIIVIING, DLESPEED..... B - 8 BEARlNG.........-.-......................... -58
coMPRESStON...... B-10 TTMtNGE1T......,........................ -59
TNSPECTTON ......... 9-10 TENSTONER, DLER....................... -sg
ON.VEHICLEAINTENANCE............ B-11 TENSTONEB P RrNG..................... -sg
PREPARATION B-l1 pu11EY.................-..-..-............... -59
T||VltNGE1T ........ B-12 ASSEI'BLY..................................... -60
CYLINDEH EADGASKET.....,....... B-17 pREPARATTON .........,.................. -60
FRON'T ILSEAL.... B-21 CYLINDERLOCK
t r F A A A I I qFAI B-23 flNTERNALARTS)...................... -61
REMOVAL............ 8-26 CYLINDEHLOCK
8-26 (EXTERNALARTS)........-............ -67
ENGINE TANOMOUNTING............. B-33 cYLtNDER EAD.......................... -72
PREPARATION B-33 T I M I N GE 1 T . . . . , . . . . . . . . . . . . . . . . . . . .-.7. .6. . .
B-34 AUXtLtARYARTS........................ -79
DrsAssEMBLY....... B-36 ENGINE TANDDISMOUNTING........ -82
PREPARAIION . ..... B-36 pRocEDURE.............................. -42
AUX|LIARYARTS........................ a-37 rNST4LLAT|ON............................... -84
TIMINGE1T......... B-38 pRocEDURE............................... -84
c Y L t N D E RE A D . . . . . . . . . . . . . . . . . . .B-40
...-.-. 01a08x.001
CYLINDERLOCK
(EXTERNALARTS)..................... B'42
CYLINDERLOCK
{tNTERNALARTS)...................... B-45
 

INDEX
INDEX
INTAKEMANIFOLO

19-25 rktr (1,$-2,6 n-*t, la-19ll-rb)

lN: 0.3omm 0.012n)

E* 0.30mm 0.012n)
INSPECTION ADJUSTMENT

ENGINE @OIAMI,
SEFIVICESECTION E

ENGINE IL
INSPECTIONIEPLACEMENT,
SECTION

EXHAUSTMANIFOLD

rr-23 l&n {r.9-2.3 f-*9,

DEFLECTION AT {98 N, 10 kg, 22 lb)

MPRESSION NSPECTION AGE B-12
.0-7-0 (o.1 6.0-7.5 {0.23-0.29}
1412 14.4, O4l30O

1.Timing elt 5. Engine

RemovalI nsta||ation.................. ageB-12 R e m o v a | . . . . . . . . . . . . . . . . . . . . . . .a. .g. e.P-26
..........
2. Cylinder eadgasket Engine tandmounung. ............ B-33 age
B e p | a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . .-.1. a g eB-36
3. Frontoil seal InspecUon F]epair................-..... age 8,48
R e p l a c e m e n t . . . . . . . . . . . . . . - . . a. .g. .e. . . 2. .1. . . . a g e
A s s e m b | y . . . . . . . . . . . . . . . . . . . . . - - . . .B-60
..........
4- Rearoil seal Engine tand ismounting ........age8,82
R e p l a c e m e n t . . . . . . . . . . - . . . . . . a. .g. .e. . .-.2. 3.... 1 n s t a | I a t i o n . . . . . . . . . . . . . . . . . . .a.g. .e.8. .8. .4. . . . . .

B-2
 

UIDE
OUTLINE. ROUBLESHOOTING B
OUTLINE
SPECIFICATIONS
Engine a3
Item

Cylinder nangementnd number

Combusrionhamber
OHC, belt-driven 6 va ves
Displacemenl cc (c'r in) 1323 80.7)
Boreandstroke mm (in) 71.0x83.6(2.80x3.29)
9.4
Compressionressure kPa kg/cm'. si)'rpm 137314.4, 99)300
Open BTDC
IN
ABDC
Open BBDC 404
EX
Close ATDC
N 0.30 0.012)
Vaiv€ learance mm (in)
EX 0.30 0.012)
[/TX 750 i
ldle sp€ed rpm
ATX 1100"3
lgnition iming BTDC 16
1-3-4-2

TBOUBLESHOOTINGUIDE
Posslble Cause eemedy Page
D if ii cu li st art lng M al lun cti on ol e ng ine rel aie d c om po nen ls
B-49
Wom piston,pislon ing or cylinder 8,54,56
Faled cylinderhead gasket B-17
Mallunclion ol tuol system
Mallunclion ol igrltion system Refer o SectionG
Poor dling uallunclion of engine-rslated components
Poorvalvelo-valve eatconlact B-49
Failed ylinder eadgasket B-17
Maltunction ol tuel system
Mallunctlon l ign[ion system Reler to Section G
Oil workingup
Wornpjston inggroove r sticking iston ng 856
Wornpision r cylinder B 54,56
Oil workingdown
8-61,72
Worn alve tem r guide B-50
Oll leakage Retero Section

B-3
 

B UIDE
TROUBLESHOOTING

Remedy Ps9e
Insulticient compaession
Compresson eakage rom valve seat B-51
B -49
Weak or broken valvespfing B-52
Faiiedcylinderhead gasket B-17
Crackedor d'slorred ylinderheao B-48
Sticking damaged,or wom plslon ng B-56
Crackedor wofi pislon B-56
Mallunction ot luel system
Mallunction ot ignition system Relero Secnon
Othera
Slipping lutch
Draggng brakes

lklfunction of enginerelaled components

Siicking r burned alve B-49
weak or broken alve pnng B-52
Carbon ccumulalonn combustionhamb€r
itallunclion ol tuel system
lraltunctionof lgnllionsystem
Enginsnois€ Crsnkshaft- or bearing-rolated p.tls
Excessivenainbearingoil clearance B-64
Main bearingseizedor healdamag€d B-58
Excessive rankshait nd Dlav B-65
Excessive onnecting od bearingoii clearance B-65
Connecting od bearingseizedor heat_damaged B-58

PBton-related parls
8 5 5
Wompiston r pislonPn 8 5 6
8 5 6
Damaged ston rng 8 5 6

valves or timing-related Parls

Broken alve ping B-52
Excessve alve ude clearance B -49

Malfunctlon f coolingsystem Refor o Secton E

llralluncllon of tuel sFtem
others
l water umpbearing
lvlaLfunction Befer to seci on E
lmproper rivebeLlenslon
Malfunctioni aternalor eanng Reler o SectionG
Exhaust as eakage
N,4afunctioni I mingbeli ensioner B-13

B-4
 

ENGINE UNE-UP ROCEDURE

ENGINE UNE.UP ROCEDURE
PBEPARATION
ssr
49 9200 020 49 8019 9A0

Tension auge, ignilion iming

ENGINEOIL
Inspection
1. Be sure he vehicles on levelg round.
2. Warm p heengineto ormaloperating emperaturend
stop rI.
3. Wait or fiveminutes.
4. Removeheoild ipsticknd heckheoil evelandondition.
5. Add or replace il f necessary.
Note
. Thedislance elween he Land F markson he dip.
stick repressnts .8 iter (0.85US qt, 0.70 mp qt).

ENGINE OOLANT
Inspectign
Coolant evel (englnecold)
Warning
. Never emove he radiatorcap whlle he engine s
hot.
. Wlapa thlckclotharound he capwhen emovingl.

1.Verilyhat hecoolantevel s near he radiatoriller eck.

2. Check hat hecoolantevel n hecoolanteservoirs be'
tween he FULLand LOWmarks.
3. Add coolanll necessary.

Coolanlquality
1.Verifyhat here s no buildup i rustor scalearound he
radiator ap or radiatorillerneck.
2. Verifyhat he coolants freeof oil.
3. Fleplacehe coolanli necessary.

ORIVEBELT
Inspection
1.Checkthe rive eltsorwear, racks, nd raying. eplace
V.RIBEEDELT if necessary.
2. Verity hat he drivebeltsare correctlymounted n the
MtwJtM puleys.

o x

B-5
 

ENGINE UNE-UP ROCEDURE

3. Checkhedrive eltd eflectiony applying oderateres-
sure 98 N, l0 kg, 22 b) midway etweenhe pulleys, s
!.t-q/lotL
2",.r shown.A djust l necessary.
\ puMp
Y/ \ cutteY Dellection trnnn/
" fi.i sp,an'// Drivebet
l,.PULrEV 50 70 6.0-7.5
(019 0.27) (o.23-O.29)
80 9.0 9 . 0 - 1 00
ALTERNATOF P/S, P/S + A/ C (0.31-035 ) (0.35-0.39)
pJc 80-90 9.0-10.0
( 0 . 3 1 - 0 5) (0.3s 0.39)

\, - P/s\
r^A /orr pui,rp 4. Checkthe rive elttensionith heSST tension auge).
Y \"ut""\
'-- '/
.4.' \\
CAANKSHAFI/.A/C\ CFANKSHAFT/ Note
'.-agy'
PULLEY CO " y . . .J" \ " " J \ . Belt tension can be measuredbetweenany two
pulleys,
Tension N(kg, b)
Drive bell
451-785 392 588
( 4 6 80. 1 0 1 - 1 7 6 ) (40-60,88 132)
491 58 9 422-491
P/S, PiS + A/C (50-60, 110 132) (43-50,95-110)
491-589 422-491
A/C (50-60, 1r0-132) (43 50,95-110)

5. lnstall he alr intakePiPe.

Adiusiment
Caution
. It a new bett s used,adiusi he bell dellectionat
the midpointot new belt specification.
Alternatorelt
oosenhealternator ounting olts@and
adruslrnooltG)
z Lever h-e lternitor utwald ndapply ensiono thebeh
Tightening orque
i& : 37-51 N.m 3.8-5.3 m-kg, 27-38 ft-lb)
\t: 18-25 N.m l'9-2'6 m-kg,13-18 ft'lb)
3. Becheckhe belt ension r deflection.

P/Sbelt.P/S + tuC belt

It necessary,oosenhe P/Soil pumpmounting@, @ and
O andadjusthebeltdeflectiony utning headjustingolt
@)
Tighlening orque
@: 19-25 Nfl (1.9-2.6 m-kg' 4-19 ft-lb)
!E, 36-54 Nm (3.7-5.5 m'kg' 27-40 ft-lb)
G : 36-54 N.m 3.7-5'5 m-kg, 27-40 flnb)

B-6
 

ENGINETUNE-UPPROCEDURE
AJCbelt
lf necessary,oosenhe ocknut@ andadjusthebeltd eflec-
tion by turning he adjusting olt@.
Tlghlening orque:
37-51 Ntn (3.8-5.3 m-kg, 27-38 fl-lb)

VALVECLEARANCE
Inspecilon Adiustment
:i\\ 1.Warmup the engineo normal peratingemperature.
a.\.\ 2. Removehe aircleaner.
3. Removeheacceleratorable-
4. Removehe cylinder eadcover.
5. Turn he crankshaftndalign he imingmarkso hat he
piston ftheNo.1 r No.4 ylindersatTDC fcompression-

6. Measurehevalve learances with heNo.'lcylinder t

TDCof compression,n d hose f @ with he No.4 ylin-
der at TDCof compression.
Valveclearanae valveslde)
lN : 0.30mm 0.012 n)
EX: 0.30mm 0.012 n)

7. lf il is not within pecification,djustand recheckthe alve

clearance.
B. Turn he crankshaft ne Lrllurn and measure he remain-
ing valve clearances. diust f necessary.

9. Installh e cylinder eadcover.

Tighteningorque
Bolt @: 4.9-9.8 Nm (50-90 cm-lq, 43-78 In-lb)
Bolt @r 7.8-11 Nm (80-110 cm-l€, 69-95 inlb)
Caution
. It the headcovergasket s reused,applysealant n
the grooveas shown.
10. nstallhe acceleratorable.
'11.lnstallhe air cleaner.
12.Start he engine nd check or excessiveappetnoise.

B-7
 

ENGINE UNE-UPPROCEDURE
IGNITION IMING,DLESPEED
Prsparalion
1.Warmup the engineo normal peratingemperature
2. Verityhat he wax odextends utwardullyand he dle
cam separatesrom he roller'
3. Turnall electricoadsOFF.
. Blower an
. Headlight
. RearWindowDefroster
hat he engine peeddoesnotchangewhen
disconnecting heairbypass olenoidalve@ connector'

5. l theeleckic oolingan soperating, aittilltheanstops

6. Verifyhat he engines running t dle n goodcondition
7. Connecthe ssT to the diagnosisonnector'
8. Connect tlmingight.
9. Connecta tachoheter o the diagnosis onnectorG- ter-
minala s shown.
Note
. ll the enginespeeddecreases, hs englne a atlll un-
der the warm-upcondition.

'10.Setswitch to position
@
1'1. etTESTSW o SELF-TEST.
Note
. It the SST s not used, ump across he TEN ermi-
nal and the GND erminal ol the diagnoalscon-
nedor.

lgnitionTiming
Inspection Adius|ment
1. Check hat ne dlespeed s wiihrnhe specification
ldle speed:MTX Neutral) 750 i:! rym
ATx (P range) ,100 :1 rpm
2. Check he gnitionimingwitha timing ight
lgnition iming:BTDC 6 + l"

oosen
3. t the onitionr|ninos not within he specilication.
the disiflbutorocLbohs nd urn hedistributoro make
the adiustment.
4.Tighte; he distributoro ckbofts o the specifiedorque
Tiohteninq orque:
is-zs-Nm (i.9-2.6 m-ks, 14-19 ftlb)
) 5. Puta sealon the distributoro ckbolt.

B-8
 

ENGINE UNE-UPPROCEDUFE
ldle Speed
'1.PerformPreparaljon"-
(Refero pageB-8.)
2. Check he dlespeedwitha tachometer.
ldle speed:MTx (Neutral) 750 it rpm
ATX P range) ,100:1 rpm

oreeos'6o"G66alj

3. lf notwithin pecification,djusthe dleby urninghe hrottle

adjusting crew.

B-9
 

COMPRESSION
COMPRESSION
ll rheenoine xnibitsow power.poor ueleconomyor poor dle check he ollowing:
1. gnrtro; ystem Beler o SectronG.)
2.Compressron
3. Fuelsvstem Fefer o Section .)

INSPECTION
1 Verifvhat hebatterys ully hargedRecharget f neces-
sarv. Refero SectionG.)
2. Warmup the engine o normal peratingemperature'
3. Turn he engineOFF.
4. Bemove ll sparkplugs.
5. Disconnecthe gnition oilconnector'

6. Connectcompressionaugetothe o spark lughole

7. Fr.rllyepresshe acceleiator nd engine'
8. Recordhe maxrmumauge eaolng
9. Check achcylinder.
Compression kPa kg/cm', silrpm
B3
Siandard 1412 t4.4, O4!3OO
103000.5, 149)-300
't96 (2.O,26)

10. f thecompression n oneor more yllnders rcw'poura

smalla mount f engine il nto he cylinder nd recheck
the compressrcn.
(1) lt thecompression n creases,he piston, iston ings'
or cvlinderw allmavbe worn
(2) lf the compressiontaysow, he valvemaybe stuck
or seatingmProperly.
' ' lt he comoression
{3) n adjacentylinderstaysow, he
cvlinder eadgaskelm aybe delective r he cylinder
head distorted.
11 Connect he ignitioncoil connector.
ubricant
12.Apply ntiseizeompoundrmolybdenum-based
to the sparkPlug hreads.
13. nsialltheparkPlugs.
Tidhlenino oroue:
is-zsi{.m (i.5-2.3 m'ks' 11-17 finb)

B-10
 

ON-VEHICLE AINTENANCE
ON-VEHICLE AINTENANCE
PREPARATION
ssT

49 G0175A 0 49 D011102

Engine uppod inslallation f

timing belt puley

49 E30106 0 49 E301 61
Brake,inggear Sody
(Panof
49 E301 60 )

49 E301062 43 SE01 10
installation t
Collar Centeingool,
(Partof
49 E301 60)

B-11
 

ON.VEHICLEl|AINTENANCE
TIMINGBELT
Femoval lnstallalign
'1.Drsconnecthe negative attery able.
2. Lilt up the vehicle.
3. Removen the ordershown n the igure, eferringo RemovalN ole.
4. Installn the reverse rderof removal,elerringo InstallalionNote

1r-25 O,r-2.6, 1a-19)

7€-rr rlo (30-110 .eks, 6e-e5 In{b)

p0-rr0 *rs, ca-es .-rb)

12-17 (1,2s-1.75, 09-rs2)

1s6-r65 05-17, 115-122)

1.Splashhield L Timingbeltcover,u pper

2. P/Sand/or A,/C rive belt L Timing eltcover, ower
Insp€ction................................... a g e 10.High-tensron eads
3-Alternatorrivebelt 11.Spark lugs
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g-e.B. . .- .5. . . . .12.Timing
. elt
Adjustment................................. a g e8 , 6 R e m o v a ol t e . . . . . . . . . . . . . . . . . . . .a. .g. e
.. -14
4. Water ump pulley I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. g
. .e. . .' .1. 4. . . . . .
5. Plate Installalion o te.... ..................... age B-1
a g e '13.Tensioner
Removal o t e . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation o te.......................... ageB - 1 6 I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a.g. .e. . .-.1. .4. . . . .
6. Pulleyock bolt Installation o te.......................... ageB-1
a g e8 , 1
R e m o v a lo t e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 14.Tensioner pring
lnstallationo te........ ...............-. ageB 1 5 I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a.g. .e. . .-.1. .4. . . . .
7. Crankshattulleyand pulleyboss Installation o te.......................... ageB-'1

B-12
 

ON-VEHICLE AINTENANCE
Removaln ote
Plate
ounting olts.

2.Suspendheenginewith he SST.

3 RemoveheenginemounlNo.3mounting olts nd urn

over he enginemountNo.3.
0mm 1.97 n)gradually.
4 Lowerheengine pproximately

i.- i\\ z
5. Removehe platemountingbolts, nd hen he plate.

Pulley ock bolt

1.Hold he oullev osswith he SST.
2. Using he SST, oosenhe pulleyock bolt.
3. Removehe pulley ockboltand pulley.

B-13
 

ON-VEHICLEIAINTENANCE
Tlming belt
i. lnstiiltneouttevoct bolland urn hecrankshaftthepin
on the oullev oss aces
Caution
. Donot turn the crankshaftw hile removing he pul'
ley lock bolt.

2. Removehe imingbelt.
Note
. Ma* the liming belt rotallon lor proper leinslal-
latlon.

lnsoeclion
Refb.ringo pageB 69, nspecthe ollowing arts:
1.Timing elt
2. Timing elt engoner nd spnng
3. Timing eltpulley
PEELIN6
4. Camshaft LrlleY

lnslallationnole
Tensioner, ensionersP.ing
1. nstallhe ensionernd he ensioner pring
2. Temoorarilvecllrehe ensioner ith he spring ullyex-
tenoeo.

Timinq belt
1.Verii lhal he rming ellp ulleymarks alQned ith he im-
Ing marK.

B-14
 

ON.VEHICLEMAINTENANCE
2. Installhe imingbeltso that here s no loosenesst the
tension ide.
Caution
. Do not tum the crankahaft ounterqlockwbe.

3. Installhe pulleybossand pulley ockbolt.

4. Turn he crankshaftwo urns lockwise,nd ace he pin
on the pulley ossuPright.
5. Verifyhat hecamshaft ulleymarks realigned ith he
cylinder eadcovermarks.
lf notaligned,emovehe iming eltandrepeatrom en'
sionernstallation.

6. Loosenhe ensionero ckbolt o apply ensiono he im-

ing belt.
Caution
. Be sure not to apply ensionother han hat of the
ienslonerspring.
7.Tightenhe ensionero okbolt.
Tighlening orque:
19-25 N.m 1.9-2,6 m-kg, 14-19 ft-lb)
8.Turn he crankshaft turnsclockwise nd verify hat he
marks re correctly ligned.
9. Checkthetimingeltd eflectiony applying oderateree
sure 98 N, l0 kg, 22 b) midway etweenhecrankshaft
pulley nd he camshaft ulley.
9aN
(10 kg, 22 lb) ll the imingbeltdellections notcorrect,emporarilye
cure ensionero ckboltsothesprings ullyextendednd
repeat teps -8 aboveor replacehe ensionerpring.
Deflection:
11.0-13.0mm 0.43-0.st In)at 98 N (10kg, 22 lb)
10.Removetheulleyockboft ndpulley oss singheSST.
Pulley ock bolt
lnstallhecrankshaftulleyand ightenhe pulleyockboll
using he SST.
Tightening orque:
157-167 N.m 16-17 m-kg,116-123 t-lb)

B-15
 

ON.VEHICLEMAINTENANCE
Plate
1. nstallhe plate.
Tlghtening orque:
iz-tz Nrn (1.25-1.7s m-kE,109-152 in'lb)

2. Litt he engine nd nstallhe enginemountNo3.

Tiohtenino
ss-r orque:
li H.. (g.s-t1.9 m-kg,8.2-10.3 n-lb)

@
3. lnstallhe stabilizer.
Tiohteninq orque:
!l-sz itm (5.s-5.9 m-ks, 4.7-5.9 innb)

StepsAfter Installation
1. Lower he vehicle.
2. Connecthe negative attery able.
3. Start he engine nd checkas follows:
. lgnitioniming Refero pageB-8.)

B-16
 

ON-VEHICLE AINTENANCE
CYLINDER EADGASKET
Replacement
Caulion
. Position he hose clamp n the orlginal ocationon the hose,and squeeze he clamp ighlly
with largepliers o ensure a good fit.
1.Disconnecthe negative attery able.
2. Drain he englne oolantntoa container.
3. Removen the ordershown n the igure, eferringo RemovalN ote.
4. Installn the reverse rderof removal,eferringo InstallationNole.

(30-110orl(gi 3r-95 h.tb)

firs-11o cn-&, 6s-95 in.lb)

FEPLACE

r9-2s11.e-2.6,4-r9)

1.Air cleaner ssembly 10.T iming ell

2. Acceleratorable RemovalI nsta||ation.................. ageB 12
Installationo te........-..... page B-20
........... 11.Front xhaust ipe
3. Throttle able 12. ntakemaniiold tay
4. Hoses 13.Cylinder eadcover
Flemoval Installationo te.--......
page B-18 14.Cylinder eadbolt
5. Harnesses R e m o v a lo t e . . . . . . . . . . . . . . . . . . .a. .g. e . . . .1. .9.
Flemoval lnstallationote.........page B-19 lnstallationo te.......................... ageB 20
6.Waierbypass ipenutsand bolts 15.Cylinderead
7.Alternatorrivebelt Disassembly .............................. ageB-40
8. Water umppulley 1 n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g.e. . .-.4. .8. . . . .
9. Timing eltcover,u pper A s s e m b 1 y . . . . . . . . . . . . . . . . . . . . .a. .g. e . . .-. 7
. .2. . . . .
16.Cylinder eadgasket

B-17
 

ON.VEHICLEMAINTENANCE
Removal Installationngte
Hoses
Disconnecthe hoses hown n the igure.

'1.Brake acuumhose 3. Vacuum ose solenoidalve)

2. Fuelhose 4. Heater ose

B-18
 

ON-VEHICLE AINTENANCE
Hatnesses
Disconnecthe harness onnectors hown n the igure.

01EOBr162
Cylinderhead bolt
1 Loosenhecylinder eadbol{s n woor hree tepsn he
order hownn the igure.
2. Removehe cylinder eadbolts.

B-19
 

ON-VEHICLE AINTENANCE
lnstallationnote
Cvlinderheadbolt
1. Applyclean ngine il o the bolt aces
2. Installhe cylinder eadbolts.
3. Tightenhecylinder eadbolts n woor hree teps n he
ordershown n the igure.
Tiohtenlnq oroue:
-N.n
is-gr 1z.z-a.l m-rg, s6-60 ft-lb)

Acceleralorcable
1. nstallhe acceleratorable.
2. Check he acceleratora bledeflectior
lf the deflections not correct, djustby turningnut @.
Delleciion:1-3mm (0,04-0'12 in)

Stepsalter installation
1.Fill he radiatorw ith he specified mount nd typeof engine oolant Refero SectionE.)
2. Conneclhe negative attery able.
3. Start he engine nd checkas tollows:
(1) Engine il and engine oolanteakage
(2) lgnitioniming, dlespeed Refero pageB-8.)
(3) Operationf emission ontrol ystem
4. Recheckhe engine oolantevel.

B-20
 

ON.VEHICLEMAINTENANCE
FRONTOIL SEAL
Replacement
1. Disconnecthe negalive ahery able.
2. Removen the ordershown n the iglre, retefiingo RemovalN ole.
3. nstalln the reverse rderof removal.eferrinoo lnstallationNole.

I ../

  ---'r@\!
(a l-.i 43)
€., $ aieurce

-na
Io

1.Timingbelt 3. Oil seal

pageB-12
Removal Inslallation.................. RemovalNote...........-...-..............
2. Timing belt pulley lnstallation
o te.......... ageB-22
...............
page B-22
lnstallationote..........................

Removaln ote
Oil seal
1.Cut he oil seal ip witha razor nife.
2. Removeheoilsealwilh screwdriverr otecled ilha rag.

B-21
 

ON.VEHICLE AINTENANCE
lnslallationnote
Oil seal
'1.Applya smallamountf clean ngine iltothe ap l a new
oil seal.
2. Push he oil sealslightlyn by hand.
Cautlon
. The oilseal must be tapPed n until it is flush with
the edge ot the oil PumPbody'
3. Tap heoilsealin venly itha suitableipeanda hammer'
Oil seal outer dlametet:50.5mm 1.98 n)

Timing belt pulley

1. nstallhe imingbeltpulley.
2. nstallthe ulleyWoodruffeywith he apered idetoward
the oil pumpbody.

ALIGNKEY GFIOOVE

B-22
 

ON.VEHICLE,|AINTENANCE
REAFOIL SEAL
Beplacement
1.Disconnecth e negative attery able.
2. Removen the ordershown n the igure, eferringo RemovalN ote.
3. Installn the reverse rderot removal,eferringo lnstallationNote.

@E

gs
; a\&h

ffi
1.Transaxl . FlywheelM TX)
MTX R e m o v a lo t e . . . . . . . . . . . . . . . . . . . . - - . . e. .l.o. .w. . . .
. .c. .t .i .o.n. . . . . . . . . l n s t a l l a t i oont e . . . . . . . . . . . . . . . . . a
S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . . . . .e . .g. .e. . .- .2. 4
ATX 4. Driveplare ATX)
S e r v i c e . . . . . . . . . ... .......- . . . . . . . . . . .e. .c. t. .i o n Removal ote............................ ageB-24
2.Clutch over, lutchdisc(MTX) Installation o te...-...................... ageB 25
S e r v i c e . - . . . . . . - . - . . - . . . . . . . . - . . . - - . . . . . . . . . . . -. O . Si lescetai ol n H
Removal ote............. ............... ageB-24
Installation o te......-................... ageB 24
Removaln ote
Flywheel MTx)
Caution
. Add approx13mm 0,51 n)ol spacers @) o space
the SST away rom the cylinderblock, (MTX)
1. Hold he lywheel ith he SST.
2. Removehe lywheel olts.
3. Removehe lywheel.

B-23
 

ON.VEHICLEMAINTENANCE
Diive plate (ATX)
1. Hold he driveplatewith he SST.
2. Removehe driveplate ockbolts.
3. Removehe backing late, riveplate, nd adapter

Oil seal
'1.Cut he oil seal ip witha razor nife
2. Removehe oilsealwitha screwdtiver rotectedwitha rag.

OIL SEAL LI P

lnstallationnote
Oll aeal
1.Applya smallamountf clean ngine iltothe ipota new
1h}'. oil seal-
2. Push he oil sealslightlyn by hand
Caution

ffi'rl
) . The oil seal must be tapped n until it is llush wllh

w
the edEeof the rear qover.
3. Tap heoilsealin venly ithasuitableipeand hammer.
Oil seal oute, dlameter:100mm 3'94 n)
Flvwheel MTxl
@ 1 Femoveihe;ahnt tom he lwheelbohholesn hecrank-
H shattand rom he lywheel olts.

EM Caution
. ll all the previous ealant annotbe removed rom
a bolt, replace he bolt'
. Do not apPlysealant t a new bolt is used.

2. Set he flywheel nto he crankshaft.

3. Applysealanto the lywheel oltsand nstallhem.
Caulion
. Addaporox13mm 0.51 n) ot space6 (O) to space
the SSi away rom the cylinderblock. (MTX)
4. Hold he lvwheel nh he SST
5. Trohtenhe bohs n twoor hreesteps n heordershown
inlhe igure.

ge-lOg= orquei
Tiohteninq
1.lm g.g-ro.s m-kg,7l-76 filb)
B-24
 

ON.VEHICLEMAINTENANCE
Drive plate (ATX)
1. Removehesealantr om he driveplateboltholes n the
crankshaftnd rom he driveplatebolts.
Caulion
. It all the prevlous ealantcannotbe removed rom
a bolt, replace he bolt.
. Do not apply newsealant f a new bolt is used.

2. Installheadapier, riveplate, ndbacking late nto he

crankshatt.
3. Applysealanto the driveplateboltsand nstallhem.
4. Hold he driveplatewith he SST.

@s
5. Tightenhe bohs n lvoor three teps n he order hown
in the igure.
Tightenlng orque:
96-103 Nm (9.8-10.5 m-kg,71-76 ftlb)

StepsAfter lnstallation
1.Connecthe negative attery able.
2. Start he engine nd perform ngine djustmeniss necessary.
osuoBx 72

B-25
 

REMOVAL
REMOVAL
PROCEDURE
1 Disconnecth e negative attery able
2. Dran the enorne oolanl nd transaxle il
3 Removen lie ordetshown n he trgure efernngo RemovalN ote

Slep t

1.Air cleaner ssembly 9. Radiaior racket

2. Battery lamp 10.Radiatornd coolingan assembly
3. Battery 11.Drive elt
4. Battery arrier 12.P/Soil pumpand bracket if equipped)
5. Acceleratorable ..... ageB-27
Removal ote.....................
6. Badiator ose 13.AJC ompressorif equipped)
7. Oilcoolerhose ATX) Rernovalote.......... . .. .. pa1eB-27
8. Coolinganconnector

B-26
 

REMOVAL
Removaln ote
P/S oil pump (il equlpped)
Cautlon
. Do not damage he hoaes,
i-
1.Removehe P/Soil pumpwith he hoses tillconnected-
2. Positjonhe pumpaway rom heengine ndaifix t withwire.
A
01E08X.062
A,/Ccompressor (it equippeo
Caution
. Do noi damage he hoaes,

1. RemovetheJC ompressorith hehoses lillconnected.

2. Positionhecompressorway rom heengine nd aflix t
withwrre.

Steo 2
Disconnecthe harness onnectorshownn the ioure.

B,-27
 

REMOVAL
Steo3
Disionnecthe hoses hown n the igure

1-Brake acuumhose 3. Vacuum ose solenoidalve)

2. Fuelhose 4. Heater ose
R e m o v a lo t e . . . . . . . . . . . . - . . . . . . . . . . . .e. .l o
. .w
........
Removaln ote
Fuel hose
Wamlng
. Keep sparks and open flame away rom the tuel
area,
Cautlon
. Cover he hosewlth a rag because uel will spray
oul when disconnectlng.
. Plug he disconnected oses o avoid uel leakage.

.,**d Disconnecthe uelhoses.

B-24
 

REMOVAL
Step 4

GASKET,

1.Speedometera ble 7. Lowerarm

2.Shift ontrol od (MTX) R e m o v a lo t e . . . . . . . . . . . .............. a
. ge -29
3. Extensionar (MTX) 8. Driveshatt
4. Shitt ontrol able ATX) Removal ote....-............... ......... ageB-30
5. Frontexhaust ipe L Enginemountm ember
6. Clutch able Fiemovalo te............................. ageB-30
Removaln ote
Lowet arm
1. Removehe bolts nd nutsat he eftand ight ower rm
ball oints.

B-29
 

REMOVAL
2. Pull he owerarm downwardo separatehem rom he
knuckles.
Caution
. Do not damage he ball-iointdusl boots.

Driveehafi
r om he ransaxley pryingwitha
Separatehe driveshafts
bar nserled etween shafta nd he case.
he

Caution
. Do not damage he oil sgal.

Enoinemount member
1. Suspendheenoinewrtha chainblock
2. Removehe No.1and No.2enginemountn uts.
3. Removethenginemountm ember olts nd nutsand he
enginemountm ember.
Caution
. Be caretul so that the engine doesnot fall when
removlng he member'
ro, J"o,^. ]F "o 1"n,",
MOUMI MOUNT

B-30
 

REUOVAL B
Step 5

01EOBX070
1.No.3 nginemount 2. Engjne nd ransaxlessembiy
Removalote......................................
elow
Removaln ote
Engineand transaxleassembly
Caution
. Donot damage nycomponenlsn the enginecom-
partment,

Lift he engine nd ransaxlessembiy ut as a unrt.

B-31
 

REMOVAL
Step 6
Sep'arateh e engine nd kansaxlen the ordershown n the igure'
MTX

ATX

1.Starter nd bracket 5. Torque onverter nd driveplatenuts ATX)

2. Throttle able ATX) 6.Transaxlenstallatianolts
3.No.'1 nginemount 7.Transaxlessy.
4. Integratedtitf ner

B-32
 

ENGINESTAND iIOUNTING B
ENGINE TANDMOUNTING
PFEPAFATION
ssT

49 0107 6804 4 9L 0 l 0 1 A 0

Enginestand Hanger et ,
engine

491010 01 49 101010 2

engrne engrne
491010 A0) 49LO101Ao)

4 9 L 0 t 0 10 3 49 1010104

Hooks
(Padol
lOl
=l l[$" g engine
49 1010 1AO) 49 Lolo 1A0)

491010 05 49 1010 m

Bolts Bolls
(Part ol iParroJ engrne
491010 1A0) 49 L0t0 1A0)

B-33
 

ENGINE TANDMOUNTING
PROCEDURE
Step I
Removen the older shown n ne gure

GASKET. EPLACE

C.V'G
\\,
6* n \Jl
a o

,'-g-\
SKET,R EPLACE

a)5
oi,tuo, @
REPLACE

1.Exhaustmanifoldnsulator 4. uC compressorracket nd dler

2. Exhaustmanifold 5.Water nletPiPe
3. Water ypass ipe 6- Exhaust iPe racket

l-
Siep 2
L-..: 1-

-) ao- -oj -o) Caution

. When nsralling he SST (enginehanger)'usethe
u l
Frl
1ll1
holesshown n lhe ligure.

fi ltr Fr

B-34
 

ENGINESTANDMOUNTING
ji,--\ 1 lnstallheSST arms) o theholes s shownn he igure,
 
\\J,
,.=r
ie l-'
ui and ooselyighten he SST (bolts).

2. AssembleheSST (bottsand plale) n he specilied o-

sition.
- F
O
AO I

3. Assemblehe SST (nuls, hooks, and bolts)

4. Installhe SST o the respectiverms.

Note
. Adiust the SST Oolts) so that lea€ han 20mm 0.79
in) ol thread is exposed.
. Make he SsT (plateand arms)parallelby adiust-
Ing the SST (bolts and nuis).
5. TightenheSST (boltsand nuts) o atfixhe SST irmly.

20mm 0.79

6. Mount he engine n the SST(englnestand).

B-35
 

DISASSEit!BLY

DISASSEMBLY
PREPARATION
ssT

49 E301 60 49 E30106 1

Brake, ing gear Body

(Partof
49 E301 60 )

49 E30106 2 49 06361008
instalationf
Collar
iller
49 E301060)

49 BO12042 49 BO12012
Body
spring itler
49 80120A2)

49 8 0 1 20 13 4 98 0 1 2 1 4
insiallalion ol
(Partol
49 BO12OA2) 49 8012oA2)

4 9 S1201 70 4 9 D 0 1 l 0 01
Support lock

49 H0110018 49 DO11 03
inslallationt

49 8t 34 045

Pistonpin guide

1 Codeall dentical arts suchas piston, iston lngs connectrng, ods'and valve prings) o that hey
can be rernslalledn fie cylinderromwhich tley were emoveo lr'
z. Cf"un n" plrts witha steim cleaner'B lowotf any remaining aterwithcompressed
Note
. 6-uring disassemoly f any partor system,be sure o sludy ts order of assembly'A lso' note
any delormation,wear, or damage. $coBr4o
B-36
 

DISASSEMBLY
AUXILIARY ARTS
'1.Drainheengine il.
2. Disassemble
n the ordershown n the ioure.

o o

o z, \

6P
@
g l
N,)

'1.Alternatorrivebelt 7. No.3enginemountbracket
2. Alternator 8. Oil pressurewitch
3. Intakemanifold tay L Engine anger
4. ntakemanifold ssembly '10.Oildipstick
5. ntakemanifold asket 1.Spark lug
6. Distributornd highlensionead 12.Oil ilter

B-37
 

DISASSEMBLY
TIMINGBELT
n the ordersnownin the igure, eferringo Disassembly ote
Disassemble

1.Water umP UlleY 7. Timing eltcover,u pper

2. Crankshait ulley olt 8. Timing eltcover' ower
Plate  
9.Timino elt
pase -99
4. Crankshaft ulley
oirZ.!"totv ote . .
5. Pulleyock bolt
r n J p " i t i o n . - . . . . . . .. .. .. .. .. . . . p a g e B - 5
. page g-47 1o.Tensioner, ensionerpring
-' -inipeition.................
Dlsassemblyote ...... .. .. .. pageB-59
6. Pulley oss

B-38
 

DISASSEMBLY
Disassembly ole
Pulley ock boll
Caution
. Add approx 3mm (0,51 n) ot spacers @) o space
lhe SSTaway rom the cylinderblock. (MTX)
1. Hold heflywheelI VTX) r driveplaie ATX) lth heSST.
2. tlemove he pulley ockbolt.

Timing belt
1.Turn he crankshaltnd allgn he marks.

- p\o'9ecrto 2. Mark he imingbelt otationor proper einsialiation.

- ' g r
-\;-,/\.t
\\-zz
W:
Caution
. Never orcetully wist the timing belt. Do not lurn

== "G it insideout or bend t.

. Be carelul not to allow oil or greaseon the belt,

W*ff.,f

B-39
 

DISASSEMBLY
CYLINDER EAD
n the ordershown n the igure, eferrinqo DisassemblyN oie.
Disassemble

@\

1. Cylinder eadcoverand gasket 13 Cylinder ead

'lnspection pageB-48
2.Thermostalo verano gasKel 'l4 Cylinder eadgasket ."
3. Thermostal
4.Thermosensor l5 Valve eeper
Disassemblyote pageB-41
5. Rocker rm and shattassembly
Disassembly ote... . . .- . . pageB-41 16 Valve pring eat' pper
6. Rocker lT Valve Prrng
Inspdction " ' pageB-52
7. Rocker rm spring ower
8. Rocker hafi lS Valve pringseat'
9. Camshaft ulleY 19
- Valve
" pageB-49
Disassemblyote .... .. . . .. .. pugeg-11 .. lnspeclion
Inspeclion......... pageB-59 20 valve eal .
Disassemblyote paqeB 41
10.Thrust late and damage
'11.Camshatt Inspectorweal
inspection......... page
- B-52 21 Valve,g-urde
Inspection " " " pageB-49
12.Cylinder eadbolts " pageB 50
Disassemblyo te .. ... ... page
- B-41 Replacement
22.Oil seal

B-40
 

DISASSEMBLY
Dlsassembly ote
Rocker arm and rocker shaft assembly
1.Removehe rocker rmandrocker haftassembly.
2. Code llrocker rmsandsprings othatthey anbe rein"
stalledn hesame lacesromwhichheywere emoved.

Camshafip ulley
1. Hold he camshaft singa suitable renchon the casl
hexaoon.
2. Remdvehe camshaft ulleybolt.
3. Removehe camshaft ullev.

Cyllnderhead bolts
1.Loosenhecylinder eadbolts n woorthree leps n he
ordershown n he igure.
2. Removehe cylinder eadbolts.

Valve keeper
1. Set heSSTagainstheupper alve pring eat sshown
in the igure.
2. Flemovehe valve eepers.

Valveseal
Removehe valve ealwith he SST

B-41
 

DISASSEMBLY

SJ'"'"'""'nn'oo'"'"".'0''*ot"
.tn",f,
3*:*1T"11?f"-"[TI"tff

, FEPLACE

E Hr."*".

1.Water
  ''i"rv]""..
PumP 7. Oil pan
" " " section diassemblyNote . .... .. .. . pageB-43
2.  Timrngbelt Pulley lnspector damage
insie"tion.......... PageB-59 8. Oilslrainer
3 Clutch over,c lutch disc (MTX) 9. Mainbearing upport late M6sl')
dte... . . ... . .. pageB-44
. .n. . . . . . . . . Disassem6ly
S e r v i c e . . . . . _ . . . . . . . . . . . . . . . . . . . .e. .c. .t .i o or damage
4 Flvwheel MTX) Inspect
'Disassembly paqeB-43 10.Oil
  - pump
Note. . ..
Inspeclor wearand damage i e r v i i e . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e. c. .t.i.o. n
....
plate and adapter ATX) 1 1. Front oil seal
5 Backi;gpbte.dnve
Disaisbmblyote........ . . . pageB-43 bisassemblyote ...... ... ... pageB-44
6. End Plate 12.Rear over
13.Rearoil seal
Disassembly o te ..... .. .... pageB-44

B-42
 

DISASSEMBLY
DbaaaemblyNote
Flywheel
Cautlon
. Add approx 3mm (0.51 n) ot spacets (@) lo space
the SSTaway rom lhe cylinderblock. (MTX)
1. Hold he lywheel ith he SST.
2. Loosenheclutch overboltsn two or hreesteps n the
ordershownn the igure.
3. Removehe clutch ove..
4. Removehe lywheel olts.
5. Bemovehe lywheel.
6. Removehe SST.

Backingplate,drive plate, and adapter ATX)

'1.Hold he driveplatewith he SST.
2. Removehedriveplatebotts.
3. Removehe backing late, riveplate, nd adapter.
4. Removehe SST.

Oll pan
'1.Removehe oil pan mounting olts.
2. nsena screwdriverr a suitableoolbetweenhe VIBSP
and oil pan,and Pry hemapart.
Caution
. Do not insert the prying ool between he MBSPand
cylinderblock.
. Do not damageor sc6tch the contactsurfaces.

B-43
 

DISASSEMBLY
ain beadngsupport plate (MBSP)
'1.Removehe MBSPmounting olts rom hemainbearing
cao.
2. Inden screwdriverr a suitableool betweenheMBSP
and cylinder lock,a nd pry hemapart.
Cautlon
. Do not damage or scratch the contact surlaceg
when removlngold sealant.

Front oll seal

Removeheoilsealw itha screwdriverrotected itha rag.
PFOTECT HEPUMP

Rsar oil seal

FOTECT HEEEAACOVEFI Removehe oilsealw itha screwdriverrotected itha rag.

B-44
 

DISASSEMBLY
CYLINDEF LOCKONTERNAL AFTSI
n rheordershown n the igure, efefiingo Disassembly ote.
D,sassemble

tr/:r
v

ry

1. Connectingod cap 6. Piston

Disassemblyo te...................... age8-46 Inspection..................-................ ageB-56
2. Connectingod 7. [/ain bearing ap
Disassemblyo te.......-............. age8-46 Disassembly ote ..................... ageB-47
Inspection....-.......-...................... ageB-57 8. Crankshaft
3.Connecting o dbearing Disassembly o te.......-.............. ageB-47
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. .e. . -. .5.8. . . . . I n s p e c t i o n . . . . . . . . . . . . . - . . . . . . a- .g. .e. . -. .5. 8. . - . .
4. Pislon ing 9. Mainbearing
Disassemblyo te ..................... ageB-46 Inspection......................-....-....... ageB-58
Inspection......................-............ age8-56 10.Thrust earing
5. Piston in 11.Oil ilteroint
Disassemblyo te ..................... age8-46 12.Cylinderlock
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. .e. . -. 5
. .7. . . . . I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. g. .e. . .-.5. .4. . . .

B-45
 

DISASSEI'BLY
DisassemblyNote
Connecting od caP
d-torJie.dving tne'connectingod caps'measurehecon-
ieciino roo sid6clearance Relero pageB 66 )

Connectlnq od
1.Beforee;ovrngneconnecingods'm easureheconnect
Refero pageB-57 )
ino roooil clea'rance-

r om he crankpinournals'
2. Removehe Plastigage
Caulion
l-do-not ""rar"tt ttt" clankshaft ournalor the cylin-
der wall.
- Use hehandle t a hammero removehepl$onandcon-
3.
i*tlng t; uo".uly throughhe opof hecylinder lock

Pision ring
Caution
. oJ not apptyexcessiveension,which maycause
the rings to anapoul.
Removehe piston ingswitha piston ingexpandercom-
merciallvvailable)

Plston oin
Caution
. Ma* lhe connecting od direction ol proPer eas-
sembly.
'1.Before isassembling hepiston ndconnectingod'check
the oscillationo rque s shown.
iiin"luioe Lno aoe"notdropby itsownweight, eplace
the piston r the Piston in

B-46
 

DISASSEMBLY
2. AssembleheSST as shown.

3. \rountthe iston ndconnectingod n heSSTasshown.

4- Press ut he pistonPin.
While emovinohe oiston in,check he pressuref iI is
lower han4905N (500 kg, 1100 b)' replacehe piston
pin or connectrngod.

@TEE

ltlaln bearingcap
1 Beloreem6vingheman beanngaps measurehecrank-
shaftend play. Retero page8-65 )

2. Loosenhe mainbearing ap bolts n two or three teps

in the ordershownn the igure.
3. Removehe mainbearing aps

Crankshaft
Before emovinohe crankshaft, easurehe mainbearing
oil clearances.Refero pageB-74.)

B-47
 

INSPECTION REPAIR

INSPECTION REPAIR
PREPARATION
ssr
49 BO12 05

gulde 83 )

grease' arbonmoistureestdue' nd
1.Clean ll parts, eing ure o remove ll gasketragments,irt,oil'
olher oreignmaterlals
Z. nsoection"anO e pairsmustbe pertormedn he orderspecified'

Caution suchas the cy'-

fuiJt a"t"s" rne oints orlrlction surtacesol alumlnum lloycomponents
Inder head or pistons). orEoBx.oe

CYLINDER EAD
i. lnspecthecyhnderead ordamage,racks, nd eakage
ot walerand oll.Replacehe cylinder ead f necessary
Z. ,reaiuielni cvtinaer eaddistortionn the sixdirections
shown n the igure.
Distortion:0.l5mm (0.006 n) max.
Caution
-selole
. qrinalns the cylinder head,check h€ tollow'
ing ani repair or rePlace he cylinder head as
necesaary.
Sinklngol valve seals
Damagl ot manifgldcgntacl sudace
cams6aftoil clearances nd end play

3. f thecylinder eaddislortionxceeds pecification'rind

thecvlindel eadsurface
e dace
ii tne vtinoer eao erghls notwithin pecilrcation
it.
Heiohl: 107.4-107.6mm 4,228-4'236 In)
Gri;ding: o.20mm 0.008 n) max.

B-48
 

INSPECTION REPAIR
4. l\4easureh e manifold ontact urface istortionn he six
directionshown n the igure.
oistorllon: 0.t5mm (0.006 n) max.
5. f distortionxceeds pecification,r ind he surface r re-
olace he cvlinder ead.

VALVEMECHANISM
Valveand ValveGulde
1. Inspect achvalve or he ollowing. eplace r resurlace
4.. -sreure the valve l necessary.
(1) Damaged r bentstem
(2) Roughor damagedace
fJ (3) Darnaged r unevenly ornstem ip
2. Measurehe valveheadmarginhickness 1eachvalve.
Replacehe valve f necessary.
Margin hicknesamin. mm {in)
B3
THICKNESS IN 1.1 0.043)
EX 1.2 O.O47)

3. Measurehe ength f eachvalve.

Length
B3
Standard 108.24 4.261't
IN
1077414.241
Standa.d 109.344.304)
EX
Minimum 108.844.?85)

. Measurehe stemdiameter f eachvalveal the points

Dlameter
B3
IN 5.970-5_985 0.2350-0.2356)
EX 5.965-5.980 {0.2348-0.23541

5. Measurehe nnerdiameter f eachvalveguideat he points

shown.
lnner diameter
B3
IN, EX 6.01-6.03 0.2366-02374)

6. Calculatehe valve tem o guideclearance-

Subtractheouterdiameter f he valve tem rom he n-
nerdiameter f the correspondingalveguide.

|h"::
Clearance
lN r 0.025-0.060mm(0.0010--1t.0024n)
EX: 0.030-0.065mm(0.0012-0.0026 n)
Maximum:0 .20mm 0.008 n)
eplacehe valve
7. lf the clearance xceeds p€cification,
and/or alveguide.
B-49
 

INSPECTION BEPAIR
8. Measurehe protrusion eightofeachvalveguide Replace
the valveguide l necessary.
Height mm in )

CYLINDEF HEAD

Replacement l valve guide

lll? tte strapes f the intake nd exhaust alve

nstall orrectly'
guides realitferent,

IN EX

he ombus'
B:fio9Jilh."ru" rioeromhe ide pposite
tion chamberw ith he SST

Installation
1 Fit he clip onto hevalveguide'

lH
\]H
N
ffi
combustion
-2. UsinqheSST. ap hevalve uide n rom hedimension
"n"ril"i "io" to inat he protrusionerghl
In the igure)s withrn pecilication

:a;l?h sft|kehardarter hecllPcontactshecvlin-

der head, he cliP will be damaged'

B-s0
 

INSPECTION REPAIR
ValveSeat
1. nspecthecontact urtace f eachvalve eatand valve
ollowing:
(1) Roughness
(2) Damage
2. f necessary,esurfacethealve eatwitha45" valve eat
cutterand/or esurfacehe valve ace.

3. Applya thincoatol Prussian lue o the valve ace.

4. Inspectthealve eating y pressinghevalve gainstthe
seat.
(1) li bluedoes otappear 600aroundhevalveace, e-
db place he valve.
(2) lf bluedoesnotappear 600aroundhe valve eat,
resurlacehe seat.

v..vl
\ \€=:.,

5. Measureheseatcontactw idth.
width mm (in)
B3
EATCONTACTWIDTH I N ,EX 0.8-1.4 (0.031-0.0s5)

if
6.Verifvhat hevalve eating osiiions at hecenter f he
vave Tace.
IN (1) lf heseating ositions oohigh, orrecthevalve eat

E"'il
witha 70o cutter nd a 45" cutter
(2) lf the seating ositions oo ow correcthevalve eat
witha 40' cutter nd a 45o cutter
7. Seat he valve o thevalve eatwith apping ompound.

8. Inspecthe sinking l the valve eat.

Measurehe protrudingength djmension) of he valve
stem.
DIMENSION Dimension : 41.05-41.95mm1.616-1.652n)

B-51
 

INSPECTION REPAIR
mm (n )

41.5-42 {r.634 1.654) No correctonn€€ded

Adjuslw ithwasher n sping
42.0-43.0 (1.654-1.693) seal areaof cylinderhead
[4ore hana3 0 (1.693) Beplace ylinderhead

ValveSpring
1. nspect achvalve pring or cracks nd damage
2. Measurehe ree engthand out oi squareReplacehe
valve pringf necessary.
Frge length standard...mm kg lb)/mm in)
in),M it]imum...N
B3
Slandard 40 7 (1.602)
IN
Minimum 133.2-r50( r358 1s.37.9 8-33 1!36 (1 17)
Slandard 40.70.602)
EX
L4inimum 133.2-150.i358-15.3/ .88-33 l)86 (1 14

Out-ol-square

IN 1.42 0.055)
EX 1.42 0055)

CAMSHAFT
1. Set he rontand rear ournals n V-blocks-
2. Measurehe camshaftunout Replacehe camshaftf
necessarv.

Runout:0.03mm 0'00'12n) max.

3. Inspecthe camshaftor wearand damageReplacehe

camshafiJnecessary.
4. Measurehecam obeheights t he wo points sshown
Height

#@
mm {rnl
B3
Slandard 36.527 .4380)
IN
lVlnimum 3 6 . 3 2 71 . 4 3 0 1 )
Slandard 36.333 1.4304)
[,'linrm!m 36.133i'1.422s)

B-52
 

INSPECTIONREPAIR
5. Measurethe o urnal iametersandY directionst he wo
points @ and @) shown.
Diameter
B3
N o . l& No . s 43.440*43.4601.7102-17.10)
No-2& No.4 43.425-43.4501.7096-1.7106)
No.3 43.41O 43.43511.7O9, 1.71OO)

Out of round: 0.05mm 0.002 n) max,

6. Measureheoilclearancesetweenhecamshaftndcyl
inderhead.
{1) Removell oreignmaterialndoil rom he ournalsnd
the camshaft ore.
(2) lvleasurehe camshaft orediameter.
03u081105

Diameler mm in)
B3
No.1 No.5 43.500-43.525.7r26-1.7135)
No.2,N o 3 , N o 4 43.500-43.5251.7126-1.7135)

(3) Subtracthe ournal iameterr om he borediameter.

Oil clealance

No.1 No.5 0.040 0.085 0.0016 0_0033)

No2&No4 0.050 0.100 0.0019 0.0039)
No-3 0.065-0.1 5 (0.0a25-0.0045)
0.15 0.006)

(4) li theclearance xceedshemaximum,eplacehecam-

shafto r cylinder ead

7. Measurehecamshaftndplay. f texceedshemaximum,
reolacehe hrustolateor camshaft.
End play : 0.060-0.200mm(0.0023-0.0078 n)
Maxlmumr .2mm 0.007 n)

B-53
 

INSPECTIONREPAIR
RockerArm and BockerArm Shaft
1 Checkorwearor damageo thecontact urface f herock-
er arm shattor the rocker rm-Replacef necessary
2. Checkthe ilclearanceetweenhe rocker rmandshalt
Replacef necessary.
(1) Measurehe rocker rm nnerdiameter'

Diameter
B3
G IN EX 19.000-l 9.033 0.7480-0.7493)

(2) Measurehe rocker rm shattdiameler'

Diameter
B3
l N, EX 1&959-18.980 0.7464-0.7472)

(3) Subt.acthe shaftdiameterrom he rocke'arm di'

ameler.

Oil clearance mm (in)

B3
tN, EX 0o20-o 074 00008-0.0029)
010 (0.004)

CYLINOER LOCK
1. Checkthe ylinder locklortheollowing nd epalror re-
place he cylinder lockas necessary
(1) Leakage amage
(2) Cracks.
(3) Sconng l wall
Z. Miasurehi distonionflhe opsLriace i hecvlinderlock
in the slx directionshownn figure
0.006n) max.
Distortion:0.15mm

3. lf thedistortionxceedshemaximum.epair y grinding
or replacehe cylinder iock
Height: 2l.smm 8'720 n)
Grinding:0.20mm 0'008 n) max.

B-54
 

INSPECTIONREPAIR
4. Measure he cylinderbores n X and Y directions t ihree
levels A, B, and C) in each cylinderas shown.
___n_

H
o c2 So Cylinder bore mm rnl
z/-I\"
r"-
$\1-l^
Slandard
B3
71.006-71.013 (2.7955-2.7958)
0-25 0.010) versize 7 1.256-7 . 263 2.8053,2.4056)
o \ 4o
-L__-r- 0.s0 0.020) vercize 71.506-71.513 2.81522.81 5)
0.75 (0 030) oversize 7 .756-71.7632.8250 2.8253)
1.00 (0.04)oversEe 72.046 72.01 12.8349-2.4352)

Caution
. The boring size should be basedon the sizeof an
overslzepislon and be the same or all cylinders.
(1) lf thecylinder oreexceedshemaximum,e borehe
cylindero oversize-
(2) If he differenceetweenmeasu.ementsand C ex-
ceeds the maximum aper, rebore he cylinder o
overslze.
Taper:0,01gmm0.0007n) max.
(3) lf the difierence etweenmeasurementsand Y ex'
ceeds he maximum utof-round,eborehe cy{inder
o7 so to oversrze.
71"1--\v Out-ol-round:0 .01gmm 0.0007 n) max.

Os-to

5. lftheupperpartof a cylinder alls hows neven ear,

rnove he ridgewitha ridge eamer.

ry
B-55
 

INSPECTIONREPAIR
PISTON.P ISTONRING,AND PTSTON IN
Plston
Caution
. lf the piston s reptaced,he piston ings mustalso
o - R|NG be replaced.
GnoovE
1. Inspecthe outercircumferencesf all pistonsorseizure
lo.7m n) or scoring.R eplacehe piston necessary
2. Measureihe uterdiameter piston t a righta ngle
OIAMETER
(90o) o the piston n, 16.5mm 0'650 n) below he oil
ring and oweredge.
Pistondiameter mm in )
70.961 7 0.967 2.7937 2.7939)
0.25 (0.010)ove6ze 71.21 71.217 2.AO36-2.aO2A)
0.50 0.020) versze 71.461 71.46712A134-2.8137)
0.75 0.030) versrze 7 t .711-71 .717 Q.A2$-2.A235)
] 00 (0 04)oversize 7 1 . 9 6 1 - 7 r . 9 6 72 . 8 3 3 1 . 8 3 3 3 )

3. Measurehe piston{o-cylinder
learance

Clearance: .039-0,052mm (0.0015-0.0020 n)

Maximum: .15mm 0.006 n)
4. lf theclearancexceedshe maximum,e placehe piston
or reborehe cylinderso fit oversize istons

Pision and Piston Rings

1 Iveasurehe piston ing o ring andclearanceroundhe
enlire ircumferencesrng new plslonnng.
Clearance Top and Second)
B3
0.030-0.070 0.0012-00028)
015 {0.006)

2 . lf heclearancexceedshe maximum,e placehepiston.

3 . Inspecthe piston ings or damage, bnormal ear, nd
breakage. eplacehe piston ings i necessary
4. Insert lie piston ing nto he cylinderby handand use he
Diston o oush it to the bottom of the ring travel

FING

B-56
 

INSPECTION REPAIR
5. Measureachpisloningendgapwitha eeler auge.Re-
place he piston ing f necessary.

Erd gap
Top : 0.15-0.30m m 0.006-0.012n)
Second: 0.30-0.45mm 0,011-0,017n)
Oil rail : 0.20-0.70mm (0.008-0.028 n)
Maximum: 1.omm 0.039n)

Pistonand PistonPin
1. Measure achpiston inholediametern X andY direc-
tionsat lour points.
Diameier:19.988-20.000mm 0-7869-0.7874 n)

f-6t'1
L'----\-v

2. Measure achoiston indiamelern X andY directionsi

fourpoints.
Diameter:19.974-19.980mm 0.7864-0.7866 n)
3. Caiculatehe oistonDin{eoiston learance.
Clearance: ,008-0.026mm 0.0003-0.0010 n)
eplacehe piston
4. Il theclearancexceeds pecification,
and/ofoiston in.

CONNECTINGOD
1.Measure achconnectingod bushingnnerdiameter.
Diameter:1 9.943-19.96lmm(0.7852-0.7859 n)
2. Calculatethe/earanceetweenheconnectinoodbush-
ingandpiston in.
Interterence: .013-0.037mm 0.0005-0.0015 n)

3. Measure achconnectingod or bending. epair r re

place he connectingod if necessary.

Bending.' .075mm 0.0030 n) max./somm 1.97 n)

B-57
 

INSPECTION REPAIR
CRANKSHAFT
1. Check he ournals nd pins or damage, coring, nd oil
holeclogging.
2. Set he crankshaftn V'blocks.
3. Measurehecrankshaftu nout t the centerournal.
Replacehe crankshaftf necessary.
Runout:0.04mm 0.0016 n) max'

4. Measureachournal iametern X andY directionst wo

points.

Main ournal
Diameter:4 9.938-49.956mm 1.9661-1.9668 n)
t t \ Out-of-round: .05mm 0.0020 n) max.
f----T----i
Crankpin ournal
\i_,i Diameter:3 9.940-39.956mm 1.5724-1.5731 n)
Out-ol-round: ,05mm 0,0020 n) 6ax.

5. lfthediameters ess han heminimum,rind he ournals

to matchan undersizeearing.
Undersize ea ng:
0.25mm 0.010n),0.50mm 0.020 n),
0.75mm 0.030 n)
Main ournal diameterundelsize mm (in)
Bearino ize
0.25 0.010) ndersze 49.688-49.706.9562 1.9569)
0.50 0.020) ndersze 49.438-49.456 1.9463-1.9470)
0.75 (0.030) ndelsEe 49 188-49.206 1.9365-1.9372)

Crankpin ournal diamelerundersize

0.25 {0.010)unde6ize 39.690-39.706{1.5626-1.5632)

0.5010.020)rndersize 39.440-39.4561.5528-1.5534)
0.7510.030)rndersize 39 190-39.206 1 5429-1 5435)

BEARING
MalnBeadngand ConnectingFod Bea ng
Check he mainbearings nd heconnectingod bearings
for peeling, coring, nd otherdamage.

EB E
$drE BB
B-58
 

INSPECTIONREPAIR
TIMINGBELT

sry6 Caution
. Never orcelully wist, turn insideout, or bend he
timing beh.
. Do nol allow oil or greaseon the belt,

f,*f^^y
1. Replacehe imingbelt f there s any oil or grease n it
2. Check he iming elt or damage, ear,peeling, racks,
andhardening. eplacehe imingbelt l necessary.

TENSIONER,D LER

G
Caution
. Do not clean he lensioneror idler with cleanlng
fluids. ll necessary, use a solt lag to wiPe them
clean,and avoid scratching hem.
Checkhe ensionernd dlerfor moothotation ndabnor-
mal noise.F leplacehe ensioner r idler l necessary

TENSIONER PRING
Measurehe ree ength f he ensionerpring.R eplacehe
tensionerpringf necessary.
Free ength:54.0mm 2.520 n)

PULLEY
r-'E Timing Belt Pulley,CamshaltPulley
T{7\\E
sry lilll-1LlE
Cautlon
. Do not clean he pulleys with cleaning luids' ll
necessary, se a soft rag to wipe them clean,and
avoid scralching hem.
-5*\ Inspecttheulleyeethorwear, eformation,ndother am-
rsr- ZilF\
reF.-
Vg
age.Beplacehe pulleyf necessary.

B-59
 

ASSEII/IBLY
ASSEMBLY
PREPARATION
ssT
49 D01100 1 4 9H 0 1 1 0 1 8

Support lock insiallation l

supponblock

49 D011 03 49 8134 04 4

Pistonpin quide inslalatLon

installer pislon ins

49 E301 60 49 E301 61

Brak€, ng gear Body

ean oi
49 E3o1 60 )

49 E301 62 49 AO12 Pe

enginerotation installalion
Collat
(Parl oi sping ilier
49 E301 60 )

4 9 B 0 l 20 1 2 498012 13
inslallationf inslallationf
Body
(Parloi (Part r
49 BO12 A2 ) 49 Bo12 A2)

498012 14 49 06361008

installation f installation f
lilter
49 80120A2)

4 9 S E 0 13 10
installation f
Centellng ool,

1.Cleanall partsbefore einstallation.

2. Aoplvnewengineoil to all sliding nd rotatilgparts.
3. R;phce plainbearingsf theyare peelingburned'o r otherwse amageo
4 Tidhren ll boltsand nuls1o he specifiedorques

cluton
. Do not reuse Easketsor oil seals.
B-60
 

ASSEMBLY
CYLINDER LOCK INTERNAL ARTS)
TorqueSpecifications

CYUNOEFWALLS

PAOTBUSTON
9 mm 0.75 n)

JOUFNALS

8-61
 

ASSEMBLY
ConnectingRod
1 Assemblehe SST as shown.

2. Applyengine il o the piston ln

3. Set he oiston n heSSTwith he F mark acing pward

4 Assemtjlehe oiston nd he connectingod n the dlrec'
tion romwhich heyweredisassembled
Pressure torce:
4905-14715 N (500-1s00 kg' I100-3300 lb)

ABK
INOENTIFICATION

5.Whirensertingie plston in.check he pressureorce f

it rs ess hanaoecified,e placehe piston in or thecon-
neclno oq.
6- Pressihe iston in nto hepiston ndconnectingodun-
til the SST contactshestopper olt
7. Check he oscillationorqueof the connectlngoo
(Refero Page8-46.)

Piston Ring
1. nstallhe hree-pieceil ringson he pistons
(1) Applvclean ngine irlo heotl ingspacer ndrails
i2) lnslall he oil rinO pacerw ith he endsupwaro
Note
. ihe upperand owertailsa.e he sameand maybe
lnstalied with elther lace upward.
(3) Installhe upper ailand owe' ail

8,-62
 

ASSEMBLY
2. Verifyhatboth ails reexpanded y hespacertangss
shownn hefigure ymaking ertainhe ailsturnmoothly
in bothdiections.
-,.--'-)
sEcoNo Caution
. The rings must be installed wlth the R marks
upward.
-/D . The second ing musl be nstalledwith the sclaper
face downward.

3. Apply lean ngine il o he op andsecond iston angs

4. Installheseconding o hepiston;h ennstallh e op ing.
Usea piston ingexpandercommerciallyv ailable).

O I LF I N G
SPACEF ENOS

PISTON

5. Positionhe end gapsof he ringsas shownn the igure

OIL RING

OIL FING PISTON

SECOND
RING

Oil Filter Jolnl

Installhe oil ilter ointso hat l protrudes s specified.
Prolrusion:19mm 0.75 n)

Crankshaft
1-Beiorenstallinghecrankshaft,nspecthe mainbearing
PLASTIGAGE oil clearancess ollows.
Oil clearance nspection
(1) Removell oreign aterjalndoil rom he ournalsnd
Deallngs.

Caution
. Install he gtooveduppermainbearings n the cyF
inder block.
. lnstall he thrust bearingswith the oil groove ac'
Ing the crankshaft.
B-63
 

ASSEMBLY
(2) lnstallhe uppermainbeanngs nd hrustbearings
THFUSI METAL i3t Set he crankshattn the cyl'nder lock
Caution
lio not totate rtte crankshaftw hen measuting he
oil clealances.
(4) PositionPlastigage top the journals n the axal
directton.

mainbearing
'-' Installhe owermainbeanngs nd the
(5)
nd € mark
iaos accordingo tne cap number
teps
- Tnh€n hemain earingapbolls n lvoor hre€
(6)
in'theordershown n the igure.

t'?l':!'Jt*.ii'irT-".0
m-ks,0-43 'rb)

'17)Remove
' hemain earingaps. Fdmeasurehe PlaslF
oaoeat eachpurnal t he wldest oini or hesmallest
ileirance and al lhe narrowest oint or lhe largest
clearance.
rind he
' ' lt he oil clearance xceeds pecilicalion
fgr
crankshaftnd useundersze mainbearings
(Refero PageB-58.)

Oil clearance: .018-O,O36mm0'0007--'{''0014n)

Maximum:O .lomm

2. Apply |beral mount l clean ngine il o hemainbea'

inqs,'thrusrearings nomain ournals
s. inidr thi crarkst'Jtl nd he marn ean'rg apsaccord-
ing to the capnumber nd e mark.

4. Tiohtenhe mainbearing ap boltsn two or threesteps

in the ordershownn the igure
Tiqhteninq
-Hmorque:
!r-sg 15.s-o'o m-rg, 40-43 ft'lb)

B-64
 

ASSEII'BLY
he crankshaftnd play.
5. \4easure
Endplay 0.080-0.282mm0.0031-0.0111n)
Maximum: .30mm 0.012 n)

(_. :/:\ ,.-

|Qro. oe,l rl
6. f heendplay xceedsthe aximum,rind hecrankshaft
and nstallan veasize
h rust earing r replacehecrank-
shaft nd hrustbearing.
Thrust beadngwidth
Standard:
2.500-2.550mm 0.0984-0.1004 in)
0.25mm 0.0t0 ln) overaize:
2.625-2.675mm 0.1033-0.1053in)
0.50mm 0.020 n) ove6ize:
2.750-2.800mm 0.1083-0.1102 tn)
0.75mm 0.030 n) oversize:
2.875-2.925mm 0,1132-0.1152 in)

Pision and ConneciingRod Assembly

Cautlon
. Prolect he connecting od bolts with rubbersleeves
to prevenldamage o the crankpin ournals.

t'r \'rinl|*
Connectlng Rod Cap
'1.[/easufeheconnectingod bearing ilclearancessang
thesame rocedures or hemainbearing ilclearance.
Caution
. Align he matchingmarksgn lhe cap and he con-
necting odwhen nstalling he connecting odcap.
Tighlening orque:
29-34 N.m 3.0-3.5 m-kg, 22-25 ft-lbl
MATCHINGMAFKS

Oil clearance: .028-0.068mm 0.001 -0.0027 in)

Maximum: .lomm (0.004 n)
2. ftheoilclearancexceedsthe aximum,rind hecrank-
shaft nd useundersizeearings.Refero pageB-58.)

B-65
 

ASSEMBLY
3. lvleasurehe connectingod sideclearances'

MEASURTNGOCATION
Sideclearance: .110-0.262mm(0.0043-0.0103n)
Maximum:0 .30m8 (0.012 n)
4. lf lheclearancexceedshe maximum'eplacehe con-
necting od and cap.

5. Appry liberal mount f cleanengine ilto he crankpin

iournals nd connectlngoo Deanngs
6. nstall he connectingod capswith he matchingmarks
alioned.
7.Tig-hten he connectingodcap nuts n woor hree teps
Tiohtenino orque:
is-31-Nm {ir.o-e.s m-t<g, 2-25 lr'tb)

' 'll ll I L))=r -

8-66
 

ASSEMBLY
CYLINDER LOCK EXTERNAL ARTS)
TorqueSpecilications
re-25 {1.r-2.6, 14-1r)

GAS(ET,NEW

g r l
v7h
".*$

GASKET, EW
E

7i-r! Nn (30-1r0 cm-kq,59-95 in-lb)

GASKET, EW

GASKET.
--..-t* EEi
30-1 ro cD-ks, 6s-95 inrb)
13-25 O.3-2.7, r3-20)

03uoB1.133
Fear Cover
1.Apply sma,larnount fclean ngine iltotheipofa new
o seat,
2. Push he oil sealslightlyn by hand.
Cauiion
. The oil sealmustbe pressed n until t is flush wilh
the edge ot the rear cover.
3. Presshe oll seal n evenlywitha suitabie ipe.
Oil seal outer diameter:100mm 3.94 n)

4. Applysilicone ealanto the shaded reashown n the

ngure.

8-67
 

ASSEIIIIBLY
..'i 5. lnstallhe rearcover.
! \o
\, ILL- -l- /l
Tiohleninq oroue:
?.s-t t-N.ma8o-l1Ocm'kg,69-95 in-lb)

Oll PumD
1. Applya small mounl l clean rgineorl o the ipofa new
oil seal.
2. Push he oil seals lightlyn by hand
Caution
. The oilseal musl be pressed n until t is llush with
the edge of the oil PumPbody.
3. Presshe oil seal n evenrywill' a su ablepipe
Oil seal outer diametef:44mm 1.73 n)

4. l\y'ount newgasket nd nstallhe oil pump

Tiohteninq orque:
js-zs -N.m{i.s-z.o m-tg, 14-19 tt-lb)

Caulion
. Do not sqratch he oil Pump.

5. Cutaway he portion f the gaskethatprojectsrom he

body oward he oil Panside

Oil Strainer
Mourta newgaskel nd nslall f'e oil strainer'
Tiohteninq oroue:
?.a-tt-l'lm igo-lto cm-kg, 69-95 in-lb)

B-68
 

ASSEi'BLY
Oil Pan
1. Remove ll oreignmaterialr om hecontact urfaces.
2. Applysilicone ealanto the shaded reas hown n the
figure.

3. Install ewgaskets nto he oil pumpbodyand he rear

coverwith he proiectionsn he notches s shown he
figure.

4. Applya continuouseadof silicone ealanto he oil pan

along he nside f he boltholes ndoverlaphe ends.
5. Installhe oil pan.
-/-= {. I Tightening orque:
7.8-ti N.m 80-110 cm-kg, 69-95 in-lb)

Qr)
End Plale
Installhe end plate.
Tightening orque:
7.8-ll N.m 80-ll0 sm-kg,69-95 nlb)

Flywheel MTX)
1- Removehesealantrom he lwheel boltholesn hecrank-
shaftand rom he lywheel olts.
@
Cautlon
. lf all the previous ealant annotbe removed rom

BM a bolt, replace he bolt,

. Do not apply sealant f a new bolt is used.

2. Set he lywheel nlo he crankshaft.

3. Applysealanto the lywheel oltsand nstallhem.

B-69
 

ASSEMBLY
4. Hold the flywheelw ith he SST

Caution
. Addapprox 3mm0.51n)ol spacersO) to space
the S5i away rom he cylinder lock' MTX)
5. Trghtenhe oolls nn/vo r h'ee steps n neoldershow4

go-roJ orque:
Tiohtenino
H.ms.s-r0.s m-ks, 1-76 tt'lb)

Clutch Disc and ClutchCover MTX)

Caution
. Add aporox13mm 0.51 n) of spacers @) o space
the SSi ayyayrom the cyllnder block. (MTX)
lnstallheclutchdiscandclutch overusing he SST.
(Refero Section .)

-t'torque:
Tiohtenino
i a-zo m ti.e-z.t m-xl,13-20 ft'lb)

Drive Plate (ATX)

1.Removeh-e ealantrom he oriveplateboll holes n he
crankshaftnd rom he driveplatebolts.
Caution
. ll all the previous ealant annotbe removed rom
a bolt. replace he bolt'
. Do nor aiply sealant t a new bolt is used,

2. Insrallheaoapter. 've plale, ndback|.gplate nto he

crankshaft.
3 Aoolvsealanto lhe driveplalebolrcand nstallhem
+. ttbio tne driveplatewith heSST.

i@el
5-Tiohtenhe bo{s n wo or hreesteps n heorder hown
Tlohtenlnq olque:
!s-rod tt.m g.s-t0.5 m-ks,7l-76 ft-lb)

B-70
 

ASSEMBLY
Timlng Belt Pulley
1. Installhe imingbeltpulley.
2. InstalltheulleyWoodrutfeywith he apered ide oward
the oil pumpbody.

WaterPump
1. Remove ll oreignmaterialr om hewaterpumpmount-
ino surface.
2. PEcea new water umpgasket n position.
3. Installhe watefpumo.
Tightenlng olque:
19-25 Nm (1.9-2.6 m-kg, 14-19 ft-lb)

B-71
 

ASSEMBLY
CYLINDEB EAD
TorqueSpecitlcalions

{50-90 cn-kg, 43-73 In'lb}

12,2-2.9, 16-211

Pe
e-__u

(65-e5 cd-&, 56-t2 rFlb)

valve Seal
1. nstallhe newvalvesealo nto he valveguideby hand
@ to specitication
2. After nstallation,d justhe protrusion
Proltusion: 8.1-18.7mm 0.713-0.736n)

93GOBr S0
B-72
 

ASSEMBLY
Valveand ValveSpring
1 Installhe ower pring eat.
2. nstallhevalve.
Caution
. Install he springwlth lhe closerpitch toward he
@GBEATEFTHAN@
cylinderhead.
3. ,nslallhe valve pnngand the upoerspring eat.
H E A OS I D E

4. Compressne valve pringw[h the SST.and nslallhe

varveKeepers_
5. Removehe SST.
6.Tapthe ndof hevalve ternightlylwo r hreeimeswith
a plastic ammertoerifythalthe eepersre ully eated.

CylinderHeadGasket
1.Remove ll oreignmaterialr om the op of the cylinder
block.
2. Place he newcylinder eadgasketn position.
CylinderHead
1. nstallh ecylinderead.
2. Apply lean nglne il o the bolt hreads nd seat aces.
3. Tightenhecylinder eadbolts n woor hree tepsn he
oroer nown.
Tighteninq orque:
76-81 N.m 7.7-8.3 m-kg, 56-60 tt-lb)

CamshattO il Seal
1.Applya thincoatof engine il o hecamshaftilsealand
cylinder ead.
2. Tapthe amshaftilsealintotheylinder eadwith suita-
ble pjpe.
Cautlon
. The oil seal must be tapped n unlil it is llush with
the cylinderhead,
Oil seal outer diameter:40mm (1.57 n)

Camshall
1.Apply ngine ,l o heJournalsndbearing
2. Insen ndmounthecamshaltntoposition ith he hrust
plate.

B-73
 

ASSEUBLY
CamshaftP ulley
OOWEL PIN ANO PIN GFOOVE
Note
. Becertain hat the dowel pin ot the camshaftalso
laces straighl upward.

.t'i 1. nsiallhecamshaft ulley nto he dowelp inwith hepin

groove acingstraight pward

2. Trohlenhecamshattulley olt Hold hecamshaflsing

a ;uitablewrench n Ihe casthexagon s showr.

ls-ot'itm oroue:
Tiohteninq
(6.0-o.z m-tg, 36-45 ft'lb)

RockerArm and RockerShalt Assembly

Cautlon
. Face he rockershalt ldentilicationmark upward'
. The nstallationbolt holes are dlfterent or the ex-
hausi and intakesides.
ldentilication mark
lN ........,.,.... ellow reen
E X . . . . . . . . . . . . . .i n
. k
'1. Assemblehe rocker rm and rocker haftassembly s
shownn the igure-

2. nstallhe rockerarmand rocker haftassembly-

Caution
. Theboltsmusl be ightened radually nd n he or'
der shown.
Tidhteninq
zz-za orque:
il.m (tz.z-z.sm-xg, 6-21 tlb)
ValveClearanceAdiustment
Refer o pageB-7.

B-74
 

ASSEMBLY
Temperature augeunit

;nY\v Installtheemperatureaugeunit nto hecylinder eadwith

seal ape on the hreads.

w"ffi Tlghtenlng olque:

6.4-9.3 Nm (65-95 cm-kg,56-82 in-lb)

Thermostat and Thermostal Cover

1. Remove ll foreignmaterialr om the thermostatover
mounting urface.
2. Installhe hermostatith he igglepin acingupward.
3. Install newgasket nd he hermostatover.
Tighlening orque:
l9-25 N{n (1.9-2.6 m-kg,14-19 ft-lb)

Caution
. Thg pdnted side ol the gasketmust ace he thermg-
stat.

PBINT€OSIOE
a _-/-$ 1
?\+
C:lrlinderHead Cover
lnstallhe cylinder eadcover.
Tightenlng orque:
4.9-8.8 N.m 50-90 cm-kg,43-78 in-lb)
Caution
. lf the headcovergasket s reused,a pplysealant n
the grooveas shown.

OlEOBXJS3

B-75
 

ASSEIIBLY
TIIIIINGBELT
Torque Specificallons

t9-25 O.9-2.5, r/Frg)

7.t-ll r*o (30-110 cr*1, 6!l-95 i.'lb)

12-17 fl .25-r.75, r09-r52)

r!i6-106 {16-17, 1r5-122)

Timing Belt Tensionel

1.lnstellhe ensionernd he ensionerpring
2. Temporarilyecurehe ensioner ith hespring ullyex-
tended.

Timino Belt
1. Verii that hetmingbelt ulleymark saligned ilh he im-
Ing marK.

o3uoB11s4
B-76
 

ASSEMBLY
2. Verifyhat hecamshaftulleymarks realignedwith he
cylinder eadcovermarks.

3- nstallhe iming elt o hal here s no oosenesst he

lensionide.
caution '/-\
. Do not turn he crankshaft ounierclockwiscd

4. Turn hecrankshaft wo urns lockwise,ndalign he im-

ing belt pulley
markwith he imingmark.
5. Verify hat hecamshaft ulleymarks realignedwith he
cylinder eadcovermark.
lf notaligned,emovehe iming €liand epeatrom en-
sioner nstallation.

6. Loosenhetensionero lt oapplytension
o hetiming elt.
Caulion
. Be sure not o apply ensionother han thal ot the
tensionerspring,
7.Tlghtenhe ensionerolt.
Tightening orque:
'19-25 N.m
1.9-2.6 m-kg, 14-19 ft-lb)
8. Turn hecrankshaftr o urns lockwisendverityhat he
timingmarks recorrectly ligned.

9. Measurehe iming eltdeflectiony applyingmoderate

pressure98 N, 0 kg, 22 b) midway etweenhecrank-
shaftpulley nd hecamshaft ulley.
9aN lf the iming eltdeflections notcorrect,emporarilye'
(10 kg. 22 lb)
cure he ensioneroltso hespring s ullyextended nd
repeat leps4-8 aboveor replacehe ensionerpring.
Deflectlon:
'| 1.0-13.0mm 0.43---0.51n) at 98 N ('10 g, 22 b)

B-77
 

ASSEMBLY
Timlng Belt Covet
lnsta[ he owerandupper imingbeltcoversandnewgaskets
TIMINGBELT Tlqhteninq olque:
covEa ?.4-t t-Hm igo-tro cm-kg,69-95 in-lb)

CrankshaftP ulley
1. Installhe pulley oss.

Caution
. Add approx13mm 0,51 n) ol spacers rt) to space
the SSi away ron the cylinder block. (MTX)
2. Mount he SSTand ightenhe pulleyock bolt
Tiohteninq oroue:
iso-ro1 *m oe-t7 m-kg,115-122 inb)
3.

4. Installhe crankshatt UlleY.

5. Installhe plate.

waler Pump Pulley

Installhe waterpumpPulley.
Tiohteninq otoue:
?.9-rr-N.. a8o-1lO cm-kg, 69-95 Inlb)

0rEoBx'3c
B-78
 

ASSEMBLY
AUXILIARY ABTS
TorqueSpecilicalions

15-27 (r,5-2i, r1-20)

e3-1 13 e.5-tt.s, 3s-€3)

GASKET, EW

19-25 0,9-2.5, r.-11)

@w
r 1e-30 (1,e-3,r, 13r2)

EngineHangel
Instailhe rontand rearenginehangers.
Tlghtenlng orque
Front 37-63 N.m 3.8-5.4 m-kg,27-46 ft-lb)
Real: 19-25 N{n (1.9-2.6 m-kg, 14-19 ft-lb)

B-79
 

ASSEMBLY
Spa* Plug
ubdcant
1. Apply nitserzeompound molybdenum-based
to the sparkPlug hreads.
2. lnstallhe sparkPlugs.
Tiohteninq oroue:
is-zs'il.m
1t.s-z.s m-rg, 11-17 ftlb)
Oil Dlpstick
Installhe oil dipstick.

Oil PressureSwilch
lnstallhe oil Dressurewitch.
Tiohteninq orque:
lz-re-tt.m ti.z-r.8 m-kg,104-156 n-lb)

Oil Filter
1. Remove ll toreignmaterialr om the oil iiltermounting
surlace.
2. Applya small mount i clean ngine ilto he ubber eal
of the oil ilter.
3. Installhe oil ilterand ightent by handuntil he rubber
sealc ontactshe base.
4. Tightenhe ilter1 and 1/6 urn witha filterwrench

No.3 EngineMountBrackel
Installhe No.3enginemountbracket
Tiohteninq
ss-t otoue:
Hln g.s-i1.5 m-kg. 69-83 ttlb)

Allernator
1. Installhe alternatortrap.
Tiahtenino orque:
-t't.m
iz-sz 1s.e-s.o m-t<g, ?-38 ft'lb)
2. nstallthe lternatorndalternatorrivebeftLooselytight'
en the alternatorn stallationolt.
3. Adjusthe drivebeltdeflection.R efero pageB-5.)
Tightening orque
Alternator nslallationbolt (D :
37-52 N.m 3.8-5.3 m-kg, 27_38 ftnb)
Belt-adiustlng oll @ :
'19-25 N.m 1.9-2.6 m-kg, 14-19 tt-lb)
B-80
 

ASSEi'BLY
IntakeManltoldAssembly
'l. Remove ll oreignmaterialr om he ntakemanifold
on-
tact surtace.
2. Install newgasket nd he ntakemanifold ssembly.
Tighlening orque:
t9-25 Nm (1.9-2.6 m-kg, 14-19 fub)

Distrlbutorand High-tension ead

1.Applyengine il o the O-ring, nd positiont on he dis-
tributor.
2. Applyengine il o the blade.
3. Installhe distributor ith he blade it into he camshaft
groove.

\=.\-6FY--.-
 \ \ \ . t . u
- //t \ \

4. Temporarily,
ooselyightenhe dist.ibutorn stallingoll.
5. Connecthe high-tension e ads.
6. Adjusl he gnitionimingafterenginenstallation.
(Refero SectionG.)

B-81
 

ENGINESTANDDISMOUNTING
ENGINE TANDDISMOUNTING
PROCEDURE
1. Removehe engine rom he SST (enginestand)
2. Removehe SST (englnehanger) lom he englne.
3. nstallhe partsshown n the igure
TorqueSpecitications

37-52 (3,3-5,3, 27-34)

(fr----- ---
\

ts=;\

|5fi 1e-25 0,9-2.3, 14-r9)

37-52 {3.H.3, 27--33)

{8O-iio m-rq, 69-t5 in'lb)

O.FIING,NE W
APPLY ENGINECOOLANT 16-2311.5-2,3, 12-1n

waler lnlet Pioe

'1. Removelfdreignmaterialrom hewaternlet ipemoun!
ino surface.
2. Inatall newgaskel nd he waier nletpipe
Tiohteninq
is-zs -Nmoroue:
(i.s-z.e m-kg' 14-19 ft-lb)

B-82
 

ENGINE TANDDISMOUNTING
3. Applya small mount f engine oolanttohe newO-ring.
4. nstallhewaterbypass ipe.

ExhaustPioeBracket
lnstallhe exhaust ioebracket.
Tightening orque:
37-52 N{n (3.8-5.3 m-kg, 27-38 fi-lb)

A/C ComDressor rackel

Installhe uC comoressorracket-
Tighlening orque
@: 19-25 N.m 1.9-2.6 m-kg, t4-19 ftJb)
@: 37-52 Nm (3.8-5.3 m-kg, 27-38 ft-lb)

ExhaustManitold
1. Remove ll oreignm aterialr om heexhaust anifoldon
tact surface.
2. Insiail newgasket nd the exhaustmanifold.
Tightening orque:
16-23 Nm (1.6-2.3 m-kg, t2-17 ft-lb)

ExhaustManitold nsulalor
Installheexhaustmanitoldnsulator.
Tightening orque:
7.8-11 N.m 80-110 cm-kg, 69-95 In-lb)

B-83
 

INSTALLATION
INSTALLATION
PROCEDURE
Tighten ll boltsand nuts o the specifiedorques.
Step I
Join he engine nd ransmission.
TorqueSpecilications
  TX

6!-a9 {6.5-r.r, 47-16)

37-52 (3.3-s.3, 27-33)

37-52 (3.3-5.3, 2?-33) 3?-s2 (3.3-5.3, 27--33)

ATX

37-52 (3,3-5.3, 27Ja)

37-52 e.a-5.3, 27--33)

B-84
 

INSTALLATION
Step 2
Warning
. Be sure he vehicle s securelysuppgrtedon safetystands.

TorqueSpeqifications

Engineand transaxleassembly
1.Suspendhe engine nd transaxle ssembly.
Caution
. Do nol damaEe nycomponentsn he engine om-
partment.

2.Align he No.3enginemountb oltswith he enginemounl

mounting oles.

B-85
 

INSTALLATION
Enginemouni
1. nslallh e \o.1engine ounl utand rghten

gz-sr orque:
Tiohteninq
IffiI
1m 1il.a-s.sm-rg,27-38lr-tbl
2. Installhe No.2enginemounlnut and ighten.
Tiohteninq orque:
-tr.m
iz-st (g.g-s.g m-tg, 27-38 ft-lb)
No.2 ENGINE No.1 ENGINE
I,IOUNT MOUNT

Enginemountmember
Installhe enginemountm ember.
Tiohteninq
ea-es -Nmorque:
16.s-S.l m-t<g, 7-66 ft-lb)

Step 3
TorqueSpecificalions

15-22 0.6-23, 1r-16)

31,-46 3.2-4.7,23-33)

40-s4 {4.r-s,5, 2s--r0)

&..-..-..-------'n*.,".*,
', o,*"
37-51 (3.3-5.3. 27-33)
*-"",u.u-",, r-.",J

B-86
 

INSTALLATION
Drlveshaft
1.Applygreaseo the end ot the driveshaft.
Caulion
. When nstalling he drlveshaft,be caretul not to
damage he oil seal.
. After nstallation, ull he ront huboulward o con-
lirm that the driveshalt s sequrely eld bythe clip.
2 Fil a newclip and nstallhe driveshaft.

3. Installhe owerarmball-jointo he knuckle, nd ighten

the clinchbolt.
Tightening orque:
43-53 N.m 4.4-5.5 m-kg, 32-39 fl-lb)

Clutch cable
lnstallhe clutch ableand checkdiffrection.
(Refero Section .)

Shlft control cable (ATx)

Installhe shitt ontrol able o the ransaxle.
Tightening orque:
6.9-11 Nm (70-110 qm.kg, l-95 inlb)

Shift control rod (MTX)

Installhe shift ontrol od o the ransaxle.
Tightening orque:
'16-22 Nm (1.6-2.3 m-kg,12-16 in-lb)

Extensionbar (MTX)
Installhe extension ar o the ransaxle.
Tightening orque:
3l-46 N.m 3.2-4.7 m-kg, 23-34 in-lb)

B-87
 

INSTALLATION
Speedometer able
able
lnstallhe sDeedometer
Tldhtenlnq oroue:
?.s-rfN.m iao-rzo cm-ks, 9-96 In'lb)

Exhausipipe
'1 lnstallhe exhaust ipeanda gasketihen ooselyighten
the ocknuts.

Li, 2. Looselyighten he bracket ohs

3. Tightenhe ocknuts.
Tiohteninq oroue:
lo-sl -t'l.m
tl.t-s.6 m-kq, 29-40 ft'lb)

B-88
 

INSTALLATION

Srep4
Connecthe hoses hown n the igure.
Cautlon
. Posltion he hose clamp n the original ocationon lhe hose,and squeeze he clamp lghtly
with large pliers o ensure a good fit.

Siep 5
Connect he harness onnectors hown n the fioure.

B-89
 

INSTALLATION
Siep 6
Torque Specificationa

(30-110 n-ts, 6e-ss lFlb)

B-90
 

INSTALLATION
A/C compressor (it equipped)
E Installhe uC compressor.
Tightening orque:
37-s2 N.m 3.8-s.3 m-kg,27-38 ft-lb)

01EoBXI5a
P/S oil pump and bracket
lnstallhe P/Soil oumpand bracket.
Tightenlng orque:
37-52 N.m 3.8-5.3 m-kg, 27-38 ftlb)

Drivebell
1. nstallhe P/Sand/orA/Cdrivebelt.
I J .DLEF 2. Adjust hedrivebelldeflections.Refero pageB-5.)

IJLLEY COMPFI

Radiatorand cooling an assembly

1. nstallhe radiator nd coolingan assembly.
Tighlening orque:
7.8-11 N.m 80-il0 cm-kg, 69-95 in-lb)

2. Tightenhe AJCpipebracketo the radiator.

Tightening orqle:
6.4-9.3 Nm (65-95 cm-kg, 56-82 in-lb)

3. Connecthe uooerand ower adiator oses.

&6
Caution
. Poaltion he hoseclamp n the orlginal ocationon
ihe hose,and aqueezehe claBp lightlywlth large
pllers g ensurea good fit.

4. Connecthe coolant eservoir ose.

5. Connecthe coolingan connector.
6. Connecthe oil cooler ose. Al'X)

B-91
 

INSTALLATION
Accelerator cable
1. nstallhe acceleratora ble
ne caUte etlectiony turningnut @
Deflection: -3mm (0.04--'0.12n)

Battery duct, battery car er, and battery

1. nstallhe battery uct.
2. Installhe battery arrier.
Tlohtenlnq orque:
ig-zs l.m (i.9-2.5 m-kg, 4-19 fl-|b)

-YA 3. Install he batteryand the batterybracket.

Tiohtgnino orque:
i.s-s.5 N.m'(so-60 cm-kg, 26-52 inlb)

Air cleaner assembly

lnstall he air cleanerassembly
Undercover and slde cover
lnstallhe undercoverndsidecover.

steDs After Installatlon

i. ii'tn" 6"si"J o-'l i" drarned,i ll with he specified mount nd ypeof engine il
(Refero SectionD.)
2. Fill he radiatorw ith he mount nd ypeof engine oolant'
{Retero Section .)
s..ii il" to^""*|. oil;.s drained,ill with he specified mount nd ypeof transaxle il
(Retero Sections , K )
4. aonnect he negative attery able
5. Starthe engineand check he ollowing
{1) Enaine il, ransaxleil and engine oolanteakage
izi tgnitioniming.dlespeed Refero pageB-8)
(3) Operationt emission ontrol yslem
6. Perform road est.
7. Recheckhe engine il and engine oolantevels.

B-92
 

LUBRICATIONYSTEM
L 2
1NDEX.......,.,...,..,.......................,,.,..........
ouTLtNE.,............, ...,., L 3
sPECtFtCAT|ONS.................................... - 3
TnoUBLESHOOT|NG U|DE.,......,...,.,..,.... L 3
otL PRESSURE.........,.,........................,.,..- 4
PREPARAT|ON,,...,...............................,. - 4
TNSPECTTON - 4
...................,..................,..
ENGTNEtL,.,.....................,..,.................- 5
- s
tNSPECT|ON...........,..,..................,.,.,....
REPLACEMENT,,.,....................,............. - 5
- 6
otl F|LTER...,....,..,.,.,.,........................,...
REP1ACEMENT.......,.............................. L 6
- 7
otl PAN..................,,..............................
REMOVAL|NSTALLAT|ON......,.,..,.,........ 7
L I
otl PUMP..,.,...,..,.........................,......,...
REMOVALTNSTALLATION ...................,.- I
D|SASSEt\4BLY ASSEMBLY . ................... ll
TNSPECTTON -12
.....................,.,.,,..............
 

INDEX
INDEX

ENGINE ILSPECIFICATION
API SEBVTCED,SE OB SF

3.4 ir6.s 3-6us qr, 3.0 hp q0

l. Oil pressure 4 Oil-Pan

n stallation " pageD- 7
Inspectron...........-.................... pageD- 4 - Removal/
2. Engine il 5 OilPumP
ageD- 5 Removal/n stallation " page - I
l"nspection.......--...-...................... pageD-1'1
Rep1acement................ .. . . pi6e O- s DisassemblyAssembly
3. Oil ilter
R e p 1 a c e m e n t . . . . . . . . . . . . . . .p. a
. .g. .e.D. .-. 6

D-2
 

OUTLINE, ROUBLESHOOTING
UIDE
OUTLINE
SPECIFICATIONS

IemHmodel B:]

Tvpe
Oil pump
Regulaled ressure kPa kg/cmz,psi) 343 441 (3.5-4.5, 50-64)

Type Full.i w, pap€relement

Oil llter
Felief pres€ure itferenlial kPa (kg/cmz, sl) 98 1.0,14 )
Oilwarn g p€sslre kPa kg/cm' si) 4.9-44 (0.05-0.45, 0.7-6.4)

Tolal dryensine) lilerc USqt, mp qt) 3.4 3.6,3.0)

Oil capacily Oll pan llers USqt, mp qt) 3.0 3.2,2.6J
Oiltlter liters USqt, mp qi) 0.170.18,0.r5)
Englneoil (APlservce ) S D .S E , r S F

Recommended AEViscosity
-30 -20 -10 0 10 20 30 40 50
fc)
('D ,--20 0 20 40 60 80 100 720

5w'30 v 30 \

5EA----\ 20w.20 :
'l0w-30

@
ffi
Anticipatedmbientemperatureangebefore ucceedingil change, C ("D

TROUBLESHOOTING
UIDE
Possible Cause Remedy Page
Enginehardstarting D-5
Insuflicieni ngineoi l D-5
Exceasiveoil Oilworkngup o. down Reier to Section B
Oil eakage
Oll pressurc drop o_o
Oil eakage
Womand/of amag€d il pumpgear
Wornplungerinside il pump) r weak prins
Clossed il strain€r Clean
Excessive a,nbeanng , .orneq ng rod oea rc Reler to Seclion B

Warnlng amp Oil prcssure rop

lllumlnrteswhlle MaltunctionJoil pressurewnch Fefer o SectionT
engineb running Mallunction f electical srstenr

D-3
 

OIL PRESSURE

OIL PRESSURE
PNEPARATION
ssT
49 01872AO

Gauge,

INSPECTION
1. Removeheoil Pressurewltch

2. Screw he SST nto he oil pressure witch ole.

3. Warmup the engineo normal peratng
4. Run he engine i 10Oopmand3000 pm,and note he
gauge eaorng.

Oll pressure:
99-196 kPa
(1.0-2.0 kg/cm' 15-28 psi)'1000 pm
294-392 kPa
(3.0-4.0 kg/cmi, 43-57 psi)'3000 pm
s nolas specitied heckor hecause nd
5. t rheDressure
reoaii. Refero Troubleshootinguide.)

D-4
 

ENGINE IL
ENGINE IL
INSPECTION
1. Be sure he vehicles on levelg round.
2. Warm ptheengineo normaloperating emperaturend
stop it.
3. Wait or iveminutes.
',"u"' ndonditi
3. ET?,1",f;r","'i"t'3il"1i*ffitn" E
Note
. The distancebetween he L and F marl6 on the dip
stick represents .8 llter {0.85US ql, 0.70 mp ql}.

REPLACEi'ENT
warning
. Be carelul when drainlng; he oil is hot.

1.Warm p heengineo normal peratingemperaturend

stop rt.
2. Removehe oil iller ap and he oil pan drainplug.
3. Drain he oil ntoa suitable ontainer.
4. Install newgasket nd he drainplug.
Tightening orque:
29-41 N.m 3.0-4.2 m-kg, 22-30 flnb)
o5u00x.011

5. Relillheenginewith he specifiedypeandamount f en-

gineoil. Relero pageD-3.)
6. Retit heoil iller ap.

7. Flun he engine ndcheck or leaks.

L Check he oil evela nd add oil f necessarv.
Oil pan capaclty:
3.0 liters (3.2 US qt, 2.6 lmp ql)

D-5
 

OIL FILTER
OIL FILTER
REPLACEI'ENT
1.Removehe oil ilterwitha suitable rench.
2. Usea clean ag o wipeotf he mounting urface n the
enoine.
3. Ap-ply smallamountofl ean ngine iltothe ubber eal
of the new ilter.
4.Installthe il ilterand t by handuntil he rubber
sealcontactshe base.

5. Hand iohtenrnqvpe Numbers rinted n lilter)

,',,\ Tiohteniheiltei3i4 of a turnbv handafter t contactshe

Y cvliinderlock.
y hand s difficult, se a suitable rench

r)+
e
Example:
. Wh;n the oil filter contacls he cylinder block at " l " '
"4."
turn il 3/4 of a turn fulther to

Filterwrench i ghteningype Nonumbers rinted n ilter)

Tiohtenhe ifter and1/6 urnswitha suitable rench t-
tei it contactshe cylinder lock.
6. Start he engine nd check or eaks
7. Check ie oil evela nd add oil f necessary

Oll fllter capacity:

0.17 iter (0.18US qt, 0.15 mP qt)

D-6
 

OIL PAN
OIL PAN
RE!'OVAL INSTALLATION
1.Disconnecth e negative attery able.
2. Drain he engine il.
3. Removehe undercover nd sidecover.
4. Removen theordershown n the igure, eferringo RemovalN ote.
5. Installn the reverse rderof removal,eferringo InstallationNote.

GASKET,
BEPLAC€

REPLACE

REPIACE '@
3r-52 (4.3-5.3, 27-36)

REPlACE

{3!-110 cfrkg, 69-95 tn.tb)

1. Frontexhaust ipeand bracket 5.Gaskets

, lhr6^r.rorl di1l6n6r 6. Oilstrainer
3. Oil pan bolts
4. Oil pan
B e m o v a lo t e . . . . . . . . . . . . . . . . . . .a. .g. .e.D. .-. .8
Installationote.......................... ageD- 8

D-7
 

OIL PAN
Rgmoval Noie
1.Removehe oil pan mounting olts.
2. lnserta screwdriver r a suitableool betweenhe MBSP
and oil pan o pry them apart.

Cautlon
. Do nol Insed the prylng tool between hs iIBSP ard
cylindel block.
. Do not damage the conlact surlacea.

3. Removehe oil pan.

lnatallation Note
Oil pan

\ ^ Akit* Cauilon
. lf the bolts al€ to be reused, remove he old aaal-

ffi"::+
ant from the bolt thr€ada.
Tlghtenlng a boll with old sealant on lt may cause
cracklng nalde he bolt hole.

1. Remove ll oreignmaterialr om he contact urfaces.

2. Applysilicone ealanto the endsof a newoil pangaskets.
3. Install gwgaskets nto he oil pumpbodyand he rear
cover with he proiectionsn the noichesas shown n the
figure.

4. Applya continuouseadof silicone ealanto he oil pan

along he nside l the boltholesand overlaphe ends.
5. lnstallhe oil pan.
Tightenlng orque:
7.8-ll N.m 80-ll0 cm-kg, 69-95 in-lb)

Steps Atter Inslallallon

1. nstallheundercovernd sidecover.
2. Fillwith he specilied mount nd ypeof engine il.
(Refer o page D-5.)
3. Connect he negativebatterycable.
4. Starthe engine nd check or eaks.
5-check he oil eveland add oil f nec€ssary.
o1aoDxo11

D-8
 

OIL PUMP
OIL PUMP
REMOVAL INSTALLATION
1.Disconnecth e negative attery able.
2. Drain he engine il.
3. Removehe imingbelt. Refero Section .)
4. Removehe oil pan and ntegratedtittener.R etero pageD-7.)
5. Removen the ordershown n the igure, elerringo RemovalN ote.
6. Installn the reverse rdefof removal,eferringo InstallationNote.

o
I

19-2s _
2ir-35
REPLACE (1.9-2,6,14-rs)
e,r-_3.6i1

1.Timingbeltassembly 5. Timing eltpulley

S e r v i c e . . . . . . . - . . . . . . . . . . . . . . . . . . .e. .c.t.i.o. .n. - . . . . . . S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . . . . e
. .c. .U. .o. .n. . . . .
2. Oil pan 6.Oilpump
R e m o v a lo t e . . . . . . . . . . . . . . . . . . . a . .g. .e.D. . . .8 Disassembly Assembly..........a geD-11
Installation o te.......................... ageD- B 7. Frontoil seal
3. Aiternator Service..........................e . .c. .t.i .o. n
......
4. uC compressorw ithA/C)
R e m o v a lo t e . . . . . . . . . . . . . . . . . . . a . .g. .e. . . .1.0

D-9
 

OIL PUMP
RemovalNote
A/C compressor (with A/C)
Caution
. Do not damage he hoses.

1 Removehe A,/C ompressor ith he hoses tillconnected.

2. Positionhecompressorway rom he engine ndafiix t
withwire.

Sleps After Insiallation

1. nstallhe oil panand mainbearing upport late
(Relero pageD-8.)
2. Installhe timingbelt. Refero Section .)
3. Fillwith he specifiedmount nd ype of engine il.
(Refero pageD-5.)
4. Connecthe negative attery able.
5. Start he engine ndcheck or leaks.
6. Check he oil evela nd add oil f necessary.
orAooxol3

D-10
 

OIL PUMP
DISASSEMALYASSEMBLY
1.Disassemblen the ordqrshown n the igure, eierringo Disassembly oie.
2.Assemblen the reverse rderof disassembly,eferringo AssemblyNote.

5.9-3.3 Nm (60-00.m.kg, 52-73 i.-lb)

e-@E.
o l t ^

s_@

1.Oilseal 6. Spring eat

Disassemblyote...............................
elow 7.Pressurepring
Assembly ote... pageD-12 ageD 12
Inspeciion..............................-....
2. Pump over B.Control lunger
Inspector distortion nd damage lnspecl or wearand damage
3. Outer otor L Pumpbody
4. nner otor /nspector distortionnd damage
5. Bollpin
DisassemblyNote
Oil seal
Removeheoilsealw itha screwdriverrotected itha rag.

D-11
 

OIL PUMP
INSPECTION
Pressure Spring
1- nspecthe spring or weaknessr breaKage.
he reelength. eplacehespringf necessary'
2. [/'leasure
Free engih: 45,5mm 1.791 n)

RotorClearance
Measurehe ollowing learances. eplacehe rotor f necessary'

93G0DX{30

Tooth lp clearance: Outer otor o PumP ody: Side clearance:

0.20mm 0.0079 n) max. 0.22mm 0.0087n) max. 0.l4mm (0.0055 n) max.

A€semblyNole
Oll seal
1. Applya smallamountfclean ngine iltothe ipol a new
oil seal.
2. Push he oil sealslightlyn by hand.
Caution
r\>:>'\ . Theoil sealmustbe Pteesedn until t is flush wlth

;LS the edge ol the oll PumPbody.

3. Presshe oil seal n evenlywitha suitable ipe.

Oil sealoutel dlameler:50.5mm 1.98 n)

D-12
 

COOLINGSYSTEM
fNDEX................... ..,'.'E- 2
ouTLlNE,.............. ......E- 3
- 3
spEctFtcATloNS....,......-.......................
TROUBLESHOOTING - 3
U |DE....................,.
ENGINECOOLANT. ...... E- 4
pREPARAT|ON.......................................
- 4
-4
rNspEcTtoN............-.........-..................
REP1ACEMENT..........,........................... - 5
RADTATORAP..... ...... E- 6
PREPARAT|ON.......................................- 6
- 6
rNSPECTrON...................,...........,..........
RADfATOR........... ......E- 7
REMOVALTNSTALLATION ............,........- 7
- 7
rNSPECT|ON............,.............................
THERMOSTAT....... ..'... E- 8
REMOVALINSTALLATION ......,............'.- 8
- 9
tNSPECTrON..........,...............................
WATERPUMP....... ......E-10
REMOVALrNSTAI1AT|ON .....................-i0
ELECTRIC OOLING AN SYSTEM...'....... E-l t
SYSTEM|Rcu1r..................""""""""" E-1I
sysrEM NSPECT|ON.......................,...... -l I
FANMOTOR.......,.. ...'.' E-12
tNSpECT|ON -12
. ........................................
-2
REPLACEI,|ENT......................................
warER THEBMOSWITCH .........................- 3
REMOVALTNSTALLATION ..........-,.........- 3
lNSPEcrloN """""" E-13
FAN RELAY........... ......E-i4
REMOVALlNSTALLAT|ON ....-................- 4
lNSPEcrloN.."""""""""""""""""""' E-l4
 

E INDEX
INDEX

CONNECTOF

ENGINECOOLANT OTALCAPACITY:

5.0 5.3, ..r) 6.0 6,3, ,3 )

1. Engine oolant 6. Electric oolingan system

I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. .e. . -. . 4
...... S y s t e mi r c u i t . . . . . . . . . . . . . . . . .p a g e - 1 1
R e p | a c e m e n t . . . . . . . . . ................a ...g. e - 5 S y s t e m i n s p e c r i o n . . . . . . . . . . .a. g . .e. .E. - 1 1
2. Radiator ap 7. Fanmotor
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. .e. . -. . 6
...... l n s p e c i i o n . . . . . . . . . . . . . . . . . . . . .a. .S. .eE
. . -. 1
. .?. . . . .
3. Radiator 8 e p 1 a c e m e n t . . . . . . . . . . . . . . .p. .a. g . .e. . .-1. . .2.
RemovalI nsla|ation.................. ageE- 7 B.Water hermoswitch
4. Thermostat RemovalInsta||atron.................. ageE 13
RemovalI nstal|ation.................. ageE- 8 9. Fan elay
5. Water ump RemovalInstallation............... pageE-14
RemovalI nstaj|ation.................. ageE-10

E-2
 

OUTLINE. BOUBLESHOOTINGUIDE E
OUTLINE
SPECIFICATIONS
Enginemodel B3
|rem
Coolingsyslem orced rculation
Waier<,ooled,
Coolanl apacily lite6 (US qt, lmp qt) [4IX 5.0 s.34.4)ATX.6O(6.3.s.3)
Centnrugalell-driven
Unlliedmechanical eal
Tvpe
Openingemperature 'C fD 86.5 89.5 (187-193)

Full-openemperature 'C fR 1OO212)

Fifopen ltt mm (in) 8.5 0.335) r more

corugatedin
Radiator
Cap valveopeningpressJre hPa kg/cm?. s, 74-103 0.75-r.05. -r5)
l4olor urrenl A 6.6+1

Cooling an

Outer ameter l blade mm (in) 300 r .9)

TROUBLESHOOTING
UIDE
Problem PossibleCau3e Remedy Page
Overhealin9 Coolantevel nsuiticient E-4
Coolant eakage
Radlatori nsclogged Clean
Badialor ap malf nction E-6
Cooiing an malf nclion E-11
Thermogal alfunction E-8
Walerpassage logg€d Clean E-5
Water umpmalfunction E-10
Coro€lon E-5

E-3
 

ENGINECOOLANT
ENGINECOOLANT
PREPABATION
ssT

49 DO15 A0 49 D015 02

49 DO15

INSPECTION
Waming
. Neveiremove he radiatorcap while he engine 6
hot,
. W;D a thick clolh around he cap when removing t'
. wh;n removing he radiatorcap, loosen tslowly
to the tirst stotuntllthe Pressuren the radlalor s
released, and then remove il.
muoEx.oo6

CoolantLevel(Enginecold)
1. Venly hat he'coolantevel snear he radiatorrller eck
2. Veritv hat he coolantevel n he coolant eserviors be
weeh the FULLand LoW marks
3. Add coolantt necessary

CoolantOuality
1 Verffvhat hie is no buildup f rustor scalearoundhe
radiator ap or radiatorillerneck
2. Veritv hat coolant s lree of oil Replacehe coolant f
necessary.

CoglantLeakage
1.connect radlalorestercommerciallyv ailade) nd he
SST o the radiatorillerneck,
z. AppV tO3 kPa (1.05 kg/cm' 15 psi) pressureo the
svstem.
3. V'erifvhat he pressures held
4. lt noi as specified, heck or coolanteakage

E-4
 

ENGINECOOLANT E
CoolantProtection
Caution
. Do not uae alcohol- or methanol-basedcoolant.
. Use only soft (demineralized)water In the coolant
mixture.
1.Measurehecoolante mperaturendspecfiic ravity ith
a thermometernda hydrometer.
2. Determinehecoolant rorecliony referringo hegraphI
s. iili" loor"n, prot""tion s norproper,add w"te, o, "oolanl.E

Antlfreeze solutlon mlxture percentage

Gravityat
Coobrn pdeclion 2o.c (68.0
oolant
Above -16oC ( 3oR 65 35 1054
Above -26oC {-1soR 45 1066
Above 4ooo i-40on 45 '1o78
COOL^NTTEMPERATUFE CfF )

REPLACEMENT
ol EoEx@7
Warnlng
. Neveropen he radialor cap while the engine s hot.
. Wrapa thlckclolh around hccap when oosening.
. When emovinghe radiatorcap, oosen t slowly
to the tirst stop unlll the presaure n the radiator is
released. and then remove it.
. Use cautlonwhen draininghol coolant.

Cautlon
. Do nol use alcohol-or methanol-basedoolant.
. Useonly sotl (demineralized) ater n the coolant
mixture.
. Befors loosening he radlalor draln plug, verity thal
lhe radlatgrdrain hose aces slraight down.
1 Bemovehe radiator apand oosen e drainplugby hand
(MTE or by a wrenchATX).
2. Drain he coolanlnloa suilable ontaner.
3. Flushhecooling ystem ithwater ntil ll races f color
are gonei hen et he system raincompletely.
4. Insiallhe drainplug.
5. Fillwithhe proper mount ndmixture f ethylenelycol
based oolant y referringo the ableabove.
Coolanicapaclty lilers USqi, lmpql)
B3
i\,ITX AIX
5.0 (5.3,4.4) 6.016.3,.3)

6. Run heengine ithhe adiatorap emoved ntilthe p

per radiator ose s hot.
7. With he enginedling, ddcoolanto the radiator ntil t
reaches he bottomot the filler neck.
8. Installhe radiator ap.

E-5
 

E RADIATORCAP
RADIATORCAP
PREPARATION
ssT
49 DO15 A0 49 D015 03
AdaplerB
49 D015 A0 )

INSPECTION
Radiato. Cap Valve
1. Removeoreignmaterials uch s water esidue)r ombe
tween he radiator ap valveand he valve eat.
2. Attach heradiator ap o a radiator ap ester commer'
ciallv vailable)ith heSST.Applypressureraduallyo
74-103 kPa (0.?5-1.05 kg/cm" 11-'15 psl)
3. Waitabout O aecgnds.V erityhat he pressureasnot
decreased.
4. Feplacehe radiator ap il necessary

N€gative Pressurc valve

1. Pull he negative ressurealve10open Verify hat t
closes omDletelvhen eleased
-,-'-_ \\
2. Checkordamag;on hecontacturfacesnd orcracked
' or deformed ealPacking.
kk=fiK"DlN"
\{ ,l\\\//rIA\ ,--A\,\ 3. ReDlacehe radiator p if necessary'
f-
-/ \,\
/\\\\}1

\lt\v2liK\
'ii::\!@=-

E-6
 

RADIATOR
RADIATOR
REMOVAL INSTALLATION
Caution
. Eetore oosening the radiator drain plug, verlty lhat the radiator d.ain hose ac€s straightdown,
. Poallion he hosedamp in the original ocalionon the hose, and squeeze he clamp ightly
with large pliers to ensure a good tit.
1 Disconneclhe negatrve attery able.
2. Drain he engine oolant.
3. Removen the ordershown n the igure.
4. nstalln the reverse roerol removal
r*n {3o-1 ro cfrrg, 6F95 hrb)

1.Coolinganconnector 5. Radiator racket

2. Coolanteservoir ose 6. Radiator
3. Radialor ose I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . . .a. .g. e
. . . .7. . . . . .
4. Oilcoolerhose ATX) 7-Coolingan and radiator owling ssembly
INSPECTION
Check or he ollowing nd repair r replace s necessary.
1. Cracks, amage, nd water eakage.
2. Bent ins repair itha screwdriver).
3. Distoned r bent adiatornlet.
Sleps Atter Installation
1. Fill he radiator ith he specified mount nd ypeof en-
ginecoolant.Refero pageE-4.)
2. Connecthe negative attery able.
3. Start he engine nd check or leaks.

E-7
 

THERMOSTAT
THERMOSTAT
REi'OVAL INSTALLATION
Caution
. Betore oosening he radlator drain ptug, verlty that the radiatordrain ho€e ace€slraighl {oll.
. Position he hose clamp In the originil locatlonon the hose' and squeeze he clamp ightly
with large pliers o ensure a good tll.
L Disconnecthe negatlve attery able
2. Drain he engine oolant-
3. Removen the ordershown n the igure.
4. Installn the reverse rderof removal.

(r.9-2.6 n-kg, ra-rg ftlb,

1.Waterhermoswitchonnector 5. Thermostat
2. Upper adiator ose ageE-9
Inspection.....................................
3.Thermostatover Installation ageE-g
o te........................,...
4.Thermostatasket
ageE-g
Installationo te............................

E-8
 

THERMOSTAT
INSPECTION
'1.Visually heck hat
he hermostatalve s airtaght.
2. Place he thermostat nd a thermometern water.
3. Heat he waterand check he ollowing:
B3
Openingempe.ature "C (. D 86.5-89.5 (187-193)
Fu 'open emperalure oC (o D lOO1212)
Full-openilt mm (in) 8.5 (0.335) r more

Installation Note
Thermostat
Installthehermostatnto hecylinder eadwith he iggle in
at the op.

Thermoslal gasket
Install newgasketw ith he sealinging acing he cylinder
neao.

0rEoE(.o16

Steps Atter Installation

1. Fill he radiator ith he specifredmount nd ype of engine oolant.Refero pageE-5.)
z. Uonnecthe negatrve attery able.
3. Start he engine nd check or leaks.
01EOEX017

E-9
 

WATERPUMP

WATERPUMP
REMOVAL INSTALLATION
Cautlon
l-adfore toosenin' the radlator drain ptug,verity that the radlatordrain hose taces stralght do{vn.
. oJnoi aisasseiule the water purilp.-tta probtem s found, replace he pumPas a unit'

1. Disconnecthe negative attery able.

2. Drain he engine oolant.
3. Flemoven the ordershown n the igure.
4. lnstalln the reveaserderof removal.

f_o

@neeurce

E t
aOREPLAoE

^ _\6

FEPLACE

re-2s 0,9-2.6, 4-re)

1.Timingbelt 4 Water umpassembly

.... .... Section
Service.........-........ Inspecto rcracks, amaged ounting
2. Water ntetpipeand gasket surface, earing ondition, nd eakage
3. Waterbypass ipeand O'ring 5. Water umpgasket

StepsAller lnstallaiion
i. Fi|l n" iio"ioi ritn the spec redamount nd ypeot engine oolant Refero pageE-5 )
2. Connecthe negative attery able.
3. Start he engineand check or leaks.
E-l0
 

ELECTRICCOOLING AN SYSTEM
ELECTBICCOOLINGFAN SYSTEM
SYSTEMCIRCUIT

COOLING

TAGNOSTS
CONNECTOF
PBESSUFIE

ADDITIONAL THEFIMOSWITCH
ABOVE91"C (196'F): ON
SWITCH
MAGNETIC
CLUTCH

t-](-%,re SYSTEMNSPECTION
1. Jump acrosshe an estOFA) erminal nd he ground
(GND)erminal f the diagnosisonnector.
2. Turn he gnitionwitch Nand erifyhat he anoperates-
lithe andoesnotoperate,n specthecoolingansystem
componentsnd wiringharness.

0r EoEX.021
3. Removeheradiatorao andplacea thermometer n the
radiatorillerneck.
4. Start he engine.
5. Verityhat he anoperates hen hecoolantemperature
is as specified.
Operation emperalure:a bove91'C (196'D
lf the an doesnot operate, heck he water hermoswitch.
(Refero pageE-13.)

E-11
 

E FAN IIOTOR
FAN MOTOR
INSPECTION
1.Check hat he batterys fullycharged.
2. Disconnecthe an motor onnector.
3. Connectthe attery ndanammetero he anmotor on-
neqor.
4. Verifyhatcurrents as specilied.
Current A)
It4TX ATX
B3 6.6+1

5. ll currents notwithin peciiicationnd/orthetan oesnot

turnsmoothly,e placehe an motor'

REPLACEMENT
Cautlon
; Posiiion he hoseclamp n the orlginal ocationon the hose,and squeeze he clamp lghtly
with large pliera o ensu.e a good llt.
1.Disconneclhe negative attery able.
2. Drain he engine oolant.
3. Removen the ordershown n the igure.
4. nstalln the reverse rderof removal.

7,3-ll x{ (30-110 d*q, 30-95 lDlD)

0,01-o.oit f (0.ra--a.22 iFtg, 015-o 1l lFlb)

0.oa'0,06 Nfl (0JHr,56 crF*!,0.3!H.5o lFlb)

1. Coolingan connector 3. Coolingan

2. Fiadiatorowling 4. Fanmotor

E-12
 

WATERTHERMOSWITCH E
WATERTHERMOSWITCH
NE OVAL INSTALLATION
1.Disconnecthe negative attery able
2. Removen the ordershown n the igure
3. Installn the reverse rderoi removal,eferringo InstallatlonNote.

GFING
FEPLACE

1.Waterhermoswitchonnector 2. Water hermoswitch

1 n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g. e
. . .-. l.3. . . . . .
Insialiationote.......................... ageE-1
INSPECTION
1. Place he switch nd a thermometer
n water.
2. Heatthe ater raduallyndcheck ontinuityftheswitch
wilhan ohmmeter.
Coolante mperalure 'C fD Continuity
[4ore han91 (196)
Less han 84 {183)

3. t not as specified,e placehe water hermoswitch.

lnstallationNote
Water hermoswitch
1.Applya small mount fengine oolanto henewGring.
Caution
. Do not use an impact wrench or Installatlon.

2. nstallhe water hermoswitch.

Tighiening orque:
5.9-4.8 N.m 60-90 cm-kg,52-78 innb)
E-13
 

FAN RELAY
FAN RELAY
REMOVAL INSTALLATION
1. Disconnecthe negative attery able
2. Removehe an relay.
3. Installn the reverse rderof removal.

:-\_

-=-=l

24
INSPECTION
1. Check ontinuitys shownwithan ohmmeter.
Contlnuity
@ @ NO

o @
2. Apply12v betweenerm,rals an{ @;
Check or contrnuiryetweenermlnals, ano (9)
3. lf notas specified,eplacehe an relay.

E-14
 

FUELAND EMISSION
CONTROL YSTEMS
(EGr-S)
- 2
tNDEX....,....,,...,...,,.......,..-...,......"....-..
POSITIVE RANKCASE
-
ouTLtNE.....,...,,....,...,...,......,.......,..,... PCV)SYSTEM..,..........- 99
VENTTLATTON
S Y S T E M | A C R 4 M . . , . .. . . . . . . . . . . . . , . . . . . . .-. . - 99
DESCBtPTtON................-...,..............
VACUUI\IHOSEBOUTING - 99
PCVVALVE..........,....................,.,....
D I A G R A I \ , 1 . . . . . . . . , , . . . . . . . . . . . . . . . . . . . . . . ,- , . . . , . EVAPORATIVEMISSION ONTROL
w t R t N GD | A G B A M . . . , . . . - . . . . . . . . . . , . . . . . , .-. , . -l00
- a
spEctFtcATtoNs.........................,..... -r00
DESCRtPTION,...,....,....................,...-
coMPoNENT ESCRIPT|ONS............. - 9 SYSTEN,i PERAT|ON.,..,.......,,.....,..,,.-l01
TROUBLESHOOTTNG U|DE...........,..,.. - 11 SOLENOIDALVE
FELATTONSHTPHART......................- 11 (PURGEONTHOL)..,,................,..--. -101
ustNG Hls EcTtoN.....,... .,.,...,,,..,,.
- 't4 FUEL APOR ALVE,.....,,..,..,....,.,,,. -l01
DIAGNOSTICN DEX....,.,.........,.,...,..- cHECKVALVE i'WO-WAn..............,..- 102
PRECAUTTON - 16
,....,,.......,,...,,.....,....... cHAFCOALANrSTER....................... -102
SYMPTOMROUBLESHOOTING.......... - 17 CATALYTIC ONVERTERYSTEM...... F-'IO3
ENGTNEUNE-UP...,..,,...,.,,.......,,..,..,.,
- 61 -103
DESCRtPTtON.,,..............................-.
PREP4RAT|ON.....,..................,,....,...
- 61 oATALyTtC ONVERTER................-... -l03
BASTCNSPECT|ON.......-...............,...
- 61 DECELERATIONONTROL YSTEM..... -104
ADJUSTi\4ENT,..,,,..,...,,....,,.,...,........,
- 62 -l04
DESCRtPT1ON.......,.,.,...,.......,......,..,,
SELF-D|AGNOS|SUNCT|ON,..,...........,- 66 -ltX
DASHPOT.,................,..,..,,,..,..,...,...,
DESCRtPTION....,...,.........,...,.,........,.
- 66 A/CCUT-OFFYSTEM.........,.............,, -l05
PREPABATtON....,,.,,...............,.........
- 67 -105
DESCR1PTrON...................................
MALFUNCTION O DENUMBEF........ - 67 SYSTEMPERAT|ON............,..,.,....... -l0s
swtTcHMoNtToR UNCT|ON.......,.... - 80 DECHOKE ONTROL YSTEM.............--l06
TNTAKEtRSYSTEM.,....................,....- 83 -106
DESCFtPTtON....,,,,.......,.......-...........
coMPoNENT ABTS.........,..........,.... - 83 SYSTE|\4P ERAT|ON............,.........,..-106
- 84
tNJECTtONODY,.....,....,,............,.... AtR BYPASSCONTROL YSTET.,.,..,.,F-107
BAFFLE/INTAKE\4ANIFOLD..........,..... - 86 -107
DESCRrpION..,,-............,.................
ACCELERATOR E DAL.,,,,,..,........-.,..
- 86 sYsTEt\4PEFAT|ON............-............ -108
ACCELEFATOR - 86
A BLE.,,.......,....-...... AIRBYPASS OLENOID
- 87
FUELSYSTEM,...,,..,..,.,.,,,.,..........-...... VALVE@, @, @.............................-10e
CONTROLYSTEI,|..........................,...-110
PRECAUTION,,....,.......,......,,.,,,......,
- 88 -110
PREPARA'IrON...................,.....,.......,
SYSTET\4 - 88
PERATION...,.....,.-............. STRUCTURAL tEW,...,..,...,...,..,...,..,,
-l1 1
FUEL ANK,...,,...,,..,..,,,....,..,.,.,......,
- 90 ENGTNEONTFOL Ntr ECU..,........-112
FUELPUMP...,,...........-................,...
- 9l CBANK NGLESENSOR
FUEL tLTER.,,.................................
- -r20
itND|STRtBUTOR),...........................
crRcutTOPENINGE AY..........,...,.., - 93 AIRFLOW ENSOR
PRESSUREEGULATOR..........-......... - 94 (BYPASS OT-W|RE yPq..........,.,,,. F-l21
- 94
iNJECTOR...............................-........ wATER HEB[,4OSENSOR...,..,,.,.,.,..,.. -121
- s7
EXHAUST YSTEM.......,...................... TfIBoTTLEENSOR,....,..,,,.,,.,....,..,.. -l22
coMPONENT ARTS............,..,...,,,.,. - 97 oxyGENSENSOR............,........,.,..,.. -123
OUTLINEOF EMISSION -124
t\4AtN ELAY..,,....,.......................-..
- 9a
CoNTROL YSTEi,............................ cLUTCH WTTCH -l24
i ,,4Tn,..,...,.........,-..
STRUCTUEAL | EW....,.....,................
- NEUTRALWTTCH L 4TX).,....,.,,.....,....
-l25
POWER TEEFING FESSUFEWITCH -125
o1a0Fx.001
 

F INDEX
INDEX

STOPLIGHT WITCH IDLESPEED

SERVICE, ECTION PAGEF-€3

IGNITIONIMING

swrrcHArx)
SERVICE,ECTION

F-2
 

INDEX
1. Fuel ank 14.Air bypass olenoid alve@
Removallnspection Inspection....-............................ ageF-109
F- 90 15.Air bypass olenoid alve@
2. Fuelpump Inspection...................a . .g. .e. . . 1. .0. .9. . .
Inspectjon........................-........ ageF- 91 16.Engine ontrol nit ECU)
R e p | a c e m e n t . . . . . . . . . . . . . . . .a. .g. e . . .-. .9. .2. . . Rep1acement............................. ageF-112
3. Fuel iher low-pressurei de) I n s p e c t i o n . . . . . . . . . . . . . . . . . . . a. .g. .e. . -. .1. . 2. . . .
R e p | a c e m e n l . . . . . . . . . . . . . . . .a. .g. .e. . . .9. .3. . . 17.Airflow ensor
4. Fuel ilter high-pressure i de) fn s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g. e. . .-.1. .2. 1 ...
Replacement.-........................... ageF- 93 Rep1acement............................. ageF- 85
5. Circuit pening elay 18.Waterhermosensor
R e p l a c e m e n l . . . . . . . . . . . . . . . . a. .g. .e. . -. . 9. .3. . .
I n s p e c t i o n . . . . . . . . . . . . . . . - . . . .a. g. .e. . .-. .9. 3. . . .
6. Pressureegulator
flil"'.Y,fl;......:.''
19.Throttle ensor
... . ..833:
-:,3
Inspection................................. ageF- 94 I n s p e c t i o n . . . . . . . . . . . . . . . . . . . a. .g. .e. . . 1 . .2. .2. . .
Rep|acement............................. ageF- 94 A d i u s t m e n i . . . . . . . . . . . . . . . . . .a . .g. .e. . . 1 2
7. lnjectol Removall nstallation................ ageF- 122
lnspection o n-vehjcle).............. ageF- 94 20.Oxygen ensor
Removal/n stallation ............... ageF- 95 I n s p e c l i o n . . . . . . . . . . . . . . . . . . . .a. g. .e. . .-.1. 2. .3. . .
I n s p e c l i o n . . . . . . . . . . . . . . . . . . . .a. .g. e. . .-. .9. .6. . . Rep1acement............................. ageF-124
8. PCV alve 21.Main elay
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. g. .e. . .-. .9. 9.... Rep1acement............................. ageF-1 4
9.Solenoidalve purge ontrol) l n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. g. .e. . . 1. .2. .4. . .
Inspection................................. ageF-10'| 22.Clutch wilch MTX)
RemovalI nstallation................ ageF-101 1 n s p e c t i o n . . . . . . . . . . . . . . . . . . .a. g . .e. . . .1. 2. .4. . . .
10.Fuel aporvalve Repiacemeni............................. ageF 124
I n s p e c t i o n . . . . . . . . . . . . . . . - . . . .a. g. .e. . .-.1. 0. .1. . . 23. Neutralswitch N,,|TX)
11.Check alve two-way) Inspection................................. ageF-125
I n s p e c t a o n . . . . . . . . . . . . . . . . . . .a. .g. e. . .-.1. .0. .2. . . Rep|acement..........................-.. ageF-125
12-Charcoalanister 24.Power teering fessure witch
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. g. .e. .-.-.1. .0. .2. . Inspection................................. ageF-125
13.Air bypass olenoid alve@ 25.Crank nglesensor
1 n s p e c t i o n . . . . . . . . . . . . . . . . .p . .a. .g. .e. .-. 1. .0. .9. Inspection ................. *t".,H.r_:

F-3
 

F INDEX

1.Aircleaner 5. ntakemanifold
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g.e. . .-. .6. .2. . . Inspection.................... . ........ ageF 86
2. Dashpot 6. Intakemanifold tay
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g.e. . .-.1. .0. .4. . 7. Exhaustystem
Removal/n stallation ............... ageF- 85 Removal/nsDectlon
3. njection ody I n s t a | l a t i o n . . . . . . . . . . . . . . . . .p. a. .g. .e. F
. 9/
Inspection................. .. . ... pageF- 84 L Catalytic onverter
Disassembly Assembly........... ageF- 85 I n s p e c t i o n . . . . . . . . . . . . . . . .. .. . .p. .a. g
. .e. . .- 9 7
4. Bafile
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. g
. .e. . .-. .8. .6. . .

F-4
 

OUTLINE F
OUTLINE

@
tr
o
E

I
s

,3
o IE
6
tA
F
9*
o
{@
s
c<

a *
:t
@
T-
?F
2= i E
3" *
9

F-5
 

F OUTLINE
VACUUMHOSEROUTING IAGRAM

f
s
E
;
a

@ o
l
q
t i e
l^
M u {
O
e
q
i 6
n - A

c
e

F-6
 

OUTLINE F
WIRINGDIAGRAM

E3
2

9:

ea

€ !
et
t;

E.

E;! rt l: l

F-7
 

F OUTLINE
SPECIFICATIONS

7501"3 Neutral) 1 , 1 0 0 1 5 3P a n g e )

lsnlrioni mino' Bfqq

rtrui-,- ortprip,""*," kPa ks/cm' si) Below 38 (6.5,92 )

Nylon lementin uelPumP)

FeSrl"rrSp'e."r'" kPa rCcm),Ps) 235 275 12.4-2.A, 4-40)

Air bypass solenold valve @

Alr byp.ss solenold valve @

Alr bypass solenoid wlve @

Solenold valve (purge conlrol)

't4.6-17.8

Resistance ko
40oc 004oR
o"c (176'D

Bypass ype ol hol_wre

Besistance
H WN-HWP) ko

pr< l rs nrl lmp ga)

tv'vt"'ry
40 0 0 . 6 ,8 . 8 )

UnieadedRON 0 or hgheo
'TEN termnal of diagnosls onnectorgrounded

F-8
 

OUTLINE
COMPONENT ESCRIPTIONS

Component Rems]k
Air bypasssolenoid SLrppliesypass ir nto ntakemanilold y . Electricaoa d
valve @ openrngbypassarr passageat either ollowng a) cooling an
b) Blowermolorswltch
ilj€e1\otj a) Ensine rankins c) Headlighlwitch
$oe'i b) El€ctric oad d) Rearw indow ehoslerwitch
c) P/Spressure witchON
d) A,/C witchON
e) Bange hangeN-D)
f) Deceleralionconlrol
Air bypass solenold Supplies ypass iranlonlakemanifod y
valve @ opening ypass ir passage l eiiherollowing
a) Engine ranking
b) P/Spressure wilchON
c) Deceeralon conlrol
Air bypass solenoid S'rpplies bypass air inlo nlake manifold by
valve O opedng bypas arf passage with A/C swltch ON
Filiersair enleing injectionbody Oil p€rmeated
Detects anrounl of inlake air; sends signal to UsesVref 5v) as powersource
ECU
Batlle Drrectsuel/ai.mixture nto ntakemanilold
Cat.lyticconvener ReduceHC, CO and NOx by chemcal

Stores uel tank lmes whie enginestopped

Controlspressuren iuel tank

Circuit opening retay Vollage or {uel pump while enEne runnrnq

clutch $viich (MTx) Delectsclutchcondlioni sendssignal o ECU SwilchOFFwhen cl'rlch pedal eleased
Crank angle sensor Detectsrankangleat iaoo inlervalsie nds
Ne.signal signalo ECU
Diagnosls onneclor Concentraled eMce connectorTerminals: 2l pin (locatednear eti strut oweo
1. EGIself.diagnostcerminal
2. EC-AT elf-diagnostcermifal
3. Inilia set erminal
4. Fuel pLrmp heck erminal
5. Coollng an ch€ck erminal
6. Engine pm oulput elm nal
Oashpor Prevents lter burn when hrotlle aive closes

Ehglne onlrol unil Conkols peral n ol the ollowing.

(ECU) a) Fuel njection onlrolsystem
b) Elecironic pafkadvance ESA) ontrol
c) AJCcur-otisysrem
d) Deceleralion onlrolsyslem
e) Fuelp'rmp controlsystem
D Evaporative mission onlrolsyslem
g) Falsaleconkol ystem
h) Secondaryir njeclionystem
Fuel lllie. Filterspaniclesrom luel
Fuelpump ProvrdesLiel o nleclor Operates hale ngine unn g

Supplyonly evaporative missionnto charcoa

can sler lo prevent charcoai canisler from lue

F-9
 

F OUTLINE

Componsnt Remart

lghlllon swilch Engine ranking ignal ent1oEC U

(STABT posilion)
lnhlbllor swilch Detectsn-gear onditioniends ignalo ECU
(ATX)
Inleclion body a) lniectsuel nto nlakemanilold
b) Adiusls nlakealr amounlby throttlevalve
ct ldl;-upby air bypass olenoidave @
d) Deteclsamountol intakesalr by airlow
Swich N nNorPranges
Conssts ol throtlle vaive dashpot, throtlle sen'
sor, ast dle cam, airflow ensor, nieclor, res'
sure egulator, nd ar bypasssolenodvalve
@

Ini6ctor lniecrsue in relatlono englne eeds Conrrolledy signalsfomECU

High-ohmic n jector
Installed n injecton body
Main relay Supplies lectricurrenlo injector, CU, lc
(FUEL NJ relay)
t{eurral wnch t TD Detectsn-gear ondiLon;ends ignalo ECU SwitchON in neulral

Orygen sensoa ends ignallo

Deiects xygen oncenlrationi Zrrconiaetamic nd platrnumoatng
ECU
Contros blowby gas Introduced nloengine
P/S pressure 3witch Derecrs /Soperatoni ends ignalo ECU P/SrON when sleeing wheel um€d

Prelsure regulrtor AdjustsJue pressure upplied o injector

Specd s€nsor Detects speed: sends signal to ECU Insialledn nstrumenll uster
stopllglrr swllch Delectsbrakingoperalion deceleranon)iends
signal o ECU
Solenoidvalve Conlrolsevaporativeumes rom canister 0 n_
(purg. conltoD
Throltle sercof Deiects hrottlevalveop€nlnganglelsends sg_ Installedn njecuonod y
nal o ECU
Wat.r thetmos€nsor Delectscoolant emperature; endssignal o lnsraledon iniakemanlfo
ECU

F-l0
 

TROUBLESHOOTINGUIDE F
TROUBLESHOOTINGUIDE
RELATIONSHIPHART

OUTPUTOEVICE
.,1
o o o
z z @ @ o
z o
o
o - E
ts o
= (, z
z o (r^
dd =
F 9 t =
to
fi
= = z =
UI
z
|r| z oo
z z 9 . oa
o 40
zr) L e o o
Q . = ./J-
o<
F
(,
6-
z
I >
g 9=9 . .
z = I|rl 6? qE
' J fi lo @ n:
I PUT DEVICE
E? z
t5 c -
JO
d=.u €
EOAT @I{TFOL UI{IT o
DIAGNOSIS O IECTOR CTEN EN INAL) o o o
tcNtTtol{sw|rcH (START OSII|ON) o o o o o o
E/LSIGNAL' o o o o
P/S PRESSURE WITCH o o o o o

a/c swlTcH o o o
INHIBITORSWITCH ATX} o o o o o
EUTRALAND CLUTCHSWTTCHES ITX) o o o o o
sToPltGHT SWITCH o o
SPEEOSENSON o
THROTTLESENSOA o o o o o o o o

AINFLOIY ENSOR o o o o o o
OXYGENSENSOR o o o
WATER HER OSENSON o o o o o o o

CRANK ANGLE SENSON O{6'SIGNAL) o o o o o o o o o o

' E/L 3lgnal ls headlighls, rear window dalroster, blow€r 3witch and cooling lan.

F-11
 

F UIDE
TROUBLESHOOTING
USING HISSECTION
lntroduction
Mostol the uelandemission ontrol ystem ftenmakjngt ditficulto diagnose
oroblemsn ho system, speciallyntermittentroblems. efore undertakingctual hecks,akea few minutes
io talkwitha customer hoapproaches itha drivability omplaint hecustomer s often goodsource
of nlormationn suchproblems, speciallyn termittentn es. hroughalkswith hecustomer, necan ind
out what he symptoms reand underwhatcondjtionshey occur.

work tlow
CHECK N
I
I
LISTEN OCUSTOMEBOIVPLAINTS
I
I
REFEB O TROUBLESHOOIINGA GE HAT _ DIAGNOSTICNOEX
COBRESPONDS O ACTUAL YMPIOIV (Belero PageF 14)

CHECKFORWHATIS BAD IN SYSTEM _ - INSPECTION

CHECK ORWHATPART S BAD _ _ ACTION

I
i i
RTOAIB/FEPLACEMENT
J
I
F TROUBLE ASBEENELIMINATED
DETEBI\4INE
I Ye s
CHECKOUT

Diagnostic ndex
DESCRIPTION:
Describesach roubleshooting
ilem.
No.:
tem s
Each roubleshooting
assigned number-

TROUBLESHOOTING T EM:
There are26 troubleshooting
items.C hoosehe tem hat
mostclosely orrespondso
the actual vmDtom.

F-12
 

TROUBLESHOOTING
UIDE F
Troubleshooting hart

. E n 0 i e . u n s n o m a y a ' r d e t rd r e Foush re (Nos ,r2)l

FROUALESHOOTIIG HIf,ISI

(cotr*lo^ 'or coorad rehpe'aruE)

*rnund|onc*No'ck'l.y.d
check o' cau* (Ferero spsr'd
ch&ks4uercel

Che.N cLr em'^a lFvorase

(rernion d ox)
3Cat.F2_rle
EC! andsenDaqDss ch4ker

05u0Fx.015

OESCRIPTION:
Further escribeshe symptom. onfirmhat hechartaddresseshe actual ymptom efore eginning
troubleshooting.
TROUBLESHOOTINGINTS:
fhis describeshe possible oint f maltunction.
STEP:
Thisshows he orderol troubleshooting.r oceed ith roubleshootings ndicated.
INSPECTION:
escribesn nspection
o quickly eterminethealfunction
f parts.f a detailedrocedure
snecessary
to performhe INSPECTION, efer o ihe pageshownby the "F" mark.
ACTION:
This ecommends he appropriatectiono akeasa resultYeVNo)f he NSPECTION.o w o perform
the action s described n he referenceageshownby he "t?" mark.
0su0F1.016

F-13
 

F U IDE
TROUBLESHOOTING
DIAGNOSTICNDEX

TROUBLESHOOTING TEI OESCRIPTION PAGE

Willnol crankor cranks lowly
2 Engne ranks l normal pg€d ul shows o signot
Reier o EngineElecticalSystem G--4
F-17
lring
Engine rank€ t normal peed utshows nlypar_ F- r9
tialcombuslionndwillnolconlinueo ru n
Engine lads omallywhen old,butwillnotslana, F-21
ter running ndhoisoaked
Eng,ne ranhsal rormal speed bul reqJies eices F-23
sive cranking time belore staring
Same onditions No.swhenengine old F-25
Reslansnormally fterwa|m_up
Same ondltions No.5afler unning no ho t F-27

Starts oimally hen old

8 Engine tallsor vibrates xcessively t |dle F-29
9 Engine tallsor vlblatesexcessively l idle dlrng F-31
Enginestallsai dle
10 Engineunsnomally t dleduringwatm'up ul
vibates excessively r stallsaft€rwarmlp
11 Engine tallsor v bralesexcessively l idle wrcn F-35
E/LON }JC,P/S,or E/LON
Rough dle/Engine talls ust atier sta(ng Engine talls f v brales xcessivelynly ustaner F-36
staning acceleralionrom dle)
13 High dle speed atterwam-up ldle speedexcessveafterwam_up FJE
14 ldle movesup and down/ldlehunting Engine peedsup and down pe.iodically t dle F-39
Engrne lallson deceieralion E^grneune^pecledlv loos un'nng th le dFcele'ar F41
ing or atler decelefallo.'
16 Eng,ne ralls uddenlylntemiten0 ntemiltent slops unnhg F42
17 Hesitates/Siumblesn acceleration Flat soot occurs ustalier acceleralor epressed r F-43
mlld erking ccurs uing acceleranon
18 Surges Unexpected hange n engne sp€€d which s lsually F--45
rep€lilive
19 Pedo.manceoorunder md when hroltle alve F-17

lvlaximum peed €duced

20 Pedormance oot whileacceleral,ng F-50
21 Runs oughon deceleralion/Backlire Enq,le runs roughwhiledeceeraing 3nd abrornal
combustion occurs in exhaust sYstem
22 Abnomal combustion ccompanied y audible F-55
''pinging" nois€

23 Gaso ne odor in cabin F-57

24 Exhaust as smells ike rotteneggs F-58
25 Highoil consumpnon OilconsumplionrcessNe F-58
26 Fueleconomyunsalislactory F-59

F-l4
 

TROUBLESHOOTINGUIDE F
Doscription ol Drivablllty
STUMBLE : Mib jerkingduringacceleration.
spotoccurringustafter he acceleratoredal depressed
SURGE : Continuousoft erking uringcruise.
03u0Fx 33

ENGINESPEED

WNo.laSURGE
No.17STUMaLE

" """o'on
-12'1no
No.21
RUI{SFOUGHON
OECELEBATION

F-l5
 

F UIDE
TROUBLESHOOTING
PRECAUTION
Fuel PreasureRelease nd ServicingFuel System
Fuelinhefuelsystem emalnsnder ighpressureven
the enoines not runnrno.
a) Beto're rsconnecltngny uel ine, eleasehe fuelpres_
sure om he ue syslemo reducehe possibihtvl niury
or fire.
1.Stan he engine.
2. Removehe rearseatcushlon.
22-30 12.2-3.1 16-22t 3. Disconnecth e uel oumoconnector.
r+m(n-kg, n$) PUMP CONNFCTOB 4. After he engine lalls,urnotf he gnition witch.
5. Reconnectuelpump onnectornd nstalltheear eat
cushron.

b)Usea ragas protectionrom uelspraywhendisconnecf

ino he hoses.
Pluo he hoses tter emoval.
c) When nspectinghe uelsystem, sea suitableuelpres-
sure auge.
Cautlon
. Install hose clamps o secure he tuel pressule
gaugeto he uelfilterand he uelmainhoae o pre'
vent luel leakage,

PinchinoHose
Whenp;ching an air hoseor a fuelhosewithpliers,w rap
the hosewitha rag o prevent amage

F-16
 

UIDE
TFOUBLESHOOTING F
SYMPTOM FOUBLESHOOTING

CAANKSNORMALLY UT WILL {OT STARTiO COMBUSTION}

.Engine ranks t normal peedbutshows o signol "fting
DESCRIP. . Bane.yn normal ondrtion
Ttotl .Throttle alve oi held ullyopenwhiie rankingOechokeyslem ot operale)

ITROUBLESHOOTING INTSI
Becausel no combustDn,ossiblyn o r u e i s n F L l e d o e n g r n . o r o € 1 l i o n a l d r lc / l - d a r '
O No spark €) Low uel inepressure
. lgntion ontrolmalfunction @ Lowens,ne ompressioi
.lgnition sysiemcomponentmafunction @ ECUpower upply rrcuit pen
@ No iuel nlection @ ECUground rcui open
. Fuelpump inopefalive
.Injector noperative
INSPECTTON acTtor,l
l ls svongblue park sibe at disconnecledgh .

PerformSlep 2
/
4 ll OK, check rgnton system
(Refer o lroubleshooiing
''Misfke") (r Page G-17
>. a ff not OK, reler o speciJied heck
/)
seqlence or displayed ode No. F Page F-?0

2 ls 00" displayed n SellDiagnosisChecker

wlth gnilLon wilchON?
ri page F-67
Maltunctloncode No. displayed
Check or cause Beler o specited
check sequenceor displayed ode
No.) 17 Page F-7o
"88" flashes
CheckECU erm nal lF vo ag€ r? page F-114

voltage: Approx. 12v

(lgnillon switch ON)

4 ll OK. replaceECU ri page F-112

+ ll not OK. check wl.ingbelween
ECU and SelfDbgnosisChecker
and ECU erm nal 18 vollage
3 Rer.oveair c eanercoveri s fuei niecled rom Ch€ck ollowng poinls
injeclorwhie crankingengine? .Spark ptugs r page c-19
. tgnjtion mrng E? pag€ F-63
.Engine compressiof c? page B-lO
.Warer thermosensor -r page F-118
1.5-2.0 Nn {15-20 crks,13-17 in-rb) (ECU 20 tem nal vollase)
.Fuel pressure c7 page F-89
(lr njected uel s smallariounl)
.Inlecror 17 page F-97
(li njecled uel s smallamounl)
Check or lnjector perating ound
whllecrankng engrne

+ li OK, So o nexl siep

+ go 6

F-17
 

F UIDE
TROUBLESHOOTING

tNsPECT|Oll
Connect lagnosisonnectore rminals /P.and
GNDwith umper irei s uelpumpoperarng
solnd evidedwilh snilion witchON?
-7 pege F-92
ACTION
Check f iuel is iniecledwhib crankng
englne n this condftion
+ lf injected, heckcircultopening

4 ll not njecred, heck nieclor of

cloggingand if lue is in tank

;)).

GND

5 ls there conllnuily elween Llelpump connecior Check ncuit penrngelay c7 pageF-93

@ and @?

6 ls hercapprox. 2Vmomenlariyt ECU2V er_ Try io replace njector lniectorstuck)

mnaLwhibcranking ngine?
(Engrneignalm onitor reen nd red amps
ilash)

No Check njecloror continuity

+ lf OK,checkwlfinS elatedo
ECU errninalsY,2V,2U,an d
+ ll notOK, epace njeclor

F-l8
 

TROUBLESHOOTINGUIDE F
CRANKSNOF ALLY BUT W|LL r,rOTSTART PART|ALCOtitBUSTtOt{) U,HENEI{G[{E COLD
.Engine t normal p€ed utshows nlyparlial ombustionndwillnotconlinueo run
DESCN|P.. Batlery nranks
nomal condilion
Tt o

rrFouBLEsHooTrilct NTsl
O Air/Fuel ixtureoo rich O Lowensine ompressron
. Waterhermosensoralluncllon
O AidFuelnixtureoo ean
.Fuel nject n controlmallunction
(Corection or coolanl emperature)
.Low iuel inepressure
.An leakage f nlake irsystem
INSPECTION ACTION
1 ls 0O displayed n SellDiagnosis hecker
wlth ignilion switch ON?
MallunctionCodeNo. displayed
Checkor cause Reiero soeciiied
check equence) 17 pageF-m
"88" llashes
CheckECU elmlnal Fvoliage F pageF-114
Voltage:A ppror. 12V
(lgnltlon switch oN)
a ll OK, eplace CIJ c7 pageF-112
4 I nol OK.checkwiring elween
TESTSWiSELFTEST
ECUandS€lf-Diagnosis hecker
?

/\^\_

Checf d sr ouror cdp ard rolor c:i page G-23

/

d\<<=F
=I)'b B\
3 Connect iagnosisonnecrore tminals /Pan d
GNDwilh umperw ne;s lherecorrectuel ine
pressure ith gnition witchON?
e page F-49 Check uel line pressurewhile p nch
Fuel lne prossuae: + ll tuel ine pressurc uickly n-
235-275 kPa (2.4-2.a kg/cm', 34-40 psD creases, heck pressure egulalor
PFFSSUREGAIIGE -: il luel line pressufegradually n.
creases, heck or clogging be -
' l lween uel pump and pressure

lf not clogged, heck uei pump

maxmum pressure e page F-91
High pre$ure
ls lel relurn ose logged r res,
t"" otAGNOStS
lricled?
+ ll OK, eplace ressureegulalor c? pageF-94
CONNECTOF .) ll notOK, epa.or replace

F-19
 

F TROUBLESHOOTINGUIDE

INSPECTION ACTION
AreECU eminalv oltages K?
lEsDeciallvC, 1K,20 and 20)
c7 PageF-112 Check or cause - Page F-114
F-l16

5 ls lhere air leakageol intakeai svstemcom-

6 Does ngine tartswhenwaler hemos€nsors Chbckwater hermosensor !7 page F-121

7 A'e spark plugs OK?

F Page G-19

WEAFANDCAFBON UILDUP

BUBNS

(0.039-0.o4i, No Clean,or rep ace tr- Page G-19

AND
DETERIOFAIION

a ls enoine
  omorcssionorrect? Tryknown oodEcU andcheckaf
s PageB-10

Enoine omDression: ore han 1,030kP a Checkenginecondition .? Page B-10

(t-o.s glcr;'. 149psi)-300 Pm
.wofn pston, pislon ings or cylinder

.Defectivecylinderhead gasket
. Distorled cylindff head
.lmproper valve s€atng
. Valveslickins n Suide

F-20
 

TROUBLESHOOTINGUIDE F
CNANKSNORMALLYBUT WILL OT START PARTIALCO AUSTIOII) AFTERWARM.UP
.Engine ranks t nomalspeed ndshows artial ombustionutwillnotcontinueo runafler Lrnningnd
DESCBIP.
Tt0ll .8attery n normal ondition
. Engne slartsnormallywhencold
rrRouaLEsHooTtNGt{Tsl
O Ar/Fu6l nixture too ch @ Vapof ock
.lnsuftcientuel njectiononlrol .Fuel pressu.e otheld n uel ne afier nsine topped
(Corr€ctn or coolanlemperalue) .Hish RVP winler)u elused n warmweather
.lnjeclor uel eakase
INSPECTION ACTION
1 to normal operaling lempera- Change uel o anolherbrand

Connecl iasnor
;is conneclor erminals /P and
GNDwith ump€r wire ior 3 minrres with ignilion
swilchON, hen
l# JUMPEFwlFE
---t I 64\
Jl l^ @t),x. \ \
,'
,/,1{Q
ts

2 Connect iagnosisonnectore rmlnals/Pan d

GNDwith umperw irei s tuei lnepressureor
r€ct wilh ignitionswilchON?
rr page F-89 Check ueL ine pressurewhile pinch'

235-275 kPa (2.4-2.a kg/cln', 3/t-40 psi) .+ lf luel llne pressure uickly n-
PRESSUFE creases, check presslre reguiator
a prcssure ladually
cr€ases, heck uel ine and filter
for clogging
li not clogged,check uel purnp
FUELFILTEFi maxirnum pressure r7 page F-91
High piossure
.riupin wrne ls uel return ose logged r res

+ li OK, eplace ressureegulator s pageF-94

+ li nol OK, epair r replace

3 ln same ondilion sSlep2, is uel ne pressure Go to Step 5

heldafter gnition witchs urnedOFF?
e p.ge F-88

Fuel llne pressure: Morc than 147 kPa

('1.5 g/cm',2t psi) or 5 min.

Plugoutlei f prcsslre egulator:s uel ne Beplace ressLrre

e gulatof r- pageF-94
pressureeldatlergnilion wilchs urnedOFF?
17 page F-88 Check uel pump hold pressure c7 page F-84
Fuel lno prc3surq More han !47 kPa 4 lf OK, check nlector or fuel
(1.5 kg/cm' 21 psO or 5 min. leakage F page F-96
4 lf nof OK, rcplace iue pump .r page F-92

F-21
 

F UIDE
TROUBLESHOOTING

TNSPECTtOt{ ACTION
Ch€ckwater hermo€ensot c7 gage F-121
5 O:sconnecl ater hermosemor onnectoridoes
+ It OK,checkconn€clions t waler
themosensotnd ECU20
4 ll not OK, feplacewater her
mosensor (j PaSeF-121
No

6 hecker
ls 00" displayedn S€lt_Diagnosis
wnh onition
  switchON?
t7 Page F-'67 Mallunction code l{o. disPlayed
Check or cause Belel o specined
checksequerce) f? Page F_70

"88" llasheg
CheckECU eminal1F vollage c7 pageF-114

vollage:appror, 12v
(lgnltionswitch oN)
4 li OK, eplaceCU !1'PageF-112
+ li nol OK,checkwirng between
ECUandSeli'Diagnosish ecker

7 Are ECU erminal oltag€s K?

(EspecrallvC,20 and 20 )
c7 PageF-i12 Checkor cause - PageF-115
F-l17
F-lt9
ReplaceECU F Page F-l 12
8 Tryknown oodECUand check i condilion

Changeuel o another rand

F-22
 

TROUBLESHOOTING
UIDE F
CRANKSNORMALLYBUT HARDTO START ALWAYS
.Englne cranksal nomal speedbut req'rnesexcessive ranklng lme berore tarling
DESCRIP.. Batlervn norrnaconclition
Ttol{ .Engine unsnomally t ldle ll idlecondllion otOK, efer o "Boughidle" Nos. l2)l
FnoUBLESHOOTtfl HTNTSI
O Air/Fueln ixtureoo ea n @ Air/Fuel nure oo ch
.Fuel njectionontrolmalluncion .Fuel njeclionontrolmalfunclion
(Correclionorcoolanlemperaiurd (Correclionor coolant emperalure)
.Low uel in€pressure .Calbondeposiln hot-wireassaSe
@ Poo' snition pafk
tNSPECTtOl{ ACTIO
ls 00" dsplayedon Selloiagnos'sChecker
wth iqnition wilch oN?
F page F-57 ma[unciion Code {o, dlspl.yed
Check or cause Refero soeciiied
checksequence) ? p.ge F-70
"88" tl.shes
CheckECU ermlnal Fvoltage c7 pageF-114
Vo[.g€: Appror. l2V
(lgnition vritchO )
+ lf OK, replaceECU t:" p.ge F-172
4 ll nol OK,checkwiring elween
ECUandSsll-Diagnosis h eckef

2 ls there a r leakage ol intake air syslem com-

3 s ar cleanerelementclsan?
- page F-62
No Repace irc eaner lemenl

Doesenginesla( easllywhen hrofle valve Ch€ck hrotle valve or carbondepos-

t and hen go to Siep 6

5 ls uel ne prcs$rre ofiecla l idle?

F F-94

Checkuel inepressure hilepinch-

235-275 XPa12.4-2.A kg/cm" 34-40 psD

+ ll fuel lnepfessureuicklyn-
creases,heck ressureegulalor
+ ll fuel lnepressureraduallyn'
creases,heck orclogging e-
lween uel pumpand pressure
ll notclogg€d, h€ck uelpump
maimum prcssurc F page F-91

FUEL FILTER

F-23
 

F TROUBLESHOOTINGUIDE

INSPECTION ACTION
6 ls ar bypasssolenord alve@OX?
r' p.g€ F-104

No Replace olenoid alve

SOLENOID INJECTIONBODY
VALVE@\\\

r)
k!
7 Are ECU erminal oltagesOK? Go o nexl slep
( E s o e c , a l yC , h a n d2 0 )
c? Page F-lOg Cn""f io, "uuse r' PageF-115
F-117
F-l19
Eneckcircultopening elay c7 PageF-93
8 Connect cliagnoss conneclor tetminals F/P and
GND with umperwirei does engrnestan
a ff rclayOK,repairor teplacewi€
+ li r€laynoi OK, repiace elay

9 ConnectSystemS€lectoro diagnosis
i
onnector
and setT€st Switch o SELFTEST is lhere
corecl gnrtionmng €t dle aiterwarm_up?
e PageF-63

lgnilion iming: aTDC16 + 1c

Adjust gntion iminq !? Page F-63

,-JE"

1 0 ls enginecompression orreci?
c7 page B-lo
Checkenglnecondition c? PageB-1o
Englne ompres€lonilinimum): .Wornpislon, Lstonngs r cy noer
1.030 Pa (10.5ksr'cn', r49 Fel)-300Pm
. Delecuveylinder eadgaskei
. Dlsrodedylinder ea d
. lmpropetvalveseating
.valvest ckins n guide

1 1 Try known oodECUI oes ondilionmprove?

F-24
 

TROUBLESHOOTINGUIDE F
CRANKSNORMALLY UTHARO O START WHE E GINECOLD
.Englne crank al nofmal speed but rcquires excossivecranking lime before slarl ng
DESCRIP.. Baltery n nofmal condition
TION . Festarc OK after wam-uo
.Engrne runsno.mallyat idle [f idle cond]tions not OK, r€ter o 'Roughldle' (Nos.8-12)l
rrnouBLEsHoollt{GtNTsl
O Air/Fuel )dureoo rich @A1r/Fuel xiure oo ean
.Fuel njecliononvolm al,unction .Carbon deposlt n hol wire passage
(Correctiono r coolantemperature) . Fu€l nj€ctiononlrolm alfunction
.Thermowax allunclion (Coffeclionor coolant emperalure)
@ Poor tom ation
. LowRVP summer)uelb€rng sed
INSPECTION ACTION
ls "o0 displayedn SellDiagnosish€cker
wlth gnition witchON?
17 page F-67 MalfunctlonCode No, displayed
SELECT: Check or causeFeler 10soeciti€d
checksequencei E? page F-7O
"88" llashes
Check CU erminal Fvoltage c7 pageF-'l 14
Voltage:A pprox.12 V
(lgnition switch ON)
d ll OK, eplace CU rr pageF-112
4 ll notOK,checkwiing betlveen
ECUandSelfDiagnosishecbr

2 Are ECU eminal vollagesOK?

(Especiaiy1C. 2D, and 20)
-:r page F-112 Check or caus€ c7 page F-115
F-117
F-lt9
3 Doesengineslarteasilywhen hrotlle alve Check lhemowar c7 page F-85

4 f OK, go to Srep 5
4 ll nol OK, replace njeclionbody

ls there air leakageol inlakear systemcom'

5 ls arrcleanerelement lean?
cr page F-62
Beplaceair cleanerelement

6 Are sparkplugsOK?
e pageG-19
WEAB NDCAqBONUILOUP
BUFNS

(0.039-0.043 n)
E AND
DETEFIORATION

F-25

F TROUBLESHOOTINGUIDE
ls u6l in€pressureorrect l idle?
t7 Plge F-94
Fuel line pre$uaa:
235-275 kPa (2.4-2.8 kgL/cm"3{-40 p6i)
Iry known oodECU;doesconditionmprove?
F-26
Check uel line pressurewhil€pinch_
ing uel r€lum hose
+ lf fuel inepressurc uicklyn_
creases, heck pressure egulator
+ ll fuel inepres$rre raduallyn_
crcases,h€ck uel ine o. clog_
ging betwe€n uel PUmP nd
pr€€sure egulalor
ll nol clogged, heck u61 umP
maximum ressure c? PageF-91
High prcs3ure
ls tuel rettim hosecloggedor fes
+ ll OK, replacepressure egulator - Page F94
4 ll nol oK, reparor replace os e
Replace CL, c7 PageF-112
Change uel o anotherbrand
 

TROUBLESHOOTINGUIDE F
CRAI{KS {ORI{ALLY zuT HARDTO START - AFTERWABi&UP
.Engine cranksat normalspeedbut requires xcessive ranking me beiorestadingaller runninoand hol
DESCRIP.. Baitery n normalcondition
n0 . Enginestarlsno|mallyvlhencoLd
.Ensine unsnormally l idle ll idle ondltion ol OK, efer o Rough dle" Nos. -12)l
ITBOUALESHOOTING I TSI
Ai/Fud rni(ure oo rich @ Vaporoc k
. Fuel njecton conlrolmalfunclion .Fuel pressufe otheld n luel ineafter ngine lopped
.hieclor luel leakage .HiSh RVP wider) uelused n warmwealher
r{sPEcTtot{ acTrol{
1 ls "00" displayed n S€llDiagnosis hecker
with igniiion switch ON?
NO allunc{lon Code No. dlsplayed
Check or causeSeler to soectied
checks€quence) c7 pag€ F-70
tlashas
CheckECU ermlnal Fvoltage s pag€F-114
Voll.ge Approx.12 V
(lgnition switch oN)
=) lf OK, €place CU E' pag€F-112
+ lf not OK, ch€ck wiringbelween
ECU and SellDiagnosisCh€cker

2 Are ECU erminal oltages K? Go to nextstep

(EspeclallyC,20, and 2T)
c7 PageF-l12 Check or cause F pag€ F-115
F-|17
F-l19
3 Runengine l idlei s uel in6prossures held
after gnilion witchurnedOFF?
.7 p.ge F-88 NO Plugou.tlel f pressure egllalor and
check l Juel inepressures heldafier
Fu€t lne oreaaure: More then 147 kPa ignilion witchurnedOFF
(t.5 kg/cmz, 1 psl) or 5 fiin.
.+ lf OK, replacepressure egulalor 17 page F-94
+ lf nol OK,ch€ck uelpumphold
pressure .7 pago F-88
lf luel pump s OK, ch€ck ntector
lor iuel leak€ge r? page F-96

F-27
 

F TROUALESHOOTINGUIDE

JTEP |l{SPECT|O}l ACNON

Warm-up ngine o normalop€ratng emFera_ Changeuel to anotherbrand
lureand slop l
Connect raonosisonneclorerminals/Pan d
GNDMh iumos wira or 3 minule6 ilh gnition
switchON; do€s f englne$ans easili/?

Go to nexts|ep

Try knowngood ECU;do€s condilion mprcves? Heptace ECU E? l,d,ge F-112

5

NO Change uel o anolherbrand

F-24
 

TBOUBLESHOOTING
UIDE F
a ROUGH DLE/EXGINESTALLSAT IDLE _ ALWAYS
DESCBP- .Engrne sads normalvbul stallsor v,brares xcessvey al idle n everyco']d io n
|
FROUALESHOOTTNG t itTSl
O Air/Fuel ixlureoo ean rn r^^^-4r iira clEAd
. ldlespeedmisadiust'nent
. Fuel njeciiononlrolmalluncUon @ Oneor more park lugs ol irlng
.Low luel inepressure O Lowengine ompression
@ Low ntake ir amount @ Carbon epositn injecton ody
INSPECTION ACTION
1 ls "0O drsplayedn SeJi-Diagnosis
hecker
wilh ignitionswltchON?
Mallunclion Code No. dlsplayed
Check or caus€ Rete. o soecilied
checksequence) .? page F-70

"8a" tlaEhes
CheckECI.Jerminal F voltag€ c? pageF-114
Voltage Appro!. 12v
(lgnltion€wltchO )
+ ll OK, eplace CU o p.ge F-112
+ ll nol OK,checkwlring etw€en
ECUandSellD iagnosisheck€r
2 AreECU eminal oltages K?
(Esp€ciallyK,2M,20 and20 )
-r pageF-112 Checkorcause F pageF-115
F-117
F-l19
3 D is co nn €€ l ac h h ig ht en si on ea d al idlei does Go to Step 5
enginespeed decrease quallyat each cylinde?

ls slrongblue spark visibleat disconnected igh-

Ch€ckhrghlensionead F psge G-23

+ ll OK, checkdistrbuto. cap and

/ rotor c7 p.ge G-23
+ It nol OK, replacehighlenson

5 Arcspark lugsOK ? Check of corect engine ompression rt'page 8-10

c7 pageG-19
WE1AF ND CARBONBUTLDUP + lf OK, replace injeclor c? Page F-96
+ lf not OK, check or cause F psge B-10
AURNS

(0.039-0.0,*l
Cean or replace F page G-19
DETERIOFAIION

F-29
 

F UIDE
TROUBLESHOOTING

STEP INSPECTION ACTION

6 Connect S yslemSel
ector o diagnoss onn€ctor
to 'SELF'IEST"| is coffecl
ri at idle aiterwalm up?
ignitioniming orrer
.7 page F-62

lgnition lming:BI 16

.- /fEN Adtust gniton timing 17 Page F_52

t ,
GNo
-tfi" //

INOICATOF / D l.r9*
7 ls uel ne oressureorrccla l idle?
c7 Page F-94

Fuel ine pressure: Check uel ine ptessurewhileprnch_

235-275 kPa 12.4-2.A rg/ctn', 34-40 psi)
{vacuum hos€ to pte*3ure regulstor dls-
connected) ., .ih, (\ + ll fuel ine pressure uickly n_
""'*Y"'-94u9:-lwlllK;/ )
creases, heck Pres$re regulalor
+ I fuel ine prcssll|esradually n_
-\-,aJ.6V.]Ly.V / creases, heck or cloggingbe
tween ue punrp and pressure
regulatot
It not clogged, heck uel PUmP
maximum pressure I Page F-91

FUET IITEF
I ls thero an bakage ai intake air syslem com

9 o rrecl?
ls eno ne cornpression Tryknown oodECUanddoes on
e paEeB-10

Ensinecompressionr !nimum): Check or cause F Page B-lO

t,o3o tPa Oo.5 kg/cm'. 149Psi)-300Pm

F-30
 

TROUBLESHOOTINGUIDE F
9 ROUGHDLE./EI{GINETALLSAT IDLE_ BEFORE ARM.UP
OESCRIP-.Engine peed owor engine talls r vibrates xcessvelyl idledurlngwarm_up
Ttolt l
frRouBLESHOOT|i,rGTNTSI
O Lowntake r amount O Low fue njectiof control
.Carbon deposil n injection ody .Fuel njection ontrolmaifunclion
.Aif cleanerelement ogged (Coiiectionor coolanl emperalure)
. Thefiowax unil sluck @ Poor alornization
.Low BvP (summe0 uel used n cold wealher
INSPECTION ACTION
1 ls "00 ' displayed n SelfDiagnosisChecker
wilh igniton switchON?
F page F-67 Malfunction Code No. displayed
Check or cause Feler o specilied
check sequence) r? Page F-70

"68"
CheckECU €ffninal F voltage (7 gage F-114

Voltage:A pprox.12 v
(lgnition witchON)
+ l f O K , e p l a c eCU rpageF-ll2
€. It nor OK,checkwkins belween
TESTSW:SELFTESI ECUandSe -O gnosis hecker

2 ls therear leakageo{ intakeair syslemcom-

3 ls air cleanerelemeniclean?
17 page F-62
Aeplaceaircleanerelement

Are ECU elm nal voltagesOK?

(EspecialyK, 2M, 20, 2T and 20)
r. page F-112 Check or cause F Page F-115
F-117
F-119
5 rs a r bypasssoenold valve @ OK?
r? page F-!09

a i

:
Beplacesoenoidvaive r7 Page F-109

SOLENOID INJECTIONBOOY
varvE(A\\'
r)
o' ,(4)

F-31
 

F TROUBLESHOOTINGUIDE

ls water hermosensoresslancecorrec?

Beplacewater hemosensor r- page F-121

ConneclSyslemSeleclor o dlagnosis onneclor

'SELFTEST when en_
and set Test Swtch o
gine s cod
Does enqinespeed decr€aseas engrnewarms

Reolacenieclion odv F Page F-84

ConnectSystemSeector o diagnos connector

"SELF TEST
and sel Tesi Swllch o
ls rqnlron rmng corect al tdb aner warm up t
ci page F-62

lgnilion tlming: BTDG 16 * 1"

Adjust€ntion limlng G Page F-62

GN D

NDICATOFI TESTSW

Try known good ECU; does conditon mproves? G oaae F-112

Change ue to anoiherbland

F-32
 

TROUBLESHOOTING
UIDE F
10 ROUGHDLE/ENGINETALLSAT IDLE AFTERWARII.UP
DESCRIP. .Engine unsnormally l idleduringwam-upbutengine talls r vibrales xcessivelyflerwarm-up
TION
ITROUaLESHOOTTNG INTSI
O) dlespeed ontror vslemmallunction @ ArlFuelm i(ure oonch
@ Air/Fuel ixtureoo ean .Fuel njecl n controlmal,unclion
(Corection or coolanl emperature)
.Low fuel inepressure @ Poor gnilion
. PCVvatvestuck open) O Lowengine ompress
INSPECT|oiT ACTION
1 ls 00" displayed n Self-Diagnosishecker
with ignilionswitchON?
e page F-67 llalluncfion Code ilo. displ.yed
Check or causeGeler lo so€cilied
ch€cksequence) (? page F-m

"8a" tlashes
CheckECU ermina F vollage c7 page F-114
Volreg€: Approx. r2V
(lgnition switch ON)
+ li OK, eplace CU rz pageF-112
+ ll noiOK,checkwiringbolween
ECUandSellDiasnosishecker

2 Are ECU erminalvoltagesOK?

(EspeciallyK,2M, 20 and 20)
F page F-112 Checkor caus€ c7 pageF-115
F-117
F-r9
3 Disconnect ighlension ead at dle; does en-
glne speed d€crease quallyal al cylinders?
Go to Slep 10

ls ihere air leakageol intakearrsystem om-

5 ls air cleanerelement l€an?

e page F-62
No R€placealr cleanerelement

6 lurn thronleadjuslingscrewc, Adjust idle speed .? page F-62

does dlecondilionmprove?
AIFFLOW SENSOR

-ffiqf l";;I
No Relurn hrottleadiuslingscrew o its
original ositlon,nd go to next lep
=.\\\ /

F-33
 

F UIDE
TROUBLESHOOTING

INSPECTION ACTION
7 ls fuel ine pressure otrect at idle?
c? Page F-94

Frel lih6 pr$sure: Checkuel inepressure hilepinch_

235-275 kPa (2.4-2.A kg/cmz, 34-40 p3l)
+ ll fuel inepressureuickly n.
creas€s,heckpressureegulator
+ ll iuel inepressure€dually n-
creas€s,heck or clogging e_
tween uel pumpand pr€ssure
lf notclogged, heck uel pump
maximumprsssure E7 Page F-91

I Connect ystem elector o diagnoss onnector Go to nexl step

"SELFTEST
and setTestSwitch o
ls ignitioniming orrect t idlealt€rwarm_up?
(7 gage F-€2
No Adjusl gnrtion ystem r' Pag€ F-62
lgnition lmlng: BIDC 16 + 1'

9 Disconnectwater hermosensor onneclor Replacewat€r hermosensor

Does nglne onditionmprcve?
No Tryknown oodECUandcheck l

1 0 ls enoine
  omoressionorrecP
.7 page 8-10

Engine ompressionllhlmum): Checkengine r? Page &-10

I,O3O Pa 10.5kgL/cm', 49 psl)-3lx)pm

11 ls slrong blue spa visibleal each d sconnecled

hgh'tension ead?

c-----,-- \-\

<72oNl # Check high'tension lead

4 lJ OK, checkdislrlbulor ap and

rotor
.7 page e-23

F page G-23
/ + ll not OK, replacehigh ensron

/
12 Arespark lugsOK ? Try knowngood ECU and check
s pagoG-19
WEAF NOCAFiBONUILDUP
BUANS

(0.039-o.043 NO

DETEBIOBATION

F-34
 

TROUBLESHOOTING
UIDE F
' tl ROUGII DLE/E GI E STALLSAT IDLE - WHEI{A./C.P/S, EIL OI{
.Engine talls r vibrates xcessivelyt dlewhenP/Sor E/LON
DESCRIP..AJC, P/S,headlights, lower an and e{eciric ooling an opelale normally
Ttol{ .ldle condilions normal hen ,/C.P/SandE/LareOF F
rrRoualEsHooTtitcHtNTsl
O tdle spe€d control svslem malluncljon
;TEP INSPECTION ACTION
ls 'OO dlsplayedn SeliDiagnosishecker
wilh ignitionswilchON?
F page F-€7 ll.ltuncllon Code {o. displayod
SYSTEMSELECII I Check or caus€ Refer o soecilied
check sequenc€) rr p.ge F-m

"88" llasha6
CheckECU erminal F voltage c? page F-ll4
Vollage: Apprcx. l2V
0gnlrbn switch Ol{)
.' li OK, eplace CU e pageF-112
+ ll notOK, checkwiring belween
ECUandSelf-Diagnosis heck€r
2 UsingSellD iagnosis h€cke.M onitor ampiare
switchesOK with gnilionswitchON?
F pege F-80 NO Lamp nol ON or OFF wllh specl-
fied swatch
Check or causeFefer lo sDecif d
check sequence) tr7 P.ge F-81

k@tl
F-82

L.mp alwaF ON
Checkwringbeh{een CU emina
1D andSellDiagoosisheck€r

3 ls air bypasssolenoid alveOK? Adjust dleup enginespeed s page F-64

. A/C.....Solenoidalve @ rr prge F-109
. E/L.....Solenoidalve@ c7 p.te F109
. P/S.....Solenold.lve @ r? pageF-109

NO Replace solenoid valve

AtR AYPASSSOL.V.
rf .4
./ (o F
//-!hV
q"l' ,&
AIF BYPASSSOL.V, @
l t l '

F-35
 

F TROUBLESHOOTINGUIDE

l2 NOUGH DLE,/ENGIIIE TALLSJUST AFTEBSTATIING

DESC-RtP-.Enstr€ stansnormallybut vibratesexcessively r slalls 0st atler starting acceleralionlom idle)
Trotl .ldle conditons r€ normaln olher onditons
TTBoUBLESHOOTINGll{TSl
O Air/Fuel l{ure oo ean Throltlesensormailur'ction

.Fuel njeclionontrolmalfunction
. Low uel inepressure
}TE' tNSPECT|OI{ ACTION
ls OO"displayed n Self-Diagnoss hecker
with -onition wilch ON?
c? page F-67 No lr.ltunctlon Code No. d|sPlayed
Check or cause Refer o specilied
SYSTEM ELECT: checks€ouence) c7 PzEeF-7O

"88" tlash€5
CheckECU erminalF vollage ca p.go F-114

Volt.ge: Approx.12 v
(lgnitlon 3witch ON)
+ It OK, edaceECU c? PageF-112
+ ll nol OK,checkwirlng etween
ECUandS€lf-Diagnosis hecker
2 ls thereair leakage f intak€air systemcom_

No

3 ls uel ne prescureonectal idle?

e page F-94

Checi or uel ne pressure hile

295-275 kPa 12.4-2.a kg,fcmu, l-40 psl) pinchinguel elumhose
+ ll fuel inepressu.euicklyn_
creases, heckpressure egulaior
+ ll fuel inepressurcraduallyn-
creases, h€ck or cLogging e
Meen luel pumpand pressure
r€gulator
lf not clogged, heck uel PumP
maxmum p€ssure .? PageF-91
Hlgh pre33t|re
ls fuel ine clogged?
+ ll OK, replacepressure egulalor rj' PageF-S4
+ lf notOK, cplace
ConnectSyslemSeleclor o dlagnosi In same ondilions StsP in_
and set Test Switch o 'SELFTEST" specIon
ls ignltioniming orrecl l idleaiter Check o' conecl dle speed .? pag€ F-63
go F--{ 3
ldle speed: 750 'l rPtn (tilTx)
1,t00 1lpm (ATX)

,TEN
4 ll OK, go io nexl step
+ ll not OK,adjust dle speed 17 page F-63
f: :
GND (

\tg-aL l
NOICATOFI ]/ TES
6

F-36
 

TROUBLESHOOTINGUIDE F
STEP utsPEcTtoN ACTION
5 Are ECU erminalvoltagesOK? Go lo neil step
(Especially8, 2M, 20, and2Q )

Nole
When ch€cking voltagss, tap, moye, and
wlgglo harmss and connector to recreate

6 Arc spark lugsOK?

WEAF NDCAFBONUILDUP

EUBNS

{0_03$-0.043

OETEFIIOFATION

7 ls engine o mpressionorrec? Try knowngood ECU and check l

F page E-10
Englne ompressionMinimum): NO Checkengine c7 page B-lO
1,030kPa 10.5kg/cm', 1as psl)-3oo rpm

F-37
 

F TROUBLESHOOTINGUIDE

HIGH OLESPEEDAFTENWANM"UP
.ldle spe€dexcessive lter warm_up

ITROUBLESIIOOTING I TSI
EicssJve nlaks n supph€do engne
O Throttlevalvenol lully clos€d
ldle spe€dcodrol mallunction
.Thermowax alfuncton . 1,./C,P/Sor E/L sgnai senl o ECU
.Air bypass olenoidalveON al idle

ls lhfotle valve ullyclosedwhenaccelerator

ls lhrottle inkage orrcc{y nstalled

+ lf OK,go o Slep2
ll nol adjustor replace
linkage

o€s ast idle cam release throttle levs? Adjust dlesp€edby iumins throtlle
!7 page F_63

ls "oo" displayedon SellDiagnosrsChecker

with onition
  switchON?
-7 paq'eF-67 lltaltunction code tlo. dlspl.yed
Check or cause Beier o sp€cilied
check sequence) t- Pzge F-7O

"a8" llashe3
CheckECU erminal Fvoltage e pageF-114

- AoDrox. 2v
voltaoe
0initlon switch oN)
+ ff OK, eplace CU (? P.ge F-112
+ lf not OK,checkwiing belween
ECUand Selt-Diagnocishecker

Are ECU1P, R, 15, 1T, U, 2[,'1, Q,2R,an d Adjust dla speedby lurning hrot s
2T lerminalvoltagesOK? '
r'. Pagc F-63
_7 pag. F-115
Chech or cause
F-117
F-l19

F-38
 

TROUBLESHOOTING
U IDE F
t4 IDLEMOVES PAI{ODOWN/IDLEUNN G
DESCRIP. .Engine spesdsup and down periodically l idle
TroN I
rNrsr
5X?u68j*:SoorNG
@ Throfle sensormisadjusted
@ Fuel njectionmounln constant
@ Poor gnition
STEP INSPECTION acrtot{
1 ls rherea r leakaoear intakeair svstem? Repajror replace eak€gepoinl

2 ls PCV valve OK?

cz page F-99
NO

3 ls arrcl€aner lemenl lean?

4 Disconnecl ighlension ead at idle does en

gine speed decrease quallyal each cylinder?
No Go1ostep9

5 ls '00 displayedn SefDlagnosis hecker

wlh ignirion wtchoN?
e page F-57 NO Maltunction odeNo. d|spl.ye.d
Checkor cause Relero speciied
checksequence) cr PageF-m

"84" flashes
CheckECU€rminalF voltage 17 PageF-114
vohage:Approx.12 v
(lgnitionswilch ON)
+ lt OK, eplace CU F pageF-112
TESi SWi SELF TEST + ll nolOK,checkwins b€tween
ECUandSell-Diagnosis h ecker
6 Connecl yslem elecloro diagnosisonnector Tryknown oodEC
and setTeslSwilch " SELF EST'

F-39
 

F TROUBLESHOOTINGUIDE

ConneclSystemSetecloro diagnosis onn€cior

"SELFTEST
and set TestSwitch o
ls roftton rmrno otted at Ldle tterwarm p?
7 P.ge F-62
BTDC 6 + 1 .

Adjustgnitionming e PageFl2

tNDtcAToB--l \,,1S\ \|!/ TEsr sw

AreECU eminalvollages K?
lEsoeciallv
  [/)
e PagoF-lla CtrecXor e F-119

ls strongblue sparkvisibleat €ach disconnected

high'tensionead?_
:"''-t'
,-t'.--
_1-(_(d Check high-tensionead
+ ll OK, check dislribulor ap and

e fi not OK, replacehigh'tension

Ar€sparkplugsOK? Checkor correct ngine onrpression? pageB-10

p 17 page G-19
CompressionMinimum): ,030kP a
BUFNS (t0.5 kg/dn', 1r9 Psi)-300Pm

n)
(0.039--o.043 4 lf OK, go to nexi step
+ tJnotOK,check or cause c7 pag€A-10

Try known good ECU and check l condition

F-40
 

TROUBLESHOOTINGUIDE F
15 ENGII{ESTALLS ON OECELERATION
DESCATP-.Engineunexpectedlyt ops unning h e deceleralingr aJter ecelerallon
Tro . ldlecondition or,ral
rrRouBLEsHooTtNG|NTSI
r poor onnecloro nnection
Enginepeed ropsoomuchwheneleasingccelerator y deceleralion
s connected
O Dashpormisadjusted @ ldlespeedmisadjustment
@ Fuel ut controlmallunclion
INSPECTION ACTION
ls rdleconditon normal?

Adjustor perlorm roubleshoot g

Nos.8-11 RoUGH DLE" ,- pag"
l-?9
ls dashpoi correclly adjustecl?
13 p.ge F-104

Dashpol set speed: 2,500 + 1O0 rpm

3 |s "00" dlspLayedn SeliD iagnosis hecker
with gnltionswitchON?
sYsTEM ELECT:1 r:' pageF-67 Mallunclion Code No. dlsplayed
Check or cause Befero sDecified
checksequence) rj page F-7o
"88" tlashes
CheckECU eminal1Fvollage u pageF-111
Voltage:A pprox. 2V
(bnirion switchoN)
+ lr OK, eplace CU F pageF-112
+ ll nol OK,checkwring between
ECUandSe 'Diagnosishecker
Are air bypass sojenoid valves OK?

SOLENOI
voLut
-@-ll

5 AreECU erminaloliages K?
( E s p e c i a l yB , 2 l V , 2 0 n d \ 4
G pageF-112 Checklor cause - page F-115
F-117
F-l19
6 ls herepoorconnectiont eilher l lollowing?
. lgnilion oil
. lsniter
. Dislribulor
Try known good EC U
Doescondilion mproves?
. C rcuitopeningelay
. ECU

F-41
 

F TROUBLESHOOTINGUIDE

t6 E GDTE TALLSSUDDE LY (INTERT|TTENT}

0EscnlP. .EngrnentermitenUylops unning
Ttoil .Belorestallinq,nsrne ondition K
TTROUBLESHOOTIH INTSI
O it'frtrnitt""tv "" "p"tl "t no luel Iniection ausedby vehiclevibration, ccelefaijon, r cleceloralion
.Poor conn€ctonn wiing harness
3TE tlrsPEcTtoN ACTION
ls "m" displayedn Self-Diagnossh €cker
wilh ionition
  switchON?
r? page F-.67 NO Maltunction Cod€ No. d|3played
Check or caus€ Refef o sp€cified
checksequence) F Pagd F-70

Note
.When checklngwiainghamcssand conneclol3,
tao. mov6, and wiggle guaFcl 3enaorand/or h.r'
ndsg to r€cGale
"88" ll6ah€3
CheckECU erminal Fvoltage x7 p.ge F_114

Voltag€: App.ox. 12V

0gnition swilch ON)
TESTSW;SEIF TEST 4 lf OK, eplace CU c7 P3€eF-112
+ li not OK, ch€ckwiringbetween
tCU andSellDrag.osEhecklt
2 ls lhere poor connection t eilhel of lollowing?
. lgnition oil
. Distribdor
. High-tensionead
. Ckcuit penins elay
. ECU
3 AreECU emina, oltages K? o. 2
Go o Troubleshootjng
"CBANKSNOBMALLYUTWILL
{ E s p e c i a l l8y, 1 G ,1 1 , 2 A , 2 4 , 2 C , 2 En d2 \ i )
.7 pegeF-112 NOTSTARTNOCOIVBUSTION) ? p.ge F-17

Note No Check lor cause c7 Pag€ F-115

.when checklng volteg€, lap, move, and F-117
wlggle halne3s and conneclor to recneate F-l19

F-42
 

TROUBLESHOOTINGUIDE F
17 HESITATESFTUIIBLESON ACCELERATION
DESCND. .Flat spotoccursug ater acceleratorepressedr mrld erlingoccurs uring c.deraon
TION
ITROUBLESHOOTTHt]{TSl
O Air/Fuel xlureoecom€sean nen dep.e€srngccelerator
.Fuel injeclloncontrolmalfunction Corection or accelerating ondition)
.Fuel line pressure €creases
.Sparkadvance onlfolm alfunclion
INSPECTION ACTION
1 ls "00" display€dn SellDiagnosishecker
wilh gnilion iwilch N?
I.ltuncllon Code l{o, dhplay€d
Check or cause Refer osoec'lied
checksequerce) o page F-70
"88" fl.3hes
CheckECU erminal page

Vollag€: Approx, 12V

(lgnitlon sw[ch ON]
.> lf OK, cplace CU ri pegeF-112
.+ lf not OK,checkwiing between
ECIJand Self-Diagnosishecker
2 ls thereair leakageat iniakeair sygemcom-

3 ls a rr l ea ne r ls me nt l€ an ? Go to nen siep
tr- p.ge F-62
Replace ircleaner lemenl

4 Arc ECU €rminal K, 2M, 20 and 20 voltages Go lo nexl step

OK?
.? p.ge F-l12 No Ch€ckor cause c7 psge F-1r5
F-117
F-lt9
5 ls lhrotlle inl€ge coreclly inslalled nd does
thrcttle valve open frcel',
Cl€anor replaceas requiredany
binding r damagedinkage ndad -
lust cabl€ dell€ction l inieclionbody e pag€ F-86
6 ls uel inepressureorrect t dle? Does trel lnepressureecrease
.? p.ge F-94 whenaccelerutingu lcklf
Fuel ine preasure .+ li decreases,heck uel lineand
235-275 kPa (2.4-2.8 tg/cm', 3'F/1() psD liltef or clogging
4 lf no decrease, o to next slep

Check uel inepressure hle pinch-

+ lf luel inepressufeuicklyG
creases, heck pres$ireregulator
+ 11lueli nepressureraduallyn'
creases, heck or cloggingbe
tlve€n uel pump and pressurc
r€gulatot
uel pump
maximurn ressure 17 page F-91

F-43
 

F TROUBLESHOOTINGUIDE

t sPEcTto acfloll
7 ConnectSysternSeleclor o diagnosis onnector Does gnltionmingadvance he n
and set T€stSwilch o 'SELF TEST" accelerating?
ls ignition iming conect at idle alt€r warm_up?
ri' p.ge F--62 + ll advances, o lo ne)dstep
+ ll not advan6, replaceECU s pag€ F-112
lgnnlon lmlng: BTOC16 + l"

NO

INDICATOR

8 Are arrductand air hoses orrectlynstalled? Go to nexl step

NO R€pair

9 ls exhaust ystem est cted?

(t p.ge F-1t7
NO

1 0 Try knowngood ECUand ch€ck f conditEn

F-44
 

TROUBLESHOOTINGUIDE F
ta SUFGESWHILECRUISING
DESCRIP.. Unexpecled hanSe n enginespeedwnich s usually epetitive
TION
TIROUaLESHOOTTNGTNTSI
O Air/Fuelmixture oo ean
@ Misfirc
@ Poor onnectionn wiringharness
STEP tNSPECT|Ot{ ACTION
ls '0O displayed n SellDiagnosChecker Go 10nextslep
wth ignition wltchON?
c? page F-€? No Malluncllon Code No. displ.yed
Check or cause Beler o soecilied
ch€cks€quenc€) !? page F-70
"88" llashes
CheckECU elminal 1F voltage e p.ge F-114

Vo[age: Approx. l2V

(lgnilion sMtch ON)

+ lf OK, replaceECU r? page F-112

+ lf not OK, check wirins benxeen
ECU and Self-Diagnosishecker

2 ls throttle eosorOK? Go ro ne( step

s D4ge F-122
NO

3 Disconnect xyg€nsensor onnector;does con' Checkoxygensensor (? eage F-123

OXYGEN ENSOR ONNEC] Ft

Are ECU erminalvoltagesOK?

t- page F-112
Checkor cause .7 pegeF-115
F-117
F-It9
5 ls lh.ottle inkagecofrecly installed nd does
thronde valve open op€raies lrcely?
Corfecl, lean, r replace s requircd
anybinding r damagedinkage, nd
adiuslcalte dellectionat injeclion
body F page F-{6

6 ls hereair eakage i inlak€ rrsystem om-

7 ls arrcleanerelement lean?
o page F-62
Beplace ircl€aner lemenl

F-45
 

F TROUBLESHOOTINGUIDE

SIEF INSPECTION ACTION

a Conn€ctSyslemSelector o diagnosis onnector Does gnition timing advance \,rten
and sel Tesl Swltch o "SELFTEST"
ls Lgnll|onmrng orredat rdle tlerwam up?
.j pagc F-42 4 lf advances, go lo na)d step
+ tf not advance, replace ECU rr p.g. F-112
lgnitlon iming: BTDC16 + r'

INDICATOF

9 ls uel inepressureorrect l dle? Does uel ine pressuledecrease

E7 page F44 whenaccaleatingquickly?
+ tf decreases, heck or tuel pump
zgs-zzi xpa (z.t-z.a *g,fcm', 34-iu) p6i) maximum ressure !? PagGF-91
li OK, check uel ineand ilter for
cbggrng
4 li no decrease, o to n€xtslep

CheckueLineprsssurc y pinchang

+ ll iuel ineprcssureulcklyn-
creases, h€ckpressufa egulalor
+ lf luel line pressureSraduallyn
creases, heck or cloggingbe
lween uel pump and pressure
rcgu|alol
li not clogged, heck uelpump
maximum ressure c7 P.go F-91
High prcas0ae
Check t tuel ret'rrn ine s clogged
4 ll OK, repiacepressureegulalor e Pag. F-94
+ ll not OK, replace
or poor connection f lollowingparts
. lgnitef
. Distribuor
. Hish ensionea d
. Crrcuit pening elay
. ECU
t Try knowngood EcU and ch€ck l

F-46
 

TROUBLESHOOTING
UIDE F
19 LACK OF POWER
.Perforrnanceoorunder oadwhen hrotlle alvewideopen
DESCBIP- .
Ttot{ Beducedm aximum peed
.ldle condilion omal
TTROUBLESHOOTING INTSI
O Faclors ther hanenqrnem;runcrion @ Air/Fuel lxtureoo ean
.Cturch tipping .Fuel inepressureecreases
.ATX stipping . Fuel njection altunclion
.Brakedragging @ Poor gniton
.Low rre prcssure @ Lowengine ompresson
.Incorrect re size @ Alcohobended uelused
@ Low ntake iramount
.Throttle alve ol open ully
.Clogged ntake k system
STEP INSPECTION ACTION
l Check aclorsother han engine
. c urch slipping l? page H-3
. ATX slpprng .? page K-10
. Blake dragging c7 page P- 5 NO
. Low tire pressure F page O- 2

2 ls throltlevalve ully openedwhen acceleralor

s acceleralor cab/e correctly insl,alled r' page F-86

4 ll oK, check hroltlevalve

4 ll nol OK, install cceleralor able
corecty r? page F-86
3 ls 00 dlsplayed
wilh gnitionswitch
Mallunclion Code tlo. displayed
Check Refer
check sequence) E7 page F-70

"88" llashes
CheckECU ermnal F voltage - page F-114

Voltag€: Appror. 12V

(lgniiion swiich ON)

4 lf OK, replace ECU r:7 page F-112

€ li no OK, check wiring betw€en
TESI SW'SELFTEST ECU and S€fDiagnos Checker
SETECTSW: A
ConnectSyslemSelectoro diagnosrs onnl Check I lgnilion imingadvances
and set Tesl Switch lo SELF TEST
ls gnition ming corecl at dle afterwarm-!p?
- page F_ 62 4 ll advances, o !o next step
a li nol advance, heck ECU emi
lgnition laming: BTDC 16 * 1. nalvoliages r? page F112
t\ k\\o\\\t\\t
\\.- \ \\-*rtriff
\ - '"

\NN
-'fi"
l.

cNo ( o d

INOICATOF :: \S) a(r/ TES

l
5 A.e ECU eminalvoltages K?
( E s p e c i a l yK , 2 M , 2 K , n d2 5 )
l? pageF-112 Check or cause r:, page F-115
F-117
F-l19

F-47
 

F UIDE
TROUBLESHOOTING

;TEP INSPECTION acTtor,l

6 ls there air eakageoi intakeair systemcom_

ls air cleanerelemenlclean?
s page F-62
Beplacear cleanerelemenl

8 ls luel ine pressure orect at idle? Does ue Ine pressure ecrease

c7 pag€ F-94 when accelef nng quickly
+ li decrcases, heck uel pump
zgs-zzi rpa (z.l-z.a rg/cm' 34-40 psD maxlmum ressure 17 Page F-91
ll OK check uel ine and filtef or
cloggrng
+ ll not decr€ase, So to ne)d slep

Checkuel inepressure hilepinch

+ ll fuel inepfessurc uickly n

creases, heck pressure egulalor
+ lf luel inepressureraduallyn'
creases,heck or clogging e
iween pumpandpressure

lf notcLogged,heck uel pump

maximum ressure F PageF-91
Hlgh prcssure
Check f uel eturn ine s clogged
+ ll oK, replace ressureegllalor t7 pageF-95
4 li notOK, eplace
I Bemoveair cleaneri s there any carbon depost Clean
or drn In njecton bo4,r/' { -l - \ - i -
r t

No

1 0 Are spa.k plugs OK?

17 page G-19

WEAFANDCAFBON UILDUP

AURNS

(0.039 0.044|in)

DETERIOBATION

F-48
 

TROUBLESHOOTINGUIOE F
INSPECTION acTtofl
?l ls resistancel igntion oilOK?
c7 page c-20
Resi6tanceet 20.C 168oFl):
Primary oil winding........ .58--"0.a49
Secondary oil whding.... 9.6-14.4 ko

SECONDAFIY OI L

'12 ls engine ompfessono(ect?

c? pageB-10
No Checkenginecondition t? page B-'10
Engine clmpresslon: .Worn piston,pislon lngsor cylinder
1,030kPa 10.5kg/cm' 149psl}-300 pm
. Deteclrve yiinderhead gaskel
. Distorted cylinder head
.hproper valveseatng
.Valve stickinSn guide

1 3 Change uel; does condition mproves? Change uel o anotherbrand

Try known good ECU and see l driv'

F-49
 

F UIDE
TROUBLESHOOTING

20 POORACCELEFATION
DESCRIP- . Pe''omance poor whle acceleratng
Tlolil | .ldle condilionnomd
FROUBLESHOOTING lllTSl
O Factors lher hanenginemalfrJnction @ An/Fuel ixtureoo ean
.Clutchslipping . Fuel inepressureecreas€s
.ATX stippinS . Fuel njection alf ncl|on
. Brake raggrng @ Poor gnilion
.LOW rc pressufe @ Low ensinecompreseon
.lncoffednresze @Alcohol lendeduelus€d

@ Low ntake if amount

.Throltle alvenotopen ully
.Clogginsn intake rrsystem
INSPECTION ACTION
'I check actoG ther hanenorne
. Clutch lippins e P.ge H-3
. Brakedrassins G page P-5
. Low te pressurc s Pageo-2
. lncor€ct tirc sze 3 Page O-2
. ATX lipplng -F pageK-10
2 Does hrottlevalve ully openwtrencleprcssng Go to n€)dstep
No Check il accelefator cable ls coreclly
ndaled F page F-86

r+ lf oK, check hrotlle alve

+ li nol OK, install accelerator cable
conecily t7 Page F-E6
3 is '00' displayed n Self-Diagnosishecker Go o nexlstep
with gnition witchON?
!7 Page F-67 llallunctlon Code {o. dlsPlayed
SYS'IEM ELEcTi Cheokor cause Retero specifed
checksequence) e PageF-70

"88" llash€s
CheckECIJ erminal1F voltage t7 page F-114

voltage Appror. 12v

(bnirion swilch ON)

4 ll OK, replaceECU -Page F-112

4 ll nol OK, check winnSbelween
TESTSwi SELFTEST ECU and Sell-Dlagnosishecker

ConnectSystemSelectoro dlagnosis onn€ctor Does gnition iming advancewhen

and setTest Swilch o SELFTEST
ls ignltonimlng orrecl l ldlealterwarm_up?
!? Page F-62 + It advances, go to nexl st€P
+ ll not advance, heckECU ermi'
lgnltion iming: ETDC16 + l' nal voltages tr7 Page F-112
\\\ <\\.-\\ \\.igA'f
\to\\\l\tll -'
\ -"-

\M
"fi"
INOICATOF--/

5 AreECU ermlnal oltages K?

{Especially M) tr7 Pago F 112
'Check t7 Page F-115
Jorcause
F-l17
F-lt9

F-50
 

TROUBLESHOOTINGUIDE F
STEP ITSPECTION ACTION
6 is lhere alr leakageal inlakear systemcom-

7 ls hereanycarbon eposit r did n injection Clean

8 ls ue linepressureofiectat dle? Check ' luel inepressureecreases

c7 page F-94 whenaccel€ralg qulckly
+ ll decrease,heckuel pump
235-275 kPa 12.4-2.a kg/cmz, 34-40 psi) rnaxmurn ressure c? pageF-91
ll OK,ch€ck lel lineand iter or
clogg g
..) ll noldecrease,o o nexlstep

Check or luel line pressurewhle

pinchlng uel returnhose

4 lf luel ine prcs$re quickly n-

creases, check pressure r€gu alor
4 lf luel ine pressrfegradually n-
creases, heck or cloggingbe
tween uel pump and Pressure

ll nol clogged,check 'rei pump

ma-ximum .essure c7 Page F-91
Hagh ressure
Check l tuel lnes clogged
+ ll OK rcplace ressureegu lor s pageF-95
4 ll notOK, eplace
I Ar€ spark plugs OK?
-. page c_lg

WEAFAND CAFIBON UILDUP

EUFNS

{0.039-O.0,*t

OETEFIOFATION

F-51
 

F UIDE
TROUBLESHOOTING

t sPEcflot{ ACTION
1( Changeuel and check f acc€leralionmproves Change luel !o another brand

Go 10 nexlstep

11 Chock or corr€ctenginecomprcssion Tfy known good ECU and check il

e PageB-10 enginecondltion mproves

Engine ompr$3lon (ulnimum): NO Check ngne ondition 17 Pagea-10

1.030kP. (t0.5 kgL/cm', 49 p3lF30Opn .Wornpiston, isloo ings r cvlinder
.Defectivecylinderheadgasket
. Di$onedc''linderhead
.lmpropet alve eatmg
.valve stickingn guide

F-52
 

TFOUBLESHOOTINGUIDE F
21 RUIIS BOUGHONDECELERATION/BAC|(FIRE
DESCfitP. .Engine lirns rough w+)ile ec€lerating nd abnormal ombustion ccurc n exhauslsystem
noN .Transaxlen normai ondit n
rrRoualEsHooTr HtNTsl
O Ar/Fue{m xlure oo ich
.Arr cleaner lement logged
.Fuel nieclionortro malJunclion
F uel utcontrol)
.Iniector uel eakage
.Throttle sensormalf nction
. Dashpolmalfunciion
t]tsPEcTtol{ ACTION
1 ls OO"display€d n SellDiagnosas hecker Go to next step
with gnitlon wilch ON?
u p'g'e F-6'7 No llallunctlon Codo No, dasplayed
Check or causeGeter o soeciiied
checksequence) rt page F-70
"88" tla3he€
CheckECU eminal1Fvoltage cz pageF-114
Volt.ge: Approx. 12V
(lgnition swilch Ol{)
+ lf OK, eplace CU cz psgeF-112
4 ll nol OK, checkwiringbeiween
IEST SW: SEIF TEST ECUandSelf-Diagnos,s hsckar

2 ls there air eal.age at inlake air system com

3 ls air cleanerelement lean? Go lo nexI step

F page F-62
No Aeplaceair cleanerelement

Are ECU terminal oliagesOK ?

(Especially 21v1 nd 20)
.:7 page F-112 Ch€ck of calse .7 page F-1t5
F-117
F-119
5 ls here0V al ECU2V eminalabove ,000 pm
(Engine ignalm onilor reen amp lluminates)
Try knowngood ECUand check i

6 ls lhrotle sensorOK?
Ei pag6 F-122
Adjusl (r page F-1ZI

F-53
 

F TROUBLESHOOTINGUIDE

ls dashpoicorrectlyadiusted? Check if lhrottle valve is cornamlnai€d

c7 pageF-lo4
4 li contaminated, clean throllle
Daahpot3et speed:
Approx.2,500 + 100 Pm 4 ll nol contaminaled, replace throt_

ls there nleclor luel leakage?

.? page F-96

Fuel leakage: Below I drop/s mln.

Try knowngood ECUand ch€ck i condition

F-54
 

TROUBLESHOOTING
UIDE F
22 KN(rcKNG
DEsilcBlP..Aolormarcombust,onccompalredy audrbleprnsins no|se
|
TIROUALESHOOTTNG |NTSI
Incor€ct gnilioniming loo advanced) @ Ai/Fue mi(ure oo ea n
@ Carbon eposltsn cylinder .Fuel njecton mount otcorrect
@ overhealing .Fuel inepressureecfeasesrhileacceleraling
litsPEcTtoN ACTION
1 ConneclSyslemSelector o diagnosis onnector
and set Tesl Swilch to "SELF TEST
ls ignilion liming correct at idle after wa.rn'up?
E? page F-62

lgnilion liming: BTDC 16 + 1'

INDICATOF

2 ls '00" d splayedon Self'Diagnosis h€cker

with gn'tionswitchON?
c:r page F-67 No llaltunctlon Code lo. displayed
Checkor cause Belero specilied
checkseqlence) c7 page F-70
"88" flashes
CheckECU ermlnal1F vollage F page F-114

volrage: Approx. 12V

(lgnition swirch ON)

+ lf OK, replaceECU (? page F-112

+ ll not OK. check wking between
ECU and S€ -Diagnosis hecksr

3 ls thereair leakageol intakeair systemcom

ls engine ompressionorrecp
e pageA-10
tligh compr$sion
Englne ompressionMlnhum): Check ngnecondition c7 pageB-10
1,030kPa 10.5kg/cm' t4s psiF30o pm

F-55
 

F UIDE
TROUBLESHOOTING

ls fuel ine presswecorrectal idle? Does f fuel roep€ssure decrease

t? PaEeF-94 whenacceleralingulck\,

Fuel line pres3ure: + ll decrcas€s,h eck or clogging

235-275 kPa 12.4-2-a Wlcm', 3!t-40 psl) b€trveenuel pump and pressure
regulator
4 ll not decrease, o to next step

Checkuel inepressurc hile inch_

+ It fuel ineprcssure ulcklyn_

creases, heckpres€ureegulalot
+ ll fuel inepressureraduallyn-
creases,heck or cloggrng s
tween uel PumPand Pressure
regulator
lf notclogged, heck uel PUmP
maximumpressure r? PageF_91

ls coolingsystemOK?

.Themostat .7 Page E-8

. Et€ctic cooling lan .7 Page E-1 1
.Rad,ator .? page E-7
Tryknown oodECIJ nd check l conditon ReplaceEcU 1:7 PegeF-112

Change uel o anotherbrandor use

F-56
 

TROUBLESHOOTING
UIDE F
23 FUELODOR
DESCRIP. .Gasoline dor n cabin
IION
FROUBLESH(X)T|NGTNTSI
o Poorconnecflon . oamaqedal lue sysler- o- evaporanve msson cofrol sygem
@ Charcoara,r lerovedowdue o evaporatvemEson ont'ol l,slemma unct,on
INSPECTIOT ACT|Oir
ls tirere uel eakageor damageof fuelsystem
and evaooatve emission onirol svstem?

2 |s 00" displayedn SellDiagnosishecker Go to nexl step

with gnillon wilchON?
c? page F-67

L.lfunction Code No, dbplayed

Check or caus€ Refer o soecined
checkseqlence) t7 pag. F-7O

CheckECU erminal F voltage 6' p.ge F-114

Voltag€: Approx. l2V
(lgnltion swnch ON)
+ ll OK, eplace CU F p.ge F-112
+ li nol OK,checkwring between
ECUand SsltDiagnosisChecker

3 ls vacuum ell at solenoid alve purgeconlrol) Go to Slep 5

with engine runn,ng and throltle valve open€d?
(Neutral switch connector disconnected)

No Ch€ck orsolenoidalve peraling

+' lf OK,check acuum osesor

clogsins
4 lf noi OK, go lo next step

Apply12Vand gro0nd , solenoidvalve purge CheckECU eminai voltages rt p.ge F-112

ls vacuumeltat solenol(

V
'r<a No R ep la ce ol eno id al ve

5 Tryknown oodECUand check f condition

F-57
 

F TROUBLESHOOTINGUIDE

.Exhausl as smells bnormally

TTROUALESIIOOT|NGINTSI
Highsulfercontern uel used

Change fuel to another bland

. Ol consumphonxcessve

ITRoUBLESHOOTING INTSI
O rcV sy$em mallunction
6 Enqr# malunctionO working p workrng own or leakage)

Are there PCV hos€, venlilation hose or |hen al_

lach ng nipplesseparated. amaged,clogged,

P.ge F-99
ls thereair pressufeor oil at venulalion os€?

Checkor correci ngnecompression pageB-10

Comor€*ion ( inimum):1,030kP a
Oo.5 rgr'cm', 149 l,6il-300 rpm
+ tf OK, go to nextstep
4 lf not Ok, check or cause e page B-10

engineconoltion F seclion a
ls vacuum elt al PCVvalv€ at 'dle?
.wom pElonnnggroove
.Stuckprston ng s
.Wornpiston r cylinder

F-58
 

TROUBLESHOOTINGU'DE F
26 POORFUELECONOTIY
DESCalP- . Fueleconomyunsatislaclory
fl0N
ITRoUBLESHOOT|NG |NTSI
Whileuelconsumption s drasticallyn cfeasedy citydriving, horl-runperalion,lopand go driving, xtended inler
warm-upp€riods,etc., as opposed o 'trip" mibage,an atlernplshouldbe made o det€rmineh€se aclorswh€ncon
frontedwith "poor mileage condlrions.However, ince he operators notalwaysat taull, he iollowing s oJfercd.

O Operatordep€sslng acceleratormore han usualdue o @ Air/Fuel ninur€ oo rich

lowengine ower .Hlgh uel inepl€ssure
.Poor gnltion @ Alcohol lendeduelused
.Low intake i amount @ Highvehicleoa d
.Electronicsoarkadvanceconlrol svslemmalJunclion
.Clutchslipping/ATxlipping
. Exhaustomponente stricted .Bake dragsing
NSPECTTON AC ION
1 Check actorsother han engine
. Low tire pressufe E7 page O-2
. Unrecommendedire size € pag ()-2
. Clutchslipping s prge H.-3 NO
. Brakedragging s pege P--5
. Exhausl ornponenlestricred page F-97
2 Are air hosesconnected orrcctly?
.7 page F-Eil
NO

3 ls '0O"displayedn Self'Diagnosish ecker Go lo next slep

with gnition wilchON?
'' page F-67 NO [alfunclion Code No, dbplay€d
Ch€ck or cause Reter o soeclfied
checksequence) G gage F-7o
"88" ll.3he3
CheckECU €rminal F voltage F pageF-114
Volage: Appror. t2V
{lgnltlonswltch ON)
4 ,t OK, eplaceECU t7 page F-112
+ ll not OK,checkwiring between
TESTSW:SELFTEST ECUandSelt-Diagnosis h ecker

ls lhere air leakageal intakeair sl,stem om'

5 ls ai cleanerelement lean?
r? page F-62
NO Beplaceair cleanerelemer'1

6 Are ECU eminalvoltages K?

(EspeciallyM,2N, 2R and 2T)
.7 pageF-112 No Check or cause - pageF-115
F-l17
F-l19

F-59
 

F TROUBLESHOOTINGUIDE

It{SPECTTON acflo1{
7 Connect System Selecto! to diagnosjs connector Go o nexl slep
and ser Test Swnch to SELF TEST
ls ionition minq co(ect at idle ajt€rwafm_up?
.r gage F-t62

NO

INDICATOR

I ls lu€] ine oressurc

  onect al idl€?
s P.ge F-94

23s-274 kPa 12.4-2.a xg/cm' 3l-40 p€l)

Hlgh Pressu.€
check if vacuumhose o pressure
rcgulalor s damagedot poorly con-

+ lf OK, replacepressure egulalor F page F-94

4 ll nol OK, repat or replacehos€

9 Runengin€ t idleand henstopengme

ts uel in€pressure old?
c7 Pege F-84

Fuel llnc Drcasure: More than 147 kPa

(1.s kgr'cn" 21 p3l) of 5 min,

No Check njectofsor tu€l eakage e page F-96

1 0 ChangeJuel o anotherbrand

F-60
 

ENGINE UNE-UP F
ENGINE UNE.UP
PNEPARATION
ssT
49 8019 9A0

gnilion iming

BASIC NSPECTION
EngineOil
1. Be sure he vehicles on ievelg round.
2. Warmup heengineo normaloperating emperaturend
stop t.
3. Wait or five minutes.
4. Bemoveheoildipstickndcheckheoillevelandondition.
5. Add or replace il f necessary.
Note
. The distance between he L and F markson lhe diF
sllck represents ,8 irer (0,85US qt, 0.70 mp qt).

EngineCoolant
Coolant evel (enginecold)
Warning
. Never emove he radiatorcap while he engine s
hot.
. Wrapa thickclothalound hecapwhen emovlng t.

1.Pull ut hesub
2. Verifvhat hecoolantevel s near he radiatorillerneck.
3. Verifyhat hecoolantevel n thecoolant eservoirs be-
tween he FULLand LOWmarks.
4. Add coolant necessary.

Batlery
1.Checktheightnessf heterminals o ensure oodelectri
cal connections.
2. Check or corroded . frayedbattery ables.
3. Washhe op olthe battery ithwatero prevent rcover'
4. Verify hat he electrolytee vel s betweenhe upperand
lowermarks.A dd distilled ater f necessary.

F-61
 

F ENGINE UNE.UP
5. Disconnecthe negativebatterycable
6. Ooen he cap.
i. Miasure he pecilicgravityof each witha hydrometer'
Specilfcatlon: .27-1.29 (at 20oC 68oR)

Alr CleanetElement
1.Check heair cleaner lemento r excessiveirt,damage'
andoil.
2. Replacehe aircleaner lementl necessary'

ADJUSTUENT
PteDaralion
1.Warmup the englneo normal peratingemperalure
2. Verilvthatthe ax odhasextendedutwardu y anonal
the fast idle cam has separatedrom he roller'
3. Turnall electricalo adsOFF.
. Bloweran
. Headlisht
. Rearwindowdefroster
4. Make ure hat peeddoesnotchangewnen
Jiiconnectinghe airbypass olenoidalve@ connector'

Note
. liine engine speeadecreasea,he engine s slill un'
der the warm-uP onditlon.

ll the electric oollngan s operatingwat until t stops

6. Verifyhat heenginas running t dle n goodcondilion
7. con;ecl the SST o the diagnosisonnector'
8. Connect timing ight.
s c."""ii a tacn6m-eter o the diagnosis onnectorG-
lermlnal.

10.SetswitchG)to Position
1'!.SeiTESTSW OSELF-TEST'
Not€
. liitre ssr is not us€d,lump across he TEN €rmi-
nai and ttre GND ermlnai ot the diagnosiacon-
nector.

F-62
 

ENGINE UNE.UP F
lgnition Timlng
Inspection Adjustment
'1.PerformPreparation". o F-62.)
2. Verityhat he dlespeed s withinhe specification.
ldle speed: rTX (Neutral) 750 ::E rpm
ATX (P range)1,100 '6 rpm

INDICATOF

3. Check he gnitionimingwitha timing ight.

lgnition iming: BTDC16 + l"
oosenhe
4. lf the gnitioniming s notwithin pecification,
distributoro ckboltsand urn he distributoro make he

fi -)
adjustment.
5. Tightenhe distributoro ckbolts o the specifiedorque.
Tighlening orque:
l6-23 Nm (1.6-2.3 m-kg, 2-16 ftlb)

ldle Speed
1. Perform Preparation".
(Refero pageF-62.)
2. Check he dlespeedwitha tachometer.

ldle speed;MTx (Neuttal) ?50 158 Pm

ATX (P range)1,'100 "8 rPm

djusthe dlebytuninghe hrottle

3. l, notwithin pecification,
adjustingcrew.

F-63
 

F ENGINE UNE-UP
ldle-upSpeed
1 Perfbrm Preparanon(tleler o pageF-62 )
2. Check he dlespeedwitha tachometer'
M Tx (Neutral) 750 1fl rym
ldle sDeed:
/t  
ATX P range)1'100'3 rPm

INS iAL oi'l

"o"".-ird"i fhnlriL€ BoD'i

I
3. Adjusl he air bypass olenoid alve@ by the ollowing
orocedure.
DISTRIBUTOFI iiCrouno rn. arl bypass olenoid alve@ terminal
shownn the igure

2) Adiustthedle-uppeed y urningheadjustingcrew'
ldle speed:
' MTX Neulral)1,080 + 30 rpm
ATX (P range)1,350 + 30 rPm

3) Disconnecthe umperwire

4. Adjust he air bypasssolenoid alve @ by the following

orocedure.
i) Ground he checkconnectorblack) hown n hefigure'
'fL
qHECKCON

he dle-up peed y urningheadjustingcrew'

2) AdiL.rst
ADJUSTSCREW
ldle speed:
' MTX Neutral)1,030 :53 pm
ATX P range)1,700'6 rPm

3) Disconnecthe LlmPer rre

F-64
 

ENGINE UNE.UP F
5. Adjust he air bypass olenoid alve@ by the ollowing
procedure.
1 Djsconnectheconnector f heair bypass olenoid alve
2)Applybattery oltageo air bypass olenoid alve@
terminal.
3)Adjustthedle-uppeed y urningheadjustingcrew.
ldle sp6ed:MTX Neutral)1,250 + 25 rpm
ATX (P range)1,600 + 25.pm
4) Installhe connector f air bypass olenoidalveO.

F-65
 

F SELF.DIAGNOSISUNCTION
SELF.DIAGNOSISUNCTION
DESCRIPTION
Whintroubles ccur n hemain nput evices routput evices'heckor hecause singheSST Failures
oieactt npuiina outputd evice ie ndicatednd etrievedrom heengine ontrolunitECU) s malfunc-
tioncode numbers.
Note
. ihe EGuconstantly hecks or maltunction f the nputdevic€s.B ut'-the-ECUhecks ormaF
dndion ot output?evbes only In a perlodafter he ignltionswitch s turned
ON when he fEN lerminal ol the diagnosisconneclor s grounded.

ENGINECONTFOLUNIT
OUTPUT
oEvtcEs

SYSTEM SELF.DIAGNOSIS
SELECTOR CHECKER

F-66
 

SELF-DIAGNOSISUNCTION
PREPAHATION
ssr
43 80199A O 49 HO18 A1
diagnosis diagno6is
SystemSelector Self-Diagnosis
Checker

MALFUNCTIONODENUMBEB
InspectlonPrccedurc
1. Connecthe SST o the diagnosisonnector.
2.Setswitch@ to position .
3. SetTESTSW o SELF EST.

4. Connecthe SST o the SystemSelector nd a ground.

7 - ) 5. Set he select witcho posilion

aZWr
,6^
ir '"!

@@
6. Turn he gnition witchON.
7.Verifyhat 88" llashesonhedigitaldisplaynd he buzz-
er soundsor 3 sec, after urning he gnition witchON.
8. l "88" doesnotflash, heck hemain elay Fetero page
F-124),powersupplycircuit,a nd diagnosis onnector
wrflng.
9. f 88 lashes nd he buzzer ounds ontinuously or more
than20 sec., check or a short ircuilb etweenhe ECU
6 . lql.
terminal Fand hediagnosisonnector.eplacetheCU
if necessarynd perform teps and 7 again.
10.Note nycodenumbersndcheckforhecauses y refer-
ring to the check sequences hownon pagesF-70
throughF-78. Repair s necessary.

Note
. Cancel the code numbeB by performing the after-
repair procedure ollowing repairs.
(Refer o page F-79.)

F-67
 

F SELF-DIAGNOSISUNCTION
Prlncipleof CodeCycle
Malfunctionodesaredetermined s shownbelow

L Code cycle break

ihe tim6betweenmalfunctionodecycles s 4.0 secondslhe ime he buzzers otD

MALFUNCTION ODE
CYCLEBFEAK

2. Seconddiqit of maltunctioncode (onesposition)

-'i;;l;il
;i;;;;;i ode epresentshe number i timeshe buzzer ounds
positn ot ne marrtr.,ncli6n
0.4 secondduringonecycle

MALFIJNCTION
r cYcL€ MALFUNCTTON
OO E COoE:03

sEc. sEc

- Firsl diqit ol maltunctioncode (tens position)

3.
in" O,gii" ine lensposition t th; maffunction;de representsh e number f times he buzer is on
1.2seconds uringonecycle.
Thebuzzers off or 1.6 seconds etweenhe ongandshortpulses

I CYCLE MALFUNCTION OOE coDE 22

CYCLE

1 2 SEC SE C 4osE c

FIRSTDIGIT SECOND
DIGIT

F-68
 

SELF-DIAGNOSISUNCTION
code Numb€rs
Maltuncllon dbplay
Sensor or Condition Fail'sate llaltunctlon output slgnalpan.m
CodeNo .
Ne'sisnal No Ne-signalw hil-a Stops iu6l injection ON
crankrng
02

Open or short of aif- ON

08

Openor shod oi
20oc (68oF)

ircuil 33.degree ommand

09
;, lffilrfljll
ON
12

Oxygen ensor Cancelsengine ON

llnues nchanged
min.aflerengine x- 15
ceeds ,000 pm
Cancelsngine ON
40 sec. atterengine 17
exceeds ,500 pm
Openor short of ON
{purgecontrol) 26

ON
vaive @
valve@circujt 34

valve @
valve @ ci/cr.tt 35

Noie
. The buzzersoundsonly tor the ones positionwhen using he DlgltalCodeChecker.
To iudge he corect maltunctioncode number, eler to lhe digital display.
Caulion
. lf ihere s morc han one failure p.esent, he code numberswill be ndicated n numerical r-
der. lowesl nrmber ttst.
. Aller repairinga lailure, perform he afler-repalrprocedure. Refer o page F-79.)

F-69
 

F SELF.DIAGNOSISUNCTION
Troubleshootlng
lf a malfunction6denumber SShown n the SST,check or hecause y Usinghe chart elatedo the
codgnumber hown.

COOE o. O:I DTRIBUTOR I{E.SIGNAL)

STEI NSPECNON ACTION
ls herea poorconn€ctionn distributorircui0 Repairor replacewnng

No

2 ls therecontinud b€tweendistributor erminal Go to nextgep

wirc (B/LG)and grcund?
Check or opencircuit n wirng ifom distributoro ground

3 ls therebatteryvoltageat disltibutor etminal

NO Ch€ckor opencircut n wiing trom o main

relay fUEl INJ elay)
ls lhere aoorox.5V at ECU emlnal 2E? Wilh Go to next slep
distributor onnectordisconnected)
neplace CU

5 ls there approx.5V dist bLrtorerminal_wre Feplacedist butor

(G/R)? At harneseside onnectorwith discon_
NO Checkor snort r opencircuitn wring rcm disldbutor
ECU erminal E

CircultDiagram
O|sTR|aUTOR

DIS]RIBUTOF

TO IGNITION
IGNITION BATTEFIY swtTcH
swrTcH
TO TACHOMEIEFi

TO DIAGNOSIS
CONNECTOR
IGNITEF

G/B

F-70
 

SELF-DIAGNOSISUNCTION F
CODE t{o. 08 (ATRFLOWE SOR)
STEP IISPECTTON acTtot{
ls herepoofconnectionn airilow ensor ircuiP Repair r teplace i ng

2 ls ECU erminal20 vollageOK? ls sameCodepresenlatter performing

e page F-118 alter'repalf rocedure?
e p.g€ F-79
lgnition wilchON + lf YES, eplace CU
+ lf NO, €check irliow ensor nd
ldle ECU or poorconneclion
No Go to nextstep

3 ls lhere batteryvollageat airtlowsensor onnec'

tor teminal C with airilows€nsorconnectordis.
Checkorshort r opencircuil n wir-
ng trom aiflow sensor onneclor er-
mnalC lo main elay.
+ lJOK,checkmain ealy
+ ll notOK, epair r rcplace

ls lhe.e conlinuiiy belween airilow sensor lerrni-

na B and sround?
R€pan r rcplace iing

5 ls resislance between arrflow sensor teminals A ls here onllnuty etween CU erminal 0 and aidlow
and B OK?
E7 page F-121
+ lf OK, eplac€ idlow ensor
Resistance:+ 1 m eo"C t68.Fl) + lf notOK, epair r replace
No Aeplaceairllowsensor

CircultDiagram

FFOM IGNITION
swtTcH

t r r l
r l l
rl rl
1l G/w ll clv ,i

AIFFLOWSENSOR

F-71
 

F SELF-DIAGNOSISUNCTION

CODENO.I 09 (WATERTHERI'OSENSOR}
STEP tNSPECTTOI{ ACTION
1 ls therea poor conneciion n waler hermosen_ nepair r leplace rnng

2 ls therecontinuitybetweenwaler hermosensor Go o nexl step

andECU?
ECU
A (R/L) 20 (R/L)
B C/iG) 2D CYi )

3 ls resistance f water hermosensor orrecf

Coolant lemp. FesislancekO) No Beplacewaler hermosensor
,200c ( -40D 14.6 17.A
20.c ( 68'D 2.21-2.69
80.c 076'R 0.29-0.35

ls sameCodeNo.prcsentollowing fler_repair
F Pag€ Waterhemosensorndcrcuit

Arc ECU ermlnals D and 20 voltages orrcct? n"pru". tCu 17 PsgeF_112

5
c7 pageF-l16
Checkor shotl ircuil n wiring romwaterhemosensor
lo ECU

CircultDiaEram

ECU THROTTIE ENSOR

re
@
\lB )i

IER THERMOSENOR

re ll

@
WATEBHEFTMOSENSOF

F-72
 

SELF-DIAGNOSISUNCTION F
CODENo. r2 fTHRoTTLE EI{SOR)
SIEP INSPECTION ACTION
1 ls lhele a poor conneclion n throltle ensor Bepair r replace iing

2 ls there conllnuity ehdeenhrotllesensorand

ECU?

ECU
A (LG/R) 2K (LG/R)
B (LGMI 2M (1G,4)
D ff/B) 2D(v/G)

3 ls resislances etween erminalsB (LG/'14 nd C

(Y/B)correc"
Adlust or replace throttle sensor o page F-12.

Below kA
Approx. 5 k O

ls ECU terminal 2lV vollage cofrccl? ReplaceECU 17 page F-112

.7 page F-116
Checkor short icuil n wirng rom hrcttle ensoro
ECU

Circuil Diagram

IHFOTTLE ENSOF

re
@ ll
Y/B jl

TERTHERMOSENOR

re Y/G
@
THFOTTLESENSON

F-73
 

F SELF-DIAGNOSISUNCTION

ffiYGEN sENsoB tNAcrtvATtot{)

STEP t]{sPECTlOt{ ACTION
ls therea poor connectionn orygen sensor Repairor replacewing

2 ls oxygensensorodpul vollagecotrecr?
F PageF-123
Replace xygonsensor

3 ls therecontinuitybetlveenoxygensensorand
EclJ ermlnal N?

ls ECU terminal 2N voltage correcl?

F Page F-1lE
Checkor shod ircuitn wiring romoxvgen ensoro
ECU
aadro Fa|| s oaoe F-t12
5 ls sensitivity f oxygensensorcorrecp
t7 PageF-123
Tryknown oodotygen ensor nd
ch;ck It co;ditionmproves .? ptge F-124

Circuit Diagram

F-7 4
 

SELF-DIAGNOSISUNCTION F
mDE No. .I7 (FEEOBACK YSTEi|)
STEP I SPECTTON ACTtOl{
ls s3meCodeNo, presentafter pedormingaller-
E7 eagc F--67 NO Check xygen ensor ircuitor poor

+ li OK, p€rfom toLrbleshooling

CodeNo.15 s PageF-74
.) lf not OK, repairor replacecon-

Checkmonhoramp ol Sef-Diaqnosis heckerl Go 1o nod step

luminateat jdle alter warming.up ngineand
runningt at 2,500-3,000 pm or I minutes? ilole
. A/F mixtui€ lB rich
Go o Slep5
Nole
. A./Fmlrtur! b le.n or mi8fire occuiing
3 ls tuel inepressurc t dlecorrec0 Go to nextslep
e prge F-94
Hlgh prossuro
Fuel llne Dr€65ure: ls fuel relurnho€ecloggedor restricted?
235-275 wa (2.1-2.A r.glcnf, 3,F40 p5l)
(Vacuum ho3. lo preasurc rcgulrlot +t ll OK. replacepres$re regulalor - pag€ ru4
dbconncctcr0 + lf nol OK, rcpairor replacehose
ls here eak€ge t fuel njectot
c? page F-97
NO ls waler lhemossnsor OK? c? pege F-121

+ ll OK, Go lo Step 7
+ ll not OK, replace water lhermc
(z page F-121
5 Disconn€ct each high-iension lesd at idle; does
enganespeed decrease equally at each cyinde|?
NO Go to St€p

ClrcultDlagram

F-75
 

F SELF.DIAGNOSISUNCTION

STEP INSPECTION acTtolr

6 ls tuel ine pressure t idle conecf
r7 P.ge F-94
No
Fuel ine Dressure: Checkuel inepressr.rrehil€pinch
235-274 kPa 12.4-2,a kg/cm', 34-40 psD
(vacuum hose lo pr€*sune regulalor
a I luel inepressurcuckly n-
creases, heckpressure egulator t7 Page F-95
.t lf iuel inepressureraduallyn
creases. heck or cloggingbe_
tweenuel pumpandpressure
lf notclogged, heck uelPUmP
maximumpressure F Peg€ F-91

7 ls ihe.e air leal€ge in intake a I system com_

Go ro Step10

8 Wasmisfire ound in Slep 5 oJ nspection? Repair r replacegnitlonystem

9 Go o noxl slep
b ;me CodeNo.presertollowing edorming
atter-rcpair rocedurc? NO
c7 Pege F--67
1 0 Tryknown oodECUIdoes condition mprcve?
o page F-112

F-76
 

SELF-DIAGNOSISUNCTION F
CODENo. 26 (SOLENOIDALVE PURGE ONTROL)
STEP INSPECTION ACTtOl{
Disconnect onn€ctor rom ECIJ CheckECU erminal onnecloro. poor connecrion
ls lherc balteryvoltageat ECU erminal2X wire
hamess R/B)wnh gnilionswltchON? + lI OK, eplace CU - pageF-112
+ ,l notOK, epair r replace iring

2 Keep condilionStep 1 (R/B)

ls there bafleryvdrage al soleloid valveconnec-
tor terminal-wire (A/8)?

3 ls solenoidvalve OK? Check or shod or open circuit n wiing lrom main relay
F pago F-101 (FUEL NJ relay) o solenoid alve
Beplace solenoid valve

CODElo . 34 (AIRBYPASS OLENOID ALVEO)

STEP INSPECTION ACTION
1 D is co nn ec l on ne cl or r or n E CU Ch€ckECU erminal onnectoror poorconneclion
ls there baneryvotage al ECU eminal 2T wire
harness BM) with gnitionswtch ON? .) ll OK, rcplaceECU o page F-112
.> lf notOK, epair r replace iins

2 Keep condilionas Step 1 Repair iring(R/Vr)

ls there baltery voltage at solenojd valve connec-
lor lerminalW.e R/!9?

3 ls solenoid valve OK? Ch€ckor short r opencircuil n wiringrommain elay

F page F-109 (FUELNJ relay)o sol€noidalve
NO Re pla ce o len o v alv e

Clrcuit Diagram

SoLENOID ALVE ),
FFIOMBATTERY

FROMGNITION WITCH

SOLENOIOALVE SOLENOIDVAIVE
(PUNGE ONTROL)
soLENolo AtvE i
(PUFGEOMIFOL)ii

F-77
 

F SELF-DIAGNOSISUNCTION

35 {An AYPASSSOLEI{OIDVALVE@)

Dsconneclconnector rom ECU CheckECU etminalconnecloror poor connecron

ls lhere batleryvoLtage l ECU e|minal2R wrre
(F/B)wilh ignilionswilchON? + ll OK, eplace CU - PageF-112
.t lf noi OK, eparr r replace rrrng

Ke€o ondilion s SteP Repair i ng (R/B)

ls th;re batteryvoltageat solenoidvalveconnec'
tor termina wie (B/Bf

Ctect tot "lon ot op.n "ircul in wiing fiom maln elav

c? page F-109
Replace soLeno valve

Cllcuit Dlagram

i
AIF BYPASS i
SOLENOIDALVEG)i
FFOMBATTERY

FFOM GNITION WITCH

SOLENOIOALVE
{PURGE ONTFOL)

AIFIBYPASS OLENOID
valvE €)
z---F-----rr
ufjl-lJ

F-74
 

SELF-DIAGNOSISUNCTION
After-repair Procedure
'1.Cancelhememory f mallunctions r om he ECu by dis-
connectinghenegative attery able
brakeoedal or al least hree seconds.Reconnecthe
negative attery able.

2. ConnecttheST SystemSeleclor)othediagnosiscon-
nector.
3. Setswitch@ to position .
4. SetTESTSW o SELF-TEST.

5. ConnectheSST (Selt-Dlagnosis hecker) o the Sys-

tem Selector nd a ground.
h eckero posi-
6. Setthe elect witch f heSelf-Diagnosis
tionA.
7. Turn he gnition witchON.
8. Start ndwarm p heengine,hen un tat 2,000 pm tor
three minules.
9. Verityhat no codenumbers redisplayed.
" lEJ.

F-79
 

F SELF-DIAGNOSISUNCTION
SWITCHIONITORFUNCTION
Individualwitchesan be inspected y the SST (Selt-Diagnosis hecker).
Note
. itre TEN erminatol the diagnosisconneclormust be groundedand the ignltionswitchoN
(enginestopped),
. ti e-ntrer f i6e switches remainaclivated, he monilot lamp wlll be illuminated.

ENGINE ONTFIOLNIT
NEUTRAL wlTCH
CLUTCH WTTCH I
STOPLIGHTWITCH I
HEADIIGHT WIICH SYSIEM
SELECTOB

OEFFOS1EFSWITCH

BLOWEF ONTFOL
SwlTCH

INHIBITOB

Self.DiagnoslsChecker(Monitor lamp) R€mark

Swilch
Lighl Ol{ Llght OFF
Clutch switch ([4TX) In gear
Neutral swilch ([/1X) In gear Clulch p€dal released
Sloplight swilch
Headlighl wnch ON ights ON
Headlighls/small
ON OFF
Rearwndow defroster w ch ON
ON
Inhibltor witch (ATX) L, S, D or F range

InspeclionProcedure
1. onnecl heSST SystemSelector)o heoiagnosrscon-
nector.
2 Setsw{ch@ to posttion .
3 SeITESTSWITCHo SELF.TEST,

F-80
 

SELF.DIAGNOSISUNCTION F
4. Connecthe SST Sell-Diagnosis hecker) o the Sys-
tem Selector nd a ground.
h eckero posi-
5. Set heselect witch ftheSelf-Diagnosis
tion A.
6. Turn he gnition witchON.
7. Checkfmonitora mplluminateswhen ach witchsmade
to tunction s described elow.
Caution
. ll eitherot the switches emainaclivated. he mon-
itor lamp will be illuminated.
. Do not start the engine,

Procedure

Set conditionso deactivate achswitch Checkeach swirchand relaledwting harness

.Ail accessors OFF .Clurch and Neurral witch .Feler o pagesF 124. 125
.Transmission n neutral .Stoplightswitch :Reler o SeclionT
.Headlight swlch Reler o SectionT
Veity hal monltorarnp oesnot lluminate .Water thefmoswilch Feier o SectionE
.Rear delrosler switch :Befer to Section T
. Blower swilch Befer o Section T
.lnh brtorswltch :Beler o secfon K
Check each switch as describ€d

Neuiraland Clulch Switches MTX)

Shifl ransmissionnto gear PC .Neutral r clLrtchwitchmallunction

ls monilor mp illurninatedilhclulchpedal eleased? {Relero pages -124,125)
.Openckcuil n related irinS arness
. ECU ermlna 1\/)maitunciion
(Relero pageF-116)

Depress clutch pedal

PC . Clulchswitchmalunclion
Doesmonitor amp go out? (Reler o page F-124)
B€tu.n transmission to neutral

Stopllghtswllch

Depress rakepedal PC .Sloplightswitchmalunction

ls monitoramp llumlnaled? (Beter to Section T)
.Open circut in w rlng harnessrom sloplighl
switch to ECU
.ECU terminal 1O)maliuncllon
Sloplight wilchOK (F€fer o pase F 114)

F-81
 

SELF-DIAGNOSISUNCTION
Blower switch
'Iun blowerswitch o ON position PC: Blower witchmalfunclion
ls monitoramp lluminated? GeJer o SeclionT)
.dpen ctrcurln ||e wrr'ng aness om blower
sw ch o ECU erm,na 1S )
.ECU eminal 1S)maltunciion
(Reiero PageF 114)

Headlight witch

Tum ON headllght witch PC: Headlisht witchmalfunclion

(Reiero Sedion )
ls monrlor amp llominated? .Open crrcuiln w n19harnessromheadlighr
swich o Ecu ieminal 1u )
.ECU ermrnal1 U)mallunction
Headllghl w(ch
(Felero PageF-l16)
Tum OFF headlighl wdch

Water hermoswiichcircult (not included n switch nsPeclion)

Warninq
I'iie c'ootins "n operateswhen he diagnosls onnector ermlnalsTFA nd GNDareconnect-
ed with a iumper ttrire' Use caution.

Connectdiagnosis onnector elminalsTFA and GND PC. . Felaymalfuncton

{Beler lo Section E)
.Open circlit ln wire harness rom watef hermo_
V€rity hat monilor amp ill'rmlnates
swrlch o enginecontrolLinrl
.Enqrns controlunt lelminal 1R malluncliof

Water hemoswitchckcuit s OK
Dlsconnecljumperw rrc

Rea.defrosterswilch

Tum ON rear deffoslerswitch rc: .Fear delrosterwichmalfunclion

(Befero Seclion )
ls monitoramp lluminated? .bpen circuitn wldnsharnessrom eardefroster
switcho ECU eminal 1T)
.ECU erminal1 T)maliuncton
BeardeirosierswitchOK (Reiero pageF-114)
TurnOFF rear deliosterswlch

Inhlbitorswitch (ATx)

Shiti ransmissionnlo gear PC: hhlbiiorswitchmalllnct|on

ls monitoramp luminated? iReter o SectionK)
.Open ot shol crrcuil relaled nng harness
.ECU erminal1 V)m aLfuncton
(Betero pageF 116)
lnhilitor swilchOK
"P or range
Shlfl nto

F-42
 

INTAKEAIR SYSTEM F
INTAKEAIR SYSTEM
COMPONENT ARTS
Removal Inspectlon Installatlon
1.Removen the ordershown n the igure, eferringo RemovalN ote.
2. Visuallynspecthe intake ir system omponentsnd repair r replace s necessary.
3. Installn the reverse rderol removal

19-25 (1.9-2.5.1.-r9)
19-25 0,9-2,6, r/r-r9)

7.6-11 nn (40-t10 cn.tg,

6H5In-lb)

REPLACE

,9-2.6,
/a :;;s

(3,3-s.3. 27-33)

1.Aircleaner
Inspector excessive irt or damage age F-86
Inspection...................................
2. Injection ody 4. Intakemanifold tay
ageF-84
Inspection................................... 5. ntake anifold
Disassembly Assemb1y............. ageF-85 age 86
Inspection...................................
RemovalN ote
Coolant
1. Drainhecoolantntoa suitableontainereforeemovino
the njection ody.
2. Retillw ilhcoolanl fter nstallation.
Cautlon
. Belore ooseninghe radialordrainplugverify hai
the radiatordraln hose aces stralghl down.

F-83
 

F INTAKEAIF SYSTEI'
Fuel Pressure Releaae
FUELPUMPCOVER Belore isconnectingny uelhne, eleasehe uelpressure
trom he uelsvstemo reducehe f r
|. Slad he en-gine.
2. Removehe rearseatcushton.
3. Disconnecthe uelpumpconnector'
4. After he enoine talls,urnofithe gnition witch
5. Reconnect he uelpump onnectornd nstalltheear eat
cush|on.
PUMPCONNECTOF

INJECTION ODY
Inspeclion
1.Check he niection ody ol wearand deposils
2. Verifyhat he hrottle alvemoves moothly ith he hrot'
tle valve ever rom ullyclosed o fullyopen.

Fastldle (On-vehiclenspection)
1.Turnall electricoadsOFF.
. Bloweran
. Headlight
. Rearwindow elroster
2. Verifyhat he wax od s contractednd hat he ast dle
cam as n contactw ith he roller.

3. Connect tachometer.
4. Startheengine ndverifyhatthe ngine peed s below
4-?-2: 2,500nm.
5. Warm p heengine onormal peratingemperaturend
verfy that he engine peeogradually ecreases.

6. After heenginewarms lp, erifyhat hewax odextends

fullvand hat he camsepartesrom he roller.
7. Vdity that he dlespeed s within pecification.
ldle speed:MTX (Neutral) 750 :53 pm
ATX P range)1,1001 rpm

Note
Air bypass solenoid valve @ lrom hsll
ryanhedup condilion o wamed up condition.
. Waler empelaturewhencam ust separates s 6l
:3"C (1421!l.R @TX),55 + 8oC l3l + 46oF)
(ATD.
F-A4
 

INTAKEAIR SYSTEM F
he njectionody f necessary.
8. Fieplace
Caution
. Do not disasasmblehe iniection ody.
. Do not turn he acrewg hown n lhc ligure.

01E0Faog1

Disassembly Aaaembly
1. Disassemblen the ordershown n the igure.
2. Assemblen the reverse rderof disassemblv.

GASKET, EPLACE
3,4-a.S (35-50, 3O---4:r)

3.4-5.e (35-s0i 30-4t) ;?iil:"ts

7.4-12 t@-12O, 69-1U)

r.2-r.3(12-13, 0-r6)

O8ING,FEPLACE
2.0-2.s (20-30, r7_2G)

rl-22 lln (r.a-2.2 n.l(g,

1.Air bypass otenoidalve@ 4. Airflow ensor

I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g.e. . .-.1. .0. .9. . 1 n s p e c t , o n . . . . . . . . . . . . . . . . .page
. . . . . .F-121
..........
2. Dashpot 5. Pressureegulator
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g.e. . .-.1. .0. .4. . l n s p e c t i o n . . . . . . . . . . . . . . - . . .page
. . . . . .F-
. . . .94
.....
3. Throttle ensor R e p | a c e m e n t . . . . . . . . . . . . . .page . . . . . .F-
. . . .94.....
1nspection................................. ageF-122 6. Injector
A d j u s t m e n t . . . . . . . . . . . . . . . . . . .a. .g.e. . .-.1. .2. .2. . Inspection o n-vehicle).............. pageF- 95
Removalfnstallation................ ageF-I22 Bemovall nstallation................ pageF 96

F-85
 

F INTAKEAIR SYSTEM
BAFFLE/INTAKE ANIFOLD
INTAKEMANIFOLD Inspection
1 Visuallv heck for cracks or damageand reolace f

z. 8i"ff# ai"tonionf he ntakemanffoldnd eplacef

necessary-

ACCELERATOREDAL
Removal Inspection / Installation
'1.Removen the ordershown n the agure
2. Visually he acceleratoredaland retaineror cracks r damage'
3. Installn the reverse rderof removal.

9!-r5 {100-150, t7-r3o)

1. Acceleratorable 3 cliP
lnspectionAdjustment..... . .. pageF-86 4 Fletum pring ..
2. Retainer 5 Accelerator edal
ACCELER,ATORABLE
InsD€ction Adiustment
1 deoressheacceleratoredal ully Verifyhat he hrottle
valve s ullyopened y irrninghe hrottleeverby hand
2. nspecthe playol the acceleratorable.
Play:1-3mm (0.04-0.12 In)
3. Loosen uts@ to adjusthe play f necessary.

F-86
 

FUELSYSTEII/I F
FUELSYSTEM
DESCRIPTION
Thissystem upplieshe necessaryuelat a constant ressureo the njector.
Fuels metered nd njectednto he ntakemanifoldccordingo he njectiononkol ignal om heECU.
Thissystem onsists f the uel pump, uel ilters, ressureegulator,nd njector.

PRESSUFEIEGUFATOB

v- FUELFILIER HIGH.PBESSURE
IDE)

FUELFILTERIOW.PRESSUFEIOE}

@
\

F-87
 

F FUELSYSTEM
PRECAUTION
Fuel PressuleRelease nd ServicingFuel System
Fueln he uelsystememainsnder ighpressure hen he
engine s not running.
a) 6eforedisconnectingny uel ine' eleasehe uel pres-
sure rom he uelsystemo reducehepossrbrlityt Iniury
or re.
1.Start he engine.
2. Removehe rearseatcushlon
22-30 (2.2-3.r, 16-22)
Disconnecthe uelpumpconnedor'
PUMPCONNECTOFI 4. After he engine talls,urnotf he gnition witch.
5. Reconnecthe uelpumpconnecior nd nstallhe rear
seatcushion.

b)Usea ragas protectionrom uelspraywhendisconnecf

ing he hoses.
Pluo he hosesatter emoval.
c) Wh;n nspectinghe uelsystem, sea suitableuelpres-
suregauge.
Caution
. Instatl hose clamPs o secure he fuel pre$sure
gauge o the fuel lllter and the tuel mainhose o pre-
vent luel leakage.

SYSTEMOPERATION
Fuel PressureHold nspection
Waming
. Beloreperformlnghe followlngoperation,elease
the tueipEssure tlam the tud system o .educe the
posslbilityot inlury or lire. (Reler o above')

1.Disconnecthe negative attery able

2. Install fuel pressure auge.
3. Connecthe negative attery able-

4. Connecthe diagnosisonnectore rminals /Pand GNq

. /4,-<'-\\. \ \ witha jumperwire.
X.. \ 5. Turn he gnition witchON or l0 sec' to operatehe uel
oumo.
oteelosts\ 6. urn he gnitionwitch FF nddisconnect he umper ire
CONNECTOF
7. Observehe uelpressurelter 5 min..
Fuel pressure:
More han l4T kPa 1.5kg/cm',21psi)

F-88
 

FUELSYSTEM F
Fuel Line Pressure nsoestion
Warning
. Belorc performlng the tollowing operatlon, release
the fuel p]gs$re lrcm the tuel syslem o leduce the
possibllltyot iniury or tire. (Reter o page F-88,)

1. Disconnecthe negatNe attery able.

2. Connect fuelpressure auge.
3. Connecthe negative attery able.

4. Connect iagnosisonnectore rminals/PandGNDwith

a umoerwtre.
5. Trjrn he gnition witchON.
6. Measurehe uel inepressure.
Fuel ine pressure:
235-275 kPa (2,4-2.4 kglcm" 34-40 p8l)

F-89
 

F FUELSYSTEM
FUELTANK
Removal Inspection Installalion
Warning
i'-diiJie pertormlns he following operalion, elease he fuel-Pressurerom he fuel system o
reduce he pGstblllty ot iniury or fire. (Reler o page F-88J
. Wrren itoilns tlte fuel ia;rk,'k;t spalrrs'cigaiett-cs, nd open lames away tom it'
gas.
. i'iiiij iepiirin-g the fuet tanti, ctein ir ttrr6ug6ty with steam to lemove all exploslve
1.Removen the orde.shown n the igure.
2.Visuallynspecthe uel ankcomponents nd repairor replace-as-e cessary
3. nstalln th; reverse rderof removal, elerringo InstallationNote -

r.r-r.7 {r1-17,9.5-15)

,."-, , ,*-r ,0, rr, Q

SEALRUBBEF, EPLACE

@
. \

43--6r r+m ({.4-4.2 n.kg, 3a--{6 tt lb)

Note
. Drain he tuet lrom the tuel tank before removing he tank.

1.Rear eatcushlon 7. Fuel ank

2. Fuelpumpcover Inspeclor cracks nd corrosion
3. Fuelpumpconnector 8. Check alve twoway)
4. Fuelhoses L Fuel ankunit
5. Evaporativeoses 10.Fuelvapor alve
6. Fuel ankstraps 11.Non-returnalve

F-90
 

FUELSYSTEiI F
lnstallationNote
1. Pushheendsof hemain uelhose, uel eturn ose, nd
evaporativeoses nto he uel ank ittings i least25mm
(r.0 n).
2. Pushhefuelfillerose nto he ueltank ipeandiller ipe
al least 35mm 1.4 In).

FUELPUMP
Inspection
ltlaximum pressure
Warnlng
. Setore performing he lollowlng operalion, release
the tuel prcssu|e rom the fuel system o r€duce he
po$lbllily ol Inlury or lire. (Reter o page F-{8.}
. When inspecting luel system palts, keep sparks,
cigarettes,a nd open tlames away rom the fuel,

'1.Disconnecthe negative aftery able.

2. Connect fuelpressure auge o the uelmainpipeand
plug heoutlet f he uelpressureauge sshown.lnstall
clamos s shown.)
3. Connect he negativebatterycable.
4. Connect iagnosisonnectore rminals/PandGNDwith
a lumperwre.
5. Turn he gnitionwitchON or l0 sec. o operatehe uel
pumpand measurehe uel pressure.

Fuel pressure:
491-658 kPa (5.0-6.5 kg/cm', 7l.l-92.4 p6i)

FUELPUMPCOVER 6. Turn e ignitionwitch FF nddisconnecttte umper ire.

REANSEATCIJSHION 7. f not as specified,e placehe uelpump.

1. Removehe rearsealcushion.
2. Disconnecthe ueloumD onnector.

22--.3012.2-3, 1, 1G-2'
Nfl (Gks, n.D) | CONNECTOB

3. Checkor continuityetweenhe erminals @ and @ of

the connector t the uelpumpshown n the igure.
4. lf there s no continuity,e placehe uelpump.
(Refer o page F-92.)

F-91
 

F FUELSYSTEM
Fuel pump oPeration ound
1.Turn he gnrtionwtch ON
-.:-n 2. connectdlaonosisonnectorermtnal /P o GND
apandverityhat hefuelpumpper-
g Removehe r.relfilter
@Y... ationsound s heard.
&
s:'5
4;/
G NO

Replacement
Warning
-riltreri
i- replacins tuel sysiem parts, keep sParks, cigarettes' and open flames away lrom
the tuel.
. ieioie oerfotmfns he tollowlng operalion, elease he tuel pressure rom the fuel system o
reduce he possibilityol iniury or tire. (Refer o page F-Ear'

1. Removen the ordershownin the igure.

2. nstalln the reverse rderof removal.

*k/
r.r-r.7 (1r-17, .s-rs)
UE! HOSE,

{30-r o, 69---eq

WASHEF, EPIACE

2.7 4.1 123-42, 2a---36t

1.RearseatcushDn 7.Fuelpumpconnector
2. Fuelpump 8. Bracket
3. Fuelpumpgaugeunltconneqor 9. Rubberm ounl
4.Check alve 10.Fuel ilter
'11.FLrelump
5. Fuelhoses
6. Fuelpumpgaugeunit

F-92
 

FUELSYSTEM F
FUELFILTER
Replacement
Refer o pageF-92.

.F\
Hlgh-plessure ide
7,a-lr {a0-r1o, 6r-95) the fuel ilterm ustbereplaced t he ntervalsutlinedn he
maintenancechedLrle.
Warnlng
. Belore pertorming the tollowing operation, release
the tuel pressure rom the luel system o rduce the
posslbilityot iniury or fire. (Refer o page F-88.)
. When replacing the tuel filter, keep sparks,
cigarettesand open tlamesaway lom it.
'1.Disconnecthe uelhosesrom he uel ilter.
2. Removehe uel ilterand bracket.
3. Installn the reverse rderof removal.

CIRCUITOPENING ELAY
Replacement
'|. Disaonnecthe negative atteryerminal.
2. Removehe ECU. Refero pageF-112.)
3. Removehe relaybrackel
4. Removehecircuitopening elay rom he relaybracket.
CIRCUITOPENNINGFELAY

Inapectionot Continuity
1. Check ontinuityetweenerinals@ and@ in the ollow
ing condition.
f--_-1 Te.minals Aoolv12 V Continultv {aA- G))
Gl'. r*{ry
I L.ora\€) @ * @ NO
(b_oorqA @ " @
T , _-ir No

2. Replace he relay f not as specified.

F-93
 

F FUELSYSTEM
PRESSURE EGULATOF
Irsp€ction
Fuel lne pressure
WarninE
. BebA oerforminq he ollowingoperatlon, eleaae
the fuel'presaure lom the fuel system o lsduce the
possibllity ot Iniury or tlre. (Reter lo page F-88.)
. When inipecting the pressure regulator' keep
and open lames away rom it'

1.Disconneqhe negatNe attery able

PRESSUFIEIEGULATOFI
vAcuuM HosE ^ \ NJECTTONOOY
2. Connect fuelPressureauge.
3. Connecthe negative attery able.
4. Start he engine nd run t at idle
5. Measurehe uel inePressure.
Fuel ine Pressure:
235-2i5 kPa (2.4-2.a kglcm'' 34-40 psi)
Noie
. The tuel line pressurcwlll mt changewhen remov-
Ing the vacuum hose lrom the Plessule regulator
at ldle.

nepbcement
Warning
. Betoie oedormlng the following operatlon, lelease
the fueipressure from the luel system o lsduce ihe
possibllityof iniury or tire. (Reler o page F-88.)
. iivhen replaclng tuel system componenta' keep
sparks,cigareties, nd open lamesaway rom he
lusl.
Cautlon
. Aller removlng he air cleaner,cover he lntakeah
pagsag€ with a ctean rag to Protect the alrtlow
3.a--{.a {35-50, 3O--a3)
3enaor.

he air cleaner.
2. Disconnecthe negative attery able
3. Removehe pressureegulator s shown n the igure
4. lnstalln the reverse rderol removal
OAING,FEPIACE

INJECTOR
Inspection (On-vehlcle)
1. Removehe air cleaner over.
Caulion
. Perform he tollowing nsPection arelully o Pro-
tect the alrflowsensor tom damage.
2. Start he enoine nd run t at idle.
3. Using soundscope, erifyhat njector peralingounds
are nearo.

F-94
 

FUELSYSTEM
Removal lnstallation

Warning
. Betoreperforming he followingoperalion, elgase he uel pressurerom the tuel systemot
reduqe he possibilityof injury or tire, (Reter o pageF-88.)
. When emoving he fuel syslem parts, keep sparks,cigarettes,a nd open lamesaway rom
the tuel.
1.Loosenhe radiator rainplugand drain he coolant.
2. Removen the ordershown n the igure, eferringo RemovalN ote.(Refer 0pageF-95-)
3. nstalln the reverse rderot removal,eferringo InstallationNote.(Refero pageF-96.)
7,3-11 (30-110,69-9s)

GASKET,SEPLAC€

CIFINGS,FIEPLACE

CUSHION UBBEF, rQ-25O,e-2.6, .-t9)

ad
-e
re-25 0.e-2.6, .-19)

GASKETS. EPLACE

1.Aircleaner 5. Injecuonody
2. Water ose 6. njector over
3. Fuelhose 7. njector
4. Air bypass ose
Removd Note
. When eplacinghe njector, ush he njector ozzle ut
wjtha plastic r woodstick.

F-95
 

F FUELSYSTEM
lnslgllationNote
. UsenewGrings,cushion ubber, nd gaskets
. Applya small hountof silicone reaseo he O'rings e
lore nstallation.
REPLACE . Installtheniector quarelynto njection odyanddo not
HION
twist t while nstalling.
. Afternstallation,onnecthediagnosisonnector,/Pand
GND erminals itha iumper ire, ndcheck or uel eak'
age with he gnition witchON. Refero pageF-96.)

Inspection
Warning
. whe; inspecting the iniector, keep sparks,
cigarettes,a nd open tlamesaway rom the tuel-
Iniector esistance
1.Disconnecth e niector onnector.
2. Measureesistancel the niector ithan ohmmeter.
Resistance: -20 (20'C l68oFl)

Fuel dakage est

Caution
. Perlorm he followlng nspection arefully o pro'
iect the air bypasspassageof the airflow sensol
lrom the enllanceof dust or dirt.
1. Removehe air cleaner s shown n the agure.

2.Connecthediagnosisonnectore rminals/PandGND
witha ilmper wire.
3.Turn he gnition witchON andcheck or uel eaksrom
the njector.
Fuel eakage:Less han I drop/s minutes

F-96
t
 

EXHAUSTSYSTEM F
EXHAUSTSYSTEM
COMPONENTARTS
Inepection On-vehicle)
Start he engineand verify hat here s no exhaust as eakagerom heexhaust ystem omponents.
Removal lnspection Installation
1.Removen the ordershown n the igure.
2.Vlsuallynspecthe exhaust ystem omponentsnd repair r replace s necessary.
3. Installn the reverse rderof removal.

7.3-rt xn {3o-rt0 cn*g!

FEPLACE
GASKET,
GASKET.EPLACE re-23 i,9-2.3, r{-r4

GASKET, FIEPIACE

;:;::: ",_.-1
SPFING, 7.3-11 N.n (8c-rro cn{q,

"'_",.'"_""1".".:€
E 40-55 (4.r-5,6,30-41)

rL3 0.9-23, rr_14

crRrNG,

{o-55 (.r.1_5.6, O__-4r)

a1aoFx47a
1- nsulator 5. Calalyticonverter
2 .F r o n t i p e l n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. g. .e. . . .1. 0. .3. . .
lnspector deteriorationnd cracks 6. N.4alnilencer
3. Exhaustmanifold lnspector deleriorationndcracks
Inspector cracks 7. Oxygen ensor
4 .M i d d l e i p e Inspection...................a . .g. .e. . .- .1. 2
. .3. . .
lnspecto rdeteriorationndcracks Replacement............................. ageF 124
B. nsulalor

F-97
 

F OUTLINEOF EMISSIONCONTROL YSTEM

OUTLINEOF EMISSIONCONTROLSYSTEM
STRUCTURALIEW
The ollowing ystems re employedo reduceCO, HC,and NOxemissions.
1.PositiverankcaseentilationPCV) yslem
2, Evaporativemission ontrol ystem
3. Catalyticonve(er

W
SOLENOIDALVE
(PURGE ONTFOI)

AR
-til
CANISTEF

GHECKVALVE TWO_WA

F-98
 

POStrtvEGRANKCASEENTILATIONPCV)S YSTEM F
posrilvE GRANKCASEENTILATIONPCU SYSTEM
DESCNIPTION
ThePCV alve s operated y the ntakemanifold acuum.
When he engines running t idle, he PCV alve s opened lightly nd a small mount f blowby as
is drawn nto he ntakemanifoldo be burned.
Astheenginespeedisesthe CV alvesopenedurther, llowing proportionately argeramountotl ow-
by gas o be drawn nto he ntakemanifold.

PCV VALVE
Inspectlon
1.Warm p heengineo normal peratlngemperaturend
run t at idle.
2. Disconnect hePCV alve ndthe entilationose rom he
cylinder eadcover.
3. Block he PCV alveopening.
4. Verifyhatvacuum s telt.

5. Removehe PCVvalve.
6. Blow hrough he valve rom port@ andverifyhatairflows
lromot gort 6).
7. Blow hrbughl-healve lomport@ andverityhatno air-
flows kom of port @.
8. Reolacehe PCVvalve f not as specified.

F-99
 

F EVAPORATIVE ]IIISSION ONTROLSYSTEi'

EVAPORATIVE M]SSIONCONTROLSYSTEM
DESCRIPTION
INHIBITOHWITCHATX)

THFoTTLE ENSoF

)\M
\lh-
s!q.t
OXYGENSENSOB

WATEF TH€RMOSE

q_l
rnrrori sersoa

CANISTEF

@ CHECKVALVE

FIJELVAPOFIV ALVE

Theevaporativemission ontrol ystem onsists f the uelvaporvalve' he-ch€ck alve two'way)'he

chircoaicanister,h e solenoid alva purge ontrol),h e engine ontrol nit ECU)' nd he nputdevices'
Theevaporative u mes rawnnto heengine ndburneds controlledy purge ontrol olenoidalveThe
ibU a.G"is fneenqine's peratingoniitions y hevariousnput evices ndcontrolstheolenoidalve
operation y electricalignals ccordingo these alues.
Operation
ilie solenoid alve purge ontrol)scontrolledy signalsrom he ECU o periorm urging f hecharcoal
canister. urgings donewhen heseconditionsre met:
(1) Afterwarm-up
(2) Drivingn gear
(3) Acceleratorpedal depressed
(4) Oxygen ensorunctioningormally

F-l00
 

EVAPORATIVE MISSIONCONTROL YSTEM

SYSTE" OPEFATION
1 Wam up heengineo normal peratingemperaturend
run I at idle.
2. Disconneclhe vacuum ose rom he solenoid alveas
shownn hefigure, ndverifyhatnovacuums eltat he
solenoid alve.
3. f not as specified,heck he solenoidalve

SoLENO|DVALVE PURGE ONTBOL)

Inspection
1. Drsconnect he vacuum oses om he solenoid alve
2. Verity hatno air lows hrough he valverom port@ to
pon @.

3. Disconnecthe solenoidalve onector nd apply12V.

4. Verifyhatair lows hroughhe valve rompgrt@ t9 pgt!
CD.i no air s elt,measureheresistancel the solenoid
valve.
Reslstance: 2 + 20
5. f not as specified,e placehe solenold aNe-

'-?j-r1 Removal Inslallation

(30-110,6e-9q '1.Disconnectthevaporativeosesiromhesolenoidalve
2. Disconnecthe solenoidalve onnector.
3. RemoveJheut and he solenoid alve.
4. lnstalln the reverse rderof removal.
Tlohtenino orque:
?.4-t r-Nfl 480-1 O cm-kg,69-95 in-lb)

FUELVAPOBVALVE
Inspectlon
hevalveromport@ asshown
1.Verifuhatair lowsthrough
in he ioure.

F-10t
 

F EVAPORATIVE MISSIONCONTROL YSTEM

2. Verify hat no air lows hroughhe valve romport @ as
shown n the gure.
3. Replace valve f necessary.

CHECKVALVE GWO-WAY)
Inspecilon
1. Removehe valve.
2. Check he operation f the valvewitha vacuum ump.
Blow ,lroughvalve rcm Pon @
Applyapprox. 7 mmHg 1.46nHg)
vacuumat port @
Applyapprox. 4 mmHg 1.73 nHg)
vacuumat port @

3. Replacehe check alve f not as specified.

CHARCOAL ANISTER
Inspectlon
1.Visually heck or damage nd cracks
2. Blowair ntoeachportandverify hat heyarenotclogged.
3. ReDlacehe charcoal anisterf not as specified

F-l02
 

CATALYTICCONVERTER YSTEM F
CATALYTICCONVERTER YSTEM
DESCNIPTION
Thecatalytic onvertereducesCO,HC,andNOxby chemicaleaction.heconverterontains latinum
andrhodium ompounds.

01E0F2.1{s
CATALYTIC ONVERTER
Inspection
Ngte
. The insulatorcannoi be removed.

Removehecatal!4iconverternd visuallyheck or deteri-

oration nd cracks.

F-l03
 

F DECELERATION ONTROL YSTEM

DECELERATION ONTROLSYSTEM
DESCRIPTION
Thedashpots used o prevent he hrottle alve romsuddenly losing
osuoFx
ss

DASHPOT
lnsgeclion
1. Open he hrottle alve ully.P ush hedashpol od witha
fingerand verity hat t goes nto hedashpot lowly
2. Releasehe rod and verify hat t comesout quickly.
3. Replacehe dashpotf notas specified

4. Warmup the engine nd run t at idle

5. Connect tachometelo the diagnosis onnectorG-
terminal nd ncrease ngine peed.

DIAGNOSIS
CONNECTOB

6. Slowly ecreaseheengine peed ndverifyhat he ever

toucheshe dashpot od at the specified peed.
Specification: ,500 + 100 rPm
7. f notasspecified,o osenhe ocknut nd urn he adjust-
ing screw o adjust.

F-l04
 

A./CCUT.OFFSYSTEM F
A/C CUT.OFFSYSTEM
DEsihrPrtoN
To mprovedlesmoothnessfteruststartingheengine nd o mprove ccelerationerformance,n AJC
cut-offsvstem s used o controlA,/Coperation.

THFOTTLESENSOR

DETEFMINATION

u'o"""o*'1=:9J-1 MAGNEITC
CLUTCH IGNITIONSWITCH

fr" .*,r""

I
Operation
TheA,/Cs cut off under he conditions elow.
E glne condlllon Cui-otl pcriod
Thrcttlevalve ully open
lmpfoveddravabilily
Accelerationrom stop

SYSTEiIOPERATION
:. ;.!9- rHRorrLEL'NK 1. Turn he gnition witch, lowerswitch,ndA,/C witchON.
2. Openhe hrottle alveandverity hat headditionalfantops
for approximately 1 second.

F-l05
 

DECHOKE ONTBOLSYSTEM
DECHOKECONTROLSYSTEM
OESCRIPTION
iJtacifitate tartinqne engine t thesparkplugsbecomeouled, uchas when he engines looded,uel
injectionscut t h; thronle alve sheldwideopenwhi'e rankingheenginef heengine oolante mpera
tu'rJisO"C iz"n or uelow. hisallowshesparkplugs o dry and purges xcessuel rorn hecylinders

CFANKANGIESENSOE
INJECTOF
DEIEFMI.
NATION
cur
THFIOTTLEENSOF

WATEFTHEFMOSENSOR

SYSTEMOPERATION
1.Ve4fuhat he enqrne oolantemperaiures below ooc (32oF)
2. Verii that he enainewill not slartwhencranked t normal peedwith he hrottle alve ullyopen.
3. f theengine tarta,n specthe hrottleensor.Reiero pageF-122 and he ECU erminal Uvoltage.
(Relero pageF-116.)

F-l06
 

AIR BYPASSCONTROLSYSTEM F
AIR BYPASSCONTROLSYSTEM
DESCFIPTION
Theair bypass ystem perateso improvedlestability ndvehicle rivability.
Thissystem upplieshrottle alvebypass ir nto ntakemanilold ccordingo engineoadcondition nd
driving onditions.
Thissystem onsists t two solenoid alves ontrolled y the ECU.

AA AYPASSSOLENOIO ALVE@
ArF BYPASS OLENOTOALVE@ AIF BYPASSSOLENOID ALVE@

THAOTTLEVALVE

Operation t Ai. BypassSolenoidValve

Air bypa$ aolenold wlve
Englno condltlon
@ @
Duing cranking To improve$anability o o
lgnition wilchOFFrON To prcvenl rorn slickng o
'Acc€ssoryON o
P/Spressure w{ch ON To improvesrartability o o
,dJCswilch ON o o
Wam up (asoc-8ooc) o
SelecleverN-D (ATX) To alleviats sudden engine speed drop o
Dunng d€celelation {d€celelation conlrol) To improvedivabilty o o
'Accessoryis headlights, earwindowdefrosler,blowerswilchand coolingJan.

F-107
 

AIR BYPASSCONTBOLSYSTEM
FAST DLECAM
SYSTEMOPERATION
1. Warmup the engine o normal peratingemperalure
2. Verityhat he hermowax nit ode)dends utwardullyand
that he cam separatesrom heroller.
3. lf lhe electric oolingan is operating, aituntil t stops.
4. Verifyhat heengine s idling moothl,

5. Verifuhatclicks heardrom heail bypass olenoidalve

@ when urninghe ollowinglectficalloadNandOFF
Electricaload
. Blower an
. Headlight
soLENoto . Rearwindowdetroster

/ry
vALvEO
\

6. Verityhatclick s from he air bypass olenoid alve@

when he enoine tans.

7.Turn he gnition witch, lower witch, ndAJC witchON.

8. Rotatehe hrottleink by hand.

s heardrom heairbypass olenoidalve

L Verirythatclick
@.

F-108
 

AIR BYPASSCONTROLSYSTEM F
AIB aYPASS OLENOTDALVE@, @, @
Inspeclion or contlnuhy
AIF SYPASSSOLENOID AIF BYPASS OLENOID
1. Disconnectachair bypass olenoid alve onnector.
2. Inspector continuityetweenhe solenoid alve onnec-
tor terminals.
3. Replacehe air bypass olenoid alve f not as speciiied.

AIR BYPASS OLENOID

VALVE@

Inspection or Airllow
1. nspect ir bypass olenoid alve@.
1)Removehe air cleaner.
2) Closehe bypass ir passage ith ape.

\
r-i

3) Disconnecthe bypass ir hose rom heair bypass ole

noidvalve@ as shown n the igure.
4)Verifythatoairflowsthroughirbypass olenoidalve
@ whenblowing ir ighty nto he air bypass ose.

',:,,%rc,!
sotENotoVALVE

5)Turn he gnition witchON.

6) Groundhe ermlnal@ as shownn the lgure.
DISTFIBUTOR 4 Verifyhatair lowshrough irbypass olenoidalve@
whenblowing ir nto he air bypass ose.

2. Inspect ir bypass olenoid aive@, O

d
1) Bemove ir bypass olenoiddve @ or @.
2) Blow hroughhevalve fom port@ andverify hatno
air comesoutof port @.
3)Apply12V o the solenoid alve onnector.

r-:\*
trtlW
4) Blow hroughhevalve romport@ andverify hatair
comes ut oi port@.
Adiustment idle-upspeed)
Relero pageF-64.
__-,/'
PATTEFY

F-l09
 

F CONTROLSYSTEM
CONTROLSYSTETI'
PREPARATION
ssT

49920016 2 49 GO18 03

E CU ECU
Engine ignal

49 GO18 04 49 D015 01

Sheet ECU

49 80199A O
Syslem ignitioniming
Seiector

F-l10
 

CONTROL YSTEM F
STRUCTURAL IEW

1 .E C U 6. Oxygen ensor
R e p l a c e m e n t . . . . . . . . . . . - . . . .a. .g. .e. . . . . . . . . I n s p e c n o n . . . . . . . . . . . . . . . . . .pageF. . . . . . . . .123
......
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g. e
.....-.... R e p l a c e m e n t . . . . . . . . . . . . - .page . . . . . .F. . .124
......
2. Crankanglesensor 7. vlain elay
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g. e
.F-120
........- R e p l a c e m e n t . . . . . . . . . . . . . -page . . - . . .F. . 124
.......
3. Airflow ensor I n s p e c i r o n . . . . . . . . . - . . . . , , . .page, . . . , F-124
,,,-......
Inspeclion..... .. . ... .. page 8. Clutch witch MTX)
RemovalI nstallation................ age I n s p e c t i o. .n. . . . . . . . . . . . . . - . . . .page
. . . . . F-124
......
4. Water hermosensor R e p | a c e m e n t . . . . . . . . . . . . . .page . . . . . .F-124
.......-.
R e m o v a | . . . . . . . . . . . . . . . . . . . . . .a. .g. .e. . . . . . . . . . 9. Neutral witch MTX)
I n s p e c t i o n . . . . . . . . . . . . ..-.... ...p a g e I n s p e c n o n . . . . . . . . . . . . . . . . . .page . . . . . .F-125
.........
5. Throttle ensor R e p l a c e m e n t . . . . . . . . . . . . . .page . . . . . .F-125
.........
InspecLion Adjustme.t..... . page 10.P/Spressurewitch
I n s p e c n o n . . . . . . . . . . . . . . . . . .page . . . - . .F-l25
.........

F-111
 

F CONTROLSYSTEM
ENGINECONTROL NIT ECU)
Reolacement
'1.Removen the ordershown n the igure.
2. Installn the reverse rderof removal

.3-rr (60-rr0,69-es) (

1. Negative attery able 3. ECUconnector

2. ECU
I n s p e c l i o n . . . . . . . . . . . . . . . . . . . .a. .g. .e. . .11
. . .2. . .
Inspection
1.Disconnecthe ECUconnectors.
2. Connectthe STS EngineSignalMonitor ndAdaPter
Harness)o the ECUas shown.

a1EAF2210
F-112
 

CONTROLSYSTEM
3. Place he SST (Sheet)on the EngineSlgnalMonitor.
4. Measurehevoftage t each erminal.
(Refero pages 114 o F-119.)
5. f anyECU ermjnaloltages ncorfect,heck he elated
6 ' d inpuior output evices ndwiring.f no problems ound,

ffi replacehe ECU. Refero above.)

o .
Caulion
. Neverapply voltage o SST erminalsA and g.

-d'
6

ffi

F-l13
 

F CONTROLSYSTEM
Terminalv oltage (reterencedata)

f6r|rrlntl Input Ouipul Connecilon o Te€tcondillon Canpct olrge Rsmatt

Batlery Constani Batery ollage

]B o lgniljonswitch
OFF
iFUEL NJ reay ) ON Batleryohage
1c o lgnltionswich
(STABI) gnitionswitchON
1D o Self-Diagnosis Tesr witch l "SELF-TEST" WithSelt
Checker Lamp lluminated o r 3 sec afler gnilion Diagnosisheck-
(Moniloramp) switchOFF*ON
Lampnot lluminaledtter sec. Baneryollage Seleclor
"O2 MONITOF aI idle
Tesrswilchat
Monltor amp lluminated
Test switchat "O2 MONITOF aI idle Batleryo[age
Montor lamp nol iluminaled

o SellD agnosis Buzzer oundedor 3 sec.aflergnitDn Below .5 v

Checker swltchOFF*ON Diagnosis
(Cod€Number) uzer notsounded tter sec. Baneryotage
SystemS€leclor
Below .5V

o lgniter lgn,ron w ch ON
(ind strlbutoo ldle Apprcx. .5 V
1H
o C rc'ritopenlng
ON Batery olage
lgnitionswilch
STABT Below 1.0V
ON idle)
]J o IJC relay lgnition wilchON Batieryvollage
A/C ON Below2.5V
ldle
Batery oltage
o Dlagnosis Sysiem Selector est swilch at
"02 MONITOR"
Balteryvoltage

(TENerm al) System Se ector iest swltch al Below.0 v

,,SELF.TEST''

]L
l lvl o lgnlion swilchON

1N
10 o Stopllght wilch Brakepedalr€eased Bslow .0 V
Brake pedal depressed Batery olage
o lgnilon switchoN Battery otage
P/SoN ar dle Below .0 V
P/S OFF at dle Batery o[age

F-l 14
 

CONTBOLSYSTEM F

Inco]r€ct Yolt.ge
Always V ($aner urns)
Always battery voltage
ROOtvl 0,Alse burned
Op€n rcuii n wi ng komROO|0A fuse o ECU eminal14
Mainrelaymallunclion Rel6r o page F-124)
Op€n or shortcircuit n wiring rorn main relay o ECU erminal18
. Open r shori ircuitn wiringrcm gniton witch MTX), r inhlbitorwitch
iAlx) to ECU erminal C
Main elay FUELNJ etay)mallunclionRelero pageF-124)
Op€n ircuitn wiing ,rommain elayo diagnoslsonneclore rminal B
Open r shod ircuitn wiringromdiagnosrsonn€clore rmlnal EN o
ECU erminal D
Poor onnectiont ECIJ onnector
ECUmallunclion
ECUmallunclion

No displayon Self- Main elay FUELNJ elay)malfuncllonRelero paseF-124)

2.5V oiagnosisChecker Open irclit n wirlngrommain elayo diagnosisonnectore minal+B
''SA displayedand . Open or shorlcircuil n wiing from diagnosis onneclor erminalF EN o
ECU ermlnal1F

Always Baliery voltage Poorconnection l ECu connector

ECUmallunction
. Shoncircuit n wirinS iorn gniter o ECU eminal 1G

B efero paseF-124)
t.4alnelay FUELNJ relay)m alrunclion
Poor onnectiont ECU onnector
Open kcuil n wking romcncuit peningelay o ECU erminal l

. Open ircuitn wiing romAC reay o ECLJerminalJ

. Shon ncoitn wirng romdiagnosisonnector o ECU erminalK

erminalTEN
Alwaysbatleryvonage . Open ncuitn wiins tromdiagnosisonneclore rm alTEN o ECU em|
. Open icuil in wirinsfomdiagnosisonneclore rminal ND o ground

AIways V or Approx. V . Open r shon ircoii n wiringrcrn peed witchSeclion)to ECU emi
na 1[,1

Always elow1.ov sloplights K) . Open ircuitn wiringroms1opllghtw ilcho ECU em nal10

P/S ressurc witchmallunclloneier o pageF-125)

Short ircuitn wning romP/Spressurewitch CU erminal P
ECUmatlunction
Always battery vollage P/S ressurewilchmaltunclionR efero pageF 125) 1P
Open tcuil n wking romPA presslfe wilcho ECU e|nrinal
Op€n ircuil n wiringromP/Sprcssurewilch o grcund

F-l 15
 

F CONTROLSYSTEM

TenninJInput Oulprd Test condition Cor'ecl Yolage Remark

10 o lgniton switchON PJC W N and Below 1 0V

A/C SWOFF Batleryollage

1R o Coolingan operaungeng ecoolant Below .0 V
temperaturever97'C (207'D of das
nosls onnectore mina TFAgtounded)
Fan nol operatinq idle) Batreryolage
o BlowercontrolswitchOF F Batery otage
Elower ontrol witchON Below .0 v O N

1T o RearwindowdeiloslerswilchOFF Below1 0V lgnlion switch

Rear w ndow de'roslerswlch ON Batlery ollage O N

o l-leadliq swnch HeadlighlsON Batery voltage

HeadlighlsOFF Below .o v
o Neutral/Clutch Nedral posllion r clutch Pedal Below .0 v
swilches (MTX)

Olhers Batery oltage

Below . 0 V
(ATX)
Others Banery oLlage

Ground lnieclor) OV
28 Ground Oulpul) OV
2C Ground cPU) Constani OV
2D Ground lnput) Constanl OV
2E o lgnitionswitchON
(indisrributoo or 5V
(Ne'sisnal)

2G
2H
2l
2J Ground TITX Below 1.0V
Open ATX Batleryvolage
2K o Throttle enso/Ec
(ATX)

?t

F-1 16
 

CONTBOLSYSTEM F

. Open ircuitn wiing lromAJC witcho ECu erminal 0

Always baltery vollage . A/C sulch maliunclion Reler o Secti on J)

Open r shorl ircuitn wirng rom an retayo ECU effnina B

(elect c cool ns tan OK) ECUmallunction

Alwalsbelow1.0V bloweran OK) Shon ircut n wiring romblower onlrol wilch o ECLJerminal 5
Poor onnecliont ECU onneclor
ECUmaltunclion
Alwaysbatleryvoltage blower an OK) . Open rcuit n wirins rcmblower ontrol wilcho ECU erminalS
llluminalion
a mpON Op€n r shorl ncuirn wirlngrom earwindow strosl€rwtch o ECU
t.0v lenninal T

Open n ng rom gnition rearwindow elrosterwilch

neverON Fearwndowdefrosterwitchmalfunction B elero Section )
Alwaysbelow 1.0V HeadlighlsOK) . Open r shoncircuitn wiringromheadlighle layo ECIJ erminalU

Neulfal wilchmallunctonRefero pageF-125)

B eler o pageF-124)
Clutch witchmaliunction
Shon ircuitn wnino romECU erminalV to neukal r ciltchswitch
Neutrai wilchmallunclion o F-125)
Clulchswlch malfunctionRerero page F-124)
Opencrcut n widng rom ECU enninal1V o neutral r clurchswitch
Poorconneclion t ECU connector
Inhbilor swltchmallunctionReler o SectionK)
Short ircuitw iringrom nhibitorwitcho ECU erminal V
nhibitor wilchmallunclion Refer o SectlonK)
Openorcult in wiring rorn nhibitor wrtch o ECU rerminal1V
Poor ontacl l ground erminal
Open ircuitn wirng romECU o ground

Always pprox0V or approx. V . Refer o Troubleshooting, ode No.02 Reler o page F-70)

A ways battery vollage . Opencircuilwiring rom o ground

Shon ircultn wiring romECU enninal K o thrctlle ensor CAT convol

unil ATX), r ln aidowsensor
Poor onnectiont ECU onneclor
ECUmallunclion
Beow 4.5V of above 5.5V . ECUmailuncton

F-117
 

F CONTROL YSTEM

Teal condition Consct ontgg Rcmark

Inpui Oulput connection lo
-
-:. o Thrcttle ensor c_ Accelerator Pedal releas€d
Accelelalor pedal lully depressed
(ATx)

2N o lgnron switchON
ldle (coldengine) OV
0-0.1v
lncreasngengrnespeed altefwarmup) 0.5 1-0v
0-0.4v
20 o lqn,lon sw{ch ON
(positive) ldle Appfox. 1.2V
OV
2P o
(negatve)
2A o Engine oolantemperature0oC 68oD
Below .5 v
o Engine ranking nd ew seconds iter Appox 2.3V
2R
noid valve @
Other conditon Battery dlage

2S
2T o AccessoryON
nold valve@ Oth€rs ondition Batleryonage
2U hjector (negative) Constant
EngineSignal
2V o Inieclor positive) lgniton swtch ON
Below1.0V
I ash

o
noid valve @ ON Batleryvdlage

o Solenoid alve lgnition witchON Baltery oltage

(purgeconlroD ldle Batteryohge

OFF OV
2\ o lgniUonwitch
ON
22 o EC'AT onlrolrnrl Enginecoolant empelalurc elow70'C
(ATX) (15860 at rdre
Engine-o olantemperaLrrebove o' C Batery ofiage

F-l18

Incorrect voltage
Always pprox V aflerwamr-up
Always pprox. V or approx. V
Always approx. 0V or approx. 5V
Always pprox. V or approx. 2V
Alwaysapprox.oV or appfox. 12V
CONTROLSYSTEM F
Open ircuiln wking romECU ermnal 2[,1 o throtte sensor
Open rcuit n wiringromECU ermnal 2K to thrct e sensot
Open lrcuitn w1ringrcmECU ermnal 2D to lhrclilesensor
. Throtfle ensormrs3dtushent
. Belero TroubleshootingodeNo.15 Reiero pageF 74)
. Refer o Troubleshooting,ode No.17 (Refef o page F 75)
. Refer o Troubleshooting,ode No.O8 8efer o page F-71)
. Open ircuiln wirinSromECU erminal P o airllow ensor
. Reier o Troubleshootns, ode No.09 Reier o page F 72 )
. Ferer o ftoJblesnoor,ng. ode No.35 Feler o page F-78)
. Feler o T ouble.hoorng,C ode No 34 (Beler o pagF F-781
. Openor short ircuitn wing irom njectoro ECU enrinal v
. Open ircuiln wiins lrom njecloro ECU €minal2V
. Open or shortcrcu't in wking frcm ECU terminal W 10air bypass olenold
valve O
. Reter o TroubeshoolinS, ode No.26 Reler o page F 77)
. Oper crcLrr 1 wrflng rom man relay o ECU r€lmrnal Y
. Openor shoncircuiln wr ng romECU erminal 2 to EC'AT onlrol nit
termlnal N
F-119
 

F CONTROLSYSTEM
CRANKANGLESENSORlN OISTRIBUTOR)
Inspection
Befero SeclionG.)
2. Connect he distributoronneclors shownn the igure.
3. Connect he high-tension e ad.
4. Turn he onition witchON.

5. Connecthe SSTS EnglneSignalMonitorand Adapt-

USECONNECTOFI el) to the ECUas shown.
6. Set heSSTS EngineSignalMonitorandAdapler) er-
minal E.

7. Botatehedistributorriveby handandmeasurehe ou!

put voltage.

Speclflcation
ferminal Tesl condition Voltago
2E Rorate istributorne ull urn Apprcx.5V 4 pulses)

8. After he nspection,nstallhe distributor.

(Refero SectionG.)
9. Stari he engine nd adjust he gnitionimlng.
(Reiero pageF-63.)
^- t:,?\ lgnition imlngrBTDC16 + 10
l;-\'
l,!,-,: 0.Tightenhe distributoro ckbolts o the specifiedorque
Tighlening orque:
t6-23 N.m 1.6-2.3 m-kg, 12-16 tt'lb)

F-120
 

CONTROLSYSTEM F
INJECIIONBODY ATRFLOWENSORBYPASSHOT-WIRE YPE)
lnapoction
1. Removehe air cleaner.
2. Visuallyheck or anopencircuit f heairflow ensor ot
3. Check he airflow ensor ody or cracks.

4. Disconnecth e airflow ensor onnector.

5. Using n ohmmeter, easureesistanceetweenhe er-
mrnals.

;
Speciticaiion

ffi-fl
Terminal F$islance (20'C I68"Fl)
A - B
A - C
B - C

Femoval Installalion
Reler o page F-84.
INTAXE

FIEPLACE WATERTHERMOSENSOR
WATERIHENMO Removal
SENSOR 1.Disconnecth e water hermosensoro nnector.
2. Removehe water hermosensors ing he SST.

lnboeclion
1.Placehesensornwaterw ithathermometernd heat he
watergraduallY.
2. Usingan ohmmeter, easureesistancef the sensor.
Coolant FesisancekO)
-206C |-4aF) 1 4 . 6 17.A
o.c ( 32.D 6.5
2o.c ( 68.R 2.21- 2.69
4 0 o c (10!oR 1.0 1.3
6 0 o c (140oR 050, 0.65
8 0 o c {176oR 0.29- 0.354

3 , 0

n i
(ko) 2

WAIEFTEMPEMIUFIE {"C I"FD

F-121
 

E
a CONTROL NIT
THROTTLE ENSOR
Inspection
1.Warm the engine o normal peratingemperature.
2. Verifyhat he hermowax nit od extends utwardullyand
the cam separatesrom he roller.
3. Stop he engine nd urn he ignition wilch o ON.
4. ConnecttheSSTSEngineSignalMonitorandAdaptet
Harness) o the ECUas shown.
5. Set he SST (EngineSignal Monitor) o terminal M.

6. Rotatehe hrottleinkby handandveriiy hat he voltage

is within pecifc ations.
Speclflcallon
Throtlle valv€ conditon
ECUTerminal

2M 0.30 0.80v

7. ll not as specified,diusthe hrottle ensor.

Adiustment
1. Connecthe SST o thediagnosisonnector.
2. Setswitch@to position .
3. SetTESI SW o SELF-TEST.
Note
. lf the SST s not used, ump across he TEN ermi-
nat and the GND erminalsol the diagnosiacon-
neglor.

4. Loosenhe hrottle ensor crews.

5. Rotatehe hrottle ensor radually nd until hat he volt'
age s withjn pecification.
6. Afleradiustmenl,ightenhe hrottle ensor crews
THFOTTLE 7. Removehe SST.
SENSOB

Removal Inslallation
'1.Turn he gnition witchOFF.
2. Disconnecthe hrottle ensor onnector.
3. Removehe hrottle ensor.
Cautlon
. Do not drop the thloule aensor.

4. Adjust he hrottle ensor fter nstallation

(Refero pageF-122.)
fNJECTfON BODY Ztt n l.trtg, tFbl

F-122
 

CONTROLSYSTEM
OXYGEN ENSOR
Inapectlon ol Termlnal Voltage
1.Warm p heengineo normal peratingemperaturend
run t at idle.
2. Disconnecthe oxygen ensor onnector.
3. Connecta voltmeterbetween he oxygensensorand a
oround.

OXYGEN ENSON ONNECTOF

4. Measurehevoltage hile ncreasingnd decreasinghe

".+try'",,' engine peed uddenly everali mes.
-\1 Specitication
Engine ondilron VoltageM
Below .4
Above0. 5

o
@ o
5. Replacehe oxygen ensorf notas specified.

Inspectlonot Sensitivity
1.Warmup he engineo normal peratingemperature.
2. ConnectheSSTS SystemSelector and Self-Diagnosls
Checker) o the diagnosisonnector s shown.
3. Set switch@ to position .
4. SetTEST W o Oz MONITOR.

5. Increasehe engine peedo between2,000and 3,000

rpm, andverilyhat hemonitoramp lashesor 0 sec..
lf not as specified,eplacehe oxygen ensor.
(Refero pageF-124.)

Monltor amp:Flasheamore han S imes/l0 seconds

5AF-m6|$S6 o€OGR
6. Replacehe oxygen ensort not as specified.
;O-. ooo tl_l
/ 1r\ o r:] I
MONITOF

lnspectionot Heatel
1. Measureesistanceetweenerminals@ and @.
Realstance: 0 (20"C l68oFl)
2. Reolacehe heaterf not as soecified.

F-123
 

F CONTROLSYSTEM
Replacement
1. Disconnecthe oxygen ensor onnector'
2. Removehe boltsand remove he exhaustm anifoldn-
sulator.
i--1t lrFJtl / 3. Removeheoxygen ensor.
OXYGENSENSON 4. nstalln the reverse rderof removal
Tiohteninq orque:
-N.m
is-lg (it-s m-t<g, 2-36 ft'lb)

MAINRELAY
RELAYBRACKET neolacemeni
1. Disconnecthe negative atteryerminal
2. Removehe ECU.
3. Removehe relavbracket.
4. Removehemain elay rom he relaybracket
5. nsialln the reverse rderof removal.

Inspectionof Continuily
'1.iheck conlinuity etweenermrnals
@ and @
TerminaLs Apply12 V Continuity
r--:7-
(cF-l-{d)
Y Y @-@ No
faloouYD
r_-____J 2. ReDlacehe main elayf necessary.

cLuTcH wrTcH MTX)

InsDectlon
'1.Disconnecthe clutch witch onnector'
2. Connect nohmmetero theswitch
3. Check ontinuityf the switch.
ContinuLiy

No

4. f not as specified,e placehe clutchswitch

Replacement
'1 ioosen he nutsand removehe clutchswltch
2. nstallheclutch witch.
3. Adiustheclutchpedalh eight eferringo theaboveand
the height pec calrons.R efero SectionH )
4. Trohtenhe nuts o the specifiedorque
Ti-ohfeninqo.que,
-t*m
io-zs (2.0-z.s m-kg, 4-18 ft-lb)
CLUTCH EDAL

o1aoFr103
F-124
 

CONTROLSYSTEM F
NEUTRAL WITCH MTX)
Inspection
1. Disconnectheneutral witch onnector hownnthe iqure.
2. Connect n ohmmetero the switch.
3. Check ontinuityl the switch.
Contnuilv

Other anqss
4. lf not as soecified.e olacehe neutral wrtch.

Replacemenl
1.Disconnecthe neutral witch onnector.
2. Removehe bracket.
3. Removehe neutral witch.
4. Installn the reverse rderof rcmoval.
Tightening orque:
20-29 N.m 2.0-3.0 m-kg, 14-22 ft-lb)

POWER TEERING RESSUREWITCH

In€pectlon
1.Disconnecthe P/Spressurewitch onneclor.
2. Connect n ohmmetero the switch.
3. Stariheengine nd et t dle.C heck ontinuityf heswitch
while urning he steering heel.
P/S Continuily
Turnrng
Nol urning
4. lf not as specjfied, eplace he P/S pressure witch.

F-125
 

ENGINE LECTRICAL
t N D E X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-. .2. . . . . . . . . .
- 3 ...... ......
ouTLrNE...... ...... ....... ...... ...... .......
SPECrF|CAT|ONS.....,...........................-..
- 3 l
TROUBLESHOOTTNG U|DE...................... - 4
DTAGNOSTTC NDEX.........................,......
- 4
SYMPTOIVROUBLESHOOTING......,...,.... - 4
GHARG|NGYSTEM................................. - 6
PREPARAT|ON.......................................
- 6
ctRculTD|AGRAM.................................
- 6
TROU81ESHOOT|NG.............................. - 7
8ATTERY...............................................
- 8
A1TERNATOR........................................
-r0
DRTVEE1T...........................................
-l4
rGNrTtoNYsTEM,...................................
-r6
P R E P 4 R A T | O N . . . . . . . . . . . . . . . . . . . . . . . . . . . -. .r .6. . . . . . . . .
ctRcutTDIAGRAM................................. -16
T 8 O U 8 1 E S H O O T I N G . . . . . . . . . . . . . . . . . . . -. .1.7. . . . . . . .
l G N r T t o Nt M t N G . . . . . . . . . . . . . . . . . . . . . . . . . . . -. l. 8. . . . . .
sPARK 1UGS....................................... -l9
tGNtTloNo11....................................... -20
DtSTRtBUTOR ......-....-.....-......-.....-........ -20
t G N l T E R . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . , .-. 2
, .3. . . . . . . . .
HrGH-TENSTON EA0.............................. -23
START|NG YSTEM.......................... ........ -24
P R E P A R A T I O N . . . . . . . . . . . . . . . . . . . . . . . . . . .-. 2. .4. . . . . . . . .
CIRCUI'l IAGRANiI ................................ -24
sTARTER............................................... -25
 

INDEX
INDEX

YTE LEVEL

7Y
\'t

1.Battery 6. -gnition oil (in hedistributor)

Inspectron...... ....... paSe9 8 Inspection..................-... - . . pageG 20
Recl'argrng .............ageG- 9 7. Distributor
2. Alternator S p a r ke s t . . . . . . ........ . . . . . . . . . . . . .a. g
. .e.G . .- 2 0
RemovalI nstallataon..........-....... ageG-l 0 Eiectronrcdvance nspeclion .. page G-20
Disassembly Assemb|y............. ageG-11 Removal/n slarlation.......... ageG 21
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. g. .e. .G1
. . . .2. . Disassembry Assemb'y........ aqeG-22
3. Drivebelt I n s p e c t i o n . . . . . . . . . . . . . . . . ..... . a. .g. .e.G. .-.2- .3
I n s p e c t i o n . . . . . . . . . . . . . . . . ... .p. .a. g. .e.G. .-.1. . 8. gniter in he distrlbutoo
A d j u s t m e n t . . . . . . . . . . . . . . . . . . . .a. g. .e.G . .-.1. .4. . . . I n s p e c t i o n . . . . . . . . . . .................. .u. .s "9 - ? 9
8 e p 1 a c e m e n l . . . . . . . . . . . . . . . . .a. g . .e.G. .-. 1
...... R e p l a c e r n e n t . . . . . . . . . . . . . . . .a. .g. .eG . . . .2.3. . . . .
4. High-tension ead L Slarter
i n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. e.G. . .2. .3. . . . . Flemoval/nstallation.......... ..pageG 25
5. Sparkplugs Performance nspection...... ageG-27 ....
RemovalI nstaation.................. ageG-19 Disassembly ssembly . .....pageG-28
A
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. g. .e.G. .--1. .9. . . . . inspecron..... ... PageG-29

G-2
 

OUTLINE
OUTLINE
SPECIFICATIONS
Engine 83
'12
Volrage V
Batlery Type and capaciry (2o-houf ale) 34Br L-S 334H)
Dafl' current Mal. 20

Outout 12-65
bu r-n C requlato4
rransrsronzed
Fequlated o age V 14.1 14.7
Slandard 25 (0.98)
Brush ength mm n) 6 (O.24)
Drive bell detleclion 5 5-7 .A 0 21 O.27)
mm (inY98N, 10 ks, 22 lb 6 0-7.5 (0 23-0.29)
Oirect
12-0.85.1MTX)
outpur V.kW 12-0.95 Ar-4
Starter
Slandard 17 (0 65)
Brush englh rnm (rn) 1 15 (0 45)
lVinimum
Dsrriburor ESA
lgnilroniming BTDC t6
(IEN iermina oi dagnosis connectorgro'rnd)
0.68-0.840
Fesslance 20oC [68"F]]
9.6,14.4k0
BKRsE-11
NGK BKR6E11
Tvpe K16PR.UI1
Spark pllg NIPPONDENSO K2OPR.U11
Plussap mm rn) 1 0-t 1 (0.039-0043)
1-3,4-2

G-3
 

UIDE
TROUBLESHOOTING
TFOUBLESHOOTINGUIDE
DIAGNOSTICNDEX

o. Troubl6hooting lems Page

-1 G-4
will noi crank-starter motor do€s not operare
2 will not crank slartermolor sp ns cF4
a G-5
G-5
Ale 1alorwah 1q laarp rlu-inares whrc enSLre unnrng
5 Dischargedanery G-5
6 Mislire

SYMPTOM ROUBLESHOOTING

1 wlll not crank-starter motor do€s not oPerate

]TEP INSPECTION ACTION
Does ngine rankwith ullycharged anerv? Check charging syslem 17 Page G-7
1

2 ls baneryvollagepr€6ern t terminal8?

TERMINALB

Checkwiringharness

js battery oltagepresental lerminajS with gn i . Check maSnetc witch - Page G-29

3
lion switch n STARTPosltion? . Check leldcol F Page G-30
. Check armalure .? Page G-31

TERMINALS F Section K
. Check nhibtor switch ATX)
. Check sntof swtch r7 Section T
. Checkwring harness

will not crank-statler motor spins

JTEP INSPECTION ACTION
1 ls drve p n on pushedoul while crankrng Removeslarter nd check lywheel ng
(clck is heardwhen pushedoul)? gear teelh and slarier d ve pin|on teeth

Check magnetic wilch e Page G-29

G-4
 

TROUBLESHOOTINGUIDE

3 Cranks alowly
STEiP INSPECTION ACTION
l Does enginecrank normallywilh ully charged Check m'girg syslem s PageG-7

2 Are $aner cable connectionsooseor corroded? Bepairor repace connecton

CHECK
HECK

Ch€ckstadff lor binding suchas

bruslrand armature.)

4 Altemalorwaaningamp llumlnateswhileengine unnlng

INSPECTION ACTION
1 ls baneryvoltageconect al idle? Ch€ckwring haness benreenarcrna-
lor L teminal and alternatorwarnlng
Specificalion: 4.'l-14.7v
Check chaelng system c? Page G-7

Dischargedbsttery
INSPECTION ACTION
1 Check haelngsystem;s t OK? Tum gniuonwilchON and measurc
l? page G-7 darkcurrcnl s shown

Dafkcunenr: elow 0mA

Repair r replace artsas necessary

G-5
 

CHARGING YSTEM
CHARGING YSTEM
PREPARATION
ssT

49 920002 0
Tension auge,

CINCUITDIAGRAM

CHAFTGEAM P

T BATIEFY

II
I

Thealternatorasa self-diagnostic unctiono warnof the ollowing roblemsn the charging ystem-
lf a problem rises, he alternator arningampalluminates
1.Terminal circuit pen
2. No voltage utput
3. Field oil circuito pen
4. Terminal circuit pen
5. Voltage utput oo high

G-6
 

CHARGING YSTEM
TROUBLESHOOTING
INSPECTION acno
1 Check battery voltaget is il cofiecP

Spocltlcatlon: Above 12.4V Chec( batlery rt_ page e-a

2 SrarlenEnei does allernarorw arn^g lamp go Go to ne,( slep

Go io Slep 4

3 ls voltage al alternalor term nals coffect? Checkwiringharness etween erminal

SpeclllcElion:
lon.ONM
14.1-14.7
L 1 4.1 -1 4. 7
S 1 4.1 1 4. 7
. Checkwiringharness
. Replacealtefnator F page G-10

1. Connecl n ammeler70Amin)between Chargingyslem orna

terminai and haness
2. Starl ngine
3. Turnall electricaoadsON anddepress
4. ls output urrenl65A r moreal
2,500-3,000 pm?
Caution
. Do not grolnd terminal a

5 is drive belt e nsionOh ? Replacealternator e pag€ G-10

N iks, b)
Drive belt
451-745 392-588
(46-80, (40-60,
101-176) 88 132) . Adjustdrive belt €nsion
491 589 422 491
(50 60 . (43,50,
110 132) 95 110)

G-7
 

CHABGING YSTEiI
BATTERY
Inapecllon
Electrolyte evel
1.Chec{ the electrol}4e e vel iesbetweenhe upperand
lower ines.
2. f low' add distilled ater; o notoverfill.

Speclfic gravily ol electrolyte

Measurehe specific ravitywltha hydromeler'
Specilication:1 .27-1.29 (at 20"C 168'Fl)

Voliage leat
Check battery voltage

o l s minutesno
Ouick-charge r 1-3 hours
ouick-charse

I
l l
Below 12.0V Above 12 0V

or
Ouick-charge
3-4 hours

-----*J',ou
"*o*Cu
I
Quickcharge or 30 minutesancl
rccheckvollage

rf=r
Below 2.4V Above 12-4V

G-8
 

CHARGING YSTEM
Te]mlnaland cable
1 Checkhe ightnessf he erminalso ensure oodeli?ctri-
cal connections.
2. Check or corroded r rayedbattery ables.
3. Check he rubberprotector n he positiveeminal or proP
er coverage.
4. Cleanhe erminalsf necessary,ndcoat hemwithgrease.

Recharging
Battery Slow harge 4 Ouickcharge (A)
3itB19L€ Under lvlax. 20

Slow{harging
It is not necessaryo removehe ventcaps.

40 (164) 0O076)
TEMPEFATURECTFD

Ouick-charging
Removehebaneryrom he vehicle ndremoveheventcaps.
Warning
. Beto.epertormingmalntenance r rechatging he
banery, urn ofl all a@essoriesand stop the €ngine.
. The negative ablemusl be removed irsl and in-
stalled ast.
. Sel the battery n water when quick{harging to pre-
vent overhealing he battery.

G-9
 

CHARGING YSTEIIiI
ALTERNATOR
Removal Installation
Cautlon
. Be sqre the battery connectionsare not reversedbecause his will damage he reclifier'
. Do not use high-v6hage estefs such as a meggerbecause hey will damage he rectitier'
. Rememberh;t battet vottage s alwayspresentat the alternator erminalB'
. Do not ground erminal L $rhile he engine s running.
. D,onot;tart the engine while the connlctor is disqonnectedrom terminalsL and S'

1.Removen the ordershown n the igure, eferringo RemovalN ole.

2. Installn the reverse rderof removal,eferringo lnstallationNote

7,r-11 |}n {3o-r r0 cGrs, 69-95 h.lh}

19-25O,e-2,6 .-r9) 37-52 (3.5-5.3,27-33)

1. Negative attery able 5. N4ouniing olt

2. Connector 6. Alternator
3. Mounting olt,adjlst nut Disassembly A ssembly............. ageG-11
4. Drivebelt I n s p e c t i o n . . . . - . . . . . . . . . . . . . . . . .a.g. .e.G
. .-. 1. .2. . . -
Inspedron.......................-..........- page G-'14
A d J u s t m e n t . . . . - . . . . . . . . . . . .page
. . . . . .G-14
..........
Replacement...... . . .. . . . . . . . . .page
. . . . . G-15

G-l0
 

CHARGINGYSTEM
Removal lnstallationNote
Thealternator
s emoved nd nstalled
r omundertheehicle.
0rEoGx94

Disassembly Assembly
1.Disassemble n the ordershown n the igure.
2. Assemblen the reverse rderof disassembly.

3,2J.s ($--ne, 2e-3E

bN
(60-30, 53-70)
#9_,5.$-?.3
3.2-3.9 (33-39 2S-33)

46J3 Nm (4,7-5,4 ckg, 3.r-4G fi-lbl

r.6-2.0 (i6-20. 14-13)

orEoGX015
1.Nutset L Stator
2. Pulleyet Inspection..........-........................ ageG 12
3. Front over 9. Regulator
4. Bearing 10.Rectifier
1 n s p e c t i o n . . . . . . . . . . . . . . . . . . . .a. .g. e.G. . -. .1.2. . . . . . l n s p e c t i o n . . . . - - . . . . . . . . . . . . . . a. .g. .eG
. . . .1. 3. . . . .
5. Retainer 11.Brush older ssembly
6. Spacer Inspection
7.Rotor (Brush ndbrush pring)......... ageG-13
a g e 1
I n s p e c t i o n . . . . - . . . . - . . . . . . . . . . . . . . .G. .--1. .2. . . . . 2 . e a r r a c k e t

G-11
 

CHARGING YSTEM
Inspectlon
Rolor
1.Usean ohmmetero measure resistanceetweenhe
slip ings.
Specilicatlon: .4-2.90 (at 20"C [68cq)
eplacehe rotor.
2. l not within pecilication,

3. (1) Usean ohmmetero checkcontinuity etween achslip

rinoand he core.
(2) Replacehe rotor f there s continuity
4. Ule tinesandpapero smooth ny oughnessn heslip
nng sunace.

Stator
1. Usean ohmmetero check ontinuityetweenhe stator
coil eads.
2. Replace he stator f there s no continuity.

3. Usean ohmmetero check ontinuity etweenhe stator

coil eads nd he core.
4. Replacehe statorf there s continuity.

Bearlng6
1. Check or abnormal oise,ooseness,nd sticking.
2. Replacehe bearing(s)l necessary.

01E0GX.020
G-l2
 

CHAFGINGSYSTEM
Rectiller
Cautlon
. Don't uae megger ester to p€vent lhe reclifier trom
breaklngdown.
1. Useananalog hmmetertoheck ontinuityfhe diodes.
Conlinurty
E
B NO
E NO
B

2. Replacehe rectifierf necessary.

Bruah
lf a brush s wornalmosto the imitor beyond, edaceall
the brushes.
Siandad: 25.0mm 0.984 n)
ilinimum: 6.0mm 0.236 n)

Brush apring
1. Usea springpressure auge o measurehe orceof he
brush pring.
2. Replacehe spring f not within.
Standard lorce:
2.9-3.9 N (300-400 g, 10.6-14.1 oz)
Minimum:
0.8-1.2 N (80-120 g, 2.8-4.2 o2)
Note
. Read he spring pressurewlth the brush ip proiect-
Ing 2mm (0.079 n).

G-13
 

CHARGING YSTEM
DRIVEBELT
Inspection
hedrive elts ndpulleysorwea., racks, nd lay-
ing. Replace s necessary.
2. Nleasurerivebelt ensionwitha tenslon auge
Tension N {ks, b)
Dfive belt
451 745 392-588
(46-80, 101-176) 132)
49t-589 422-491
A/C and P€ (50-60 110 132) (43,50, 95-110)

3. reasurethe eflectionyapplyingm oderaleressure98

N, lO kg, 22 lb) midway etweenhe pulleys. djust f
necessary.
Detlection rnmrn)
Dflve bell
5.5 7. 0 6.0-7.5
{0.21 0.28) (0.23-O.30)
8-9 9-t 0
AJC and P/S (0.31-0.35) (0.35-0.39)

Adiustment
1. oosen bolls A)and @.
2. Move healternatorn or outas necessaryy urning d-
iustino ur O.
s. ignt6n ootd@ and @ and recheckhe beltdeflection
Tidhtenino
Boh orquea
N.m 1.9-2.6 m-kg, 14-18 ft'lb)
Bolt @: 38-51 Nm (3.8-5.3 m-kg, 28-38 ft'lb)

G-l4
 

CHARGING YSTEM
Replacement
1. Bemovehe uC andP/Sdrivebelt. t equipped
Note
. Retel to B Section,

2. Loosen lternatorotts@ and @.

3. Removehe afternatoreli.
4. Installtheewalternatoreltandadjustttospecifications
5. Tighten ll bolts o the specifiedorques.
Tighlening torques
Mounlingbolt:
38-51 Nm (3.8-5.3 m-kg,28-38 fi-lb)
Adlustingbolt:
l9-26 Nm (1.9-2.6 m-kg, 14-18 ft-lb)
6. Installhe AJC ndP/Sdrivebeh i equipped, nd adjust
it to specificataon.
Note
. Reter o B Seclion,

G-15
 

IGNITIONSYSTEi/I
IGNITIONSYSTEM
PREPARATION
ssT

49 80199A 0 49 HO189A1
self-diagno€isnd sell-diagnosis
SystemS€l€clor Self-Diagnosis
igniton iming Checker

CIRCUIT IAGRA''

GFOUND

TACHOMEIEFi

DTAGNOSTS
CONNECTOF

IGNITION WTCH

G-16
 

IGNITION YSTEM
TNOUBLESHOOTING
6 fi6tire
JTEF |lrsPEcTtoN ACTION
'
ls "00 displayedon Self-Diagnosis hecker
with gniton swilchON?
.? p.ge F-67 llallunctioncode no. displayed
Checkor cause Belero specified
checksequence) E7 PageF-67

"8a" tlash€s
CheckECU eminal lF voltage t7 psge F-114

Vollag6: Approl l2v

(lgnilioh switch ON)

4 li OK, replace ECU (j page F-112

+ lf nol OK, check wiringharness
belweenECU and SelfDiagnosis

2 Bemove parkplugi s herea slrongblue park lgn ion syslem s normal

whie engines cranking?
Checksparkpug r? gage G-2O

lf OK, Go o next step

lf notOK,clean r .eplace parkplug

3 ls resistance t high-tensioneadsOK?
specification:1 6 m per lm (3.28 l) Repac€ high ension eads
c? page G-23
Afe here orroslon,amage r cracks n h e
disrribulorap and rotof
17 pagec-23

5 ls ignitron oil nomal,

(7 page G-2O

6 Aredisrributoro nnectornd ECUconnector

Measure oltageot @ termlnal

(dislibutorop connector);
s l coffec?

Voltage:A pprcr. l2v

Checkmain use, gnition witch,wiflng

harness, nd ECU

I ls ECUnormal?
l? page F-r12
ReplaceEC U

G-l7
 

IGNITIONSYSTEM
IGNITIONIMING
Adiustment
---.--.- 1. heerg'neo normalperaling e noeralurend
run at rdle P ranqe ATX] r neLtrdlL4TX])
2. Turnall electricalo adsOFF.
3. Turn he uC switchOFF.
4. Connect test achometero hediagnosisonnectorG-
terminal.

_e\,t- tc _

5. Connect he SST to the diagnosis onneclor.

6- Setswitch on heSystem electoro position andTEST

SWITCHo SELF EST.
Note
. To create he est conditionwithout using he Sys'
tem Selector,connect erminalsTENand GNOof
the diagnosisconnectorwiih a iumper wiae.
7. Check he dlespeedand set t to the specitied peedt
necessary.
ldle speed:600-650 rpm (MTX)
810-860 rPm (Arx)

8. Check he gniiioniming.

Specification: BTDC 16 + 1'

9. ll the gnrtronim ng is nol as specilied oose'l he dislribL

tor |oc: bofts nd urn le dlsllibt ol Io makelheadiugment
1O- ighlen he dlstributorock bolts o specilied orque.

15."u-t'\ Tiohteninq torque:

-H.m
-,€=4 ie-za {i.s-z.s m-tg,12-16ltlb)
,N.

G-l8
 

IGNITIONSYSTEM
SPARKPLUGS
Removal Installation
1. Remove nd nstallhe
Caution
. When he spark plug lead s to be pulled ofi, pull
on the boot itself, not the wire.

2. Remove nd nstailhe sparkp ug witha plugsocket.

Caution
. Be sure the socket must be tit squarelyover he
spark plug.
3. Apply ntiseizeompoundrmolybdenum-based ubricant
to the sparkplug hreads.
4. Tightenhe sparkplug o the specifiedorque.
Tightening orque:
15-23 N.m 1.5-2.3 m-kg,11-17 ftlb)

Inspection

)x
1. Removehe sparkplug.
2. Connecthe sparkplug10a high-tension e ad.
3. Hold he highiensioneadwth insulatedliers -1omm
(0,20-0,39 in) froma ground.
4. Crankheengine ndverifyhat heresa strong lue park.
Note
. It there s no spark, eplace he sparkplug or high"
tension ead as necessary.

5. Checktheollowing.f a problemsfound,eplacehespark
plug.
. Damagednsulation
. Wornelectrodes
CAFBON . Carbon eposits
ll cleanings necessary,se a plugcleaner r a wtre
BURNED brush.C lean he upper nsulator lso
. Damaged asket
. Burned ondition

Pluggap:1,0-1,lmm (0.039-0.043n)

G-19
 

IGNITIONSYSTEIIi|
IGNITION OIL
Inspection
Primarycoil rvindlng
use an'ohmmelero ineasurees$anceol he pIimary oll
eplacehe gnition oil.
winding.f notwithin peciflcation,
Specification: .68---0.840al 20oC 68"F1)

Secondary oil windlng

Usean ohinmetero measureesistancef heprimary oil
eplacehe gnition oil.
windlng.f notwithin pecification,
Soeciflcalion:9 .6-14.4 ko (at 20"C [680Fl)

Reolacement
1. Replacehe distributor.R efero pageG-21.)
2. Adiust he gnltioniming (Refero pageG-18 )
01aoGXo40

DISTRIBUTOR
Spark Test
1 Disconnecthe hiqh-tensionead roma sparK lug.
2. Hold he ead5-iomm (0.20-0.39 in) roma ground.
3. Cfank he engine nd hat a strong bluespark s
/ visible.

ElecironicAdvance nspectlon
Verify hat the ignition imingadvanceswith engineac-
celeralon.

G-20
 

IGNITIONSYSTEM
Removal Installalion
1.Removen the ordershown n the igure.
2. nstalln the reverse rderof removal.

{r.c-2.3 Gtg, 12-16 ft-tb)

,:t,
2
a''

o140cx.019
Negative attery able 4. Mounting olt
2. High-tension
e ad 5. Distributor
ageG-23
lnspection...-............................... Disassembly ageG-22
Assembly.............
3.Connector ageG-23
1nspec1ion..................................-

G-21
 

IGNITIONSYSTEM
Disassembly Assembly
'1.Disassemblen the ordershown n the rigure
2. Assemblen the reverse rderof disassembly,eferringo AssemblyNote.

ef
^ )
,

r,o-2,0o0-20, 0.7-1n

1. Cap 4 Crankanglesensor nd gniter

G-23
Inspec1ron................................... lnspection ..... pageG-23
2. Rotor 5. -gnition oil
ageG 23
Inspection................................... InspecUon .. pageG-20
3. Cover

G-22
 

IGNITIONSYSTEM
Inspectlon
Capand rotor
orcorrosion,amage,ndcracks.
2. Replacel necessary.

01E0GX.055
IGNITER
lmpqction
1.Check he ECU. Refero pageF-| 12.)
2. Check hecondition f the connector, istributorap, o-
tor, gnition oil,andhigh-tension e ads.
3. l allarenormal utmisfire tillo ccurs,eplacehe gniter.
01a0GX.021

Feplacemert
1.Replacehedistributor.R efero pageG-21.)
2. Adjust he gnitioniming. Refero pageG-18.)
OlAOGX€2

HIGH-TENSIONEAO
Insp€ciion
1.Measureesislancef high'tensionead.
Spscification:1 6 m per I n (3.28 f)
e adset.
2. f notas specified,eplacehe high-tension

G-23
 

STARTINGSYSTEM
STARTINGSYSTEM
PREPAFATIOI{
ssr
49 E301 1'14
---) installalton l

.-\J--6-)
\--=---

CIRCUITDIAGRAI'

PULL]N COIL

FIELDCOI

G-24
 

STABTINGSYSTEM
STAFTEN
Inspection on vehicle)
Measure
Specitication: bove 12.4v
2. Crankthe ngine, ndverifyhat hestarteru rns moothly.
3. lfthestader oesnot urn, heckthe oltage fterminalS.
4. lf thevoltages above V, emove nd nspecthestaner.
ll thevoltages below V,check hewiring arness,g ni-
tionswitch, nd nhibitor Mich ATX).
01E0GX.O60

Rgmoval Installation
'1.Removen the ordershown n the igure, eterringo RemovalN ote.
2. Installn the revers€ rderof removal,eferringo InstallationNgte.
ATX

a7-5r l+n (3.&-5-3 m.kg, 2H3 n |b)

(t.3-5.3 rkg, 2a-33 fi.rb)

1. Negative attery able 2. S terminal, terminal 3. \.4ountingolt

connector
G-25
 

STARTINGSYSTEM

'a;^ rl-25 l+n O.9-2.3 rlq,

37-51 n (3,3-s.3 rl(g, 23-$ n.|b)

1. Negative attery able 2 Terminal onnectors and B 3 lvounting olt

G-26
 

STARTINGSYSTEM
Removal Insiallation Note
ATX
Thestarters removed nd nstalledrombelow he vehicle.
MTX
Thestarters removed nd nstalledromabove.
01A0GX{25

Pe.tormance Inspection
i,lagnetic awltch
Disconn€cthe erminal\,4 ire,and perlormhe ollowingests.
Pull-ln est
Theswitchsnormalf heoinion iects utward hen hebat-
tery s connecteds shown n the igure.
Caution
. Do not applypowercontinuously or mote han 10
aeconqs.

Hold-ln esl
Aftercompletinghe pullin test,disconnecthe wire rom er'
minalM (with he pinioneftejected). heholdin oil s unc-
tioningproperlyf the pinion oesnot return.

Adiuahent of pinion gap

1. Disconnecthe wiring rom erminalM
2. Whenhebatterys c;nnected etweenerminal and he
starter ody,hepinion illbeejected nd hen top.M eas-
ure heclearancepinion ap)betlveenhe pinion nd he
stoooer.
Note
. Do not applypowercontinuouslyor more han 10
aeconds.
Pinlongap: 0.5-2.omm (0.020-0.078 n)

3. lf thepinion ap snotwithin pecficaton. ake djustmenl

by ncreasingr decreasinghe number fwashers etween
themagnetic witch nd he drivehousing.ihe gap be'
comes maller s the number i washerss increased.)

G-27
 

STARTINGSYSTEM
Disassembly Assembly
i.'-o-iJiJi.6r" in theord;r shown n the figure' elerringo Disessembly.ote
i. iiGii,r.ln *" ,""erie oroerof disasse-mblv, o AssemblyNote

o-r2 (so-l30, 79-ii2)

1. Magnetic witch 5- Front over

l;spection...... PageG 29 9 eYe' . .
2. Rear over T DrivePinion
3. Brush olderassembly B Armature
. pageG-30
Inspection............................... Inspection"" " " pageG-31
4. Field oil
ageG-30
Inspection.................................

G-28
 

STARTING YSTEM
DisaasemblyNote
Drlvs plnlon
Removehe stopper theoverrunninglutchwitha pipe
as snown.

Assembly Note
Drivepinlon
1. Set hedrivepinion nto hearmature nd nstallhe ring.
2. Installh e stopperw ith heSST and press t, as shown.

Inspoctlon
agnetic awilch
1. Usean ohmmetero check ontinuityetweenhe S and
M erminals.eplacehemagneticwitchf here s nocon-
tinuity.

2. Useanohmmetero check ontinuityetweenheS ermi-

naland he body.Replacehe magneticwitchf there s
no continuity.

3. Useanohmmetero check ontinuity etweenhe M and

B termanals.e placehe magnetic witchl there s con-
tinuity.

G-29
 

STARTINGSYSTEM
Brush and brush holder
1. Usean ohmmetero check ontinuityetween ach nsu'
lated brushand the 9late.
Replacehe brushholderl there s continuity.

2. Usea springbalanceo measurehe orceol the brush

spring.
Standard:
18.9-23.1N (1.89-2.31 9, 4.18-5'12 b)

BAUSHSPFING 3. Replacehe spring f notas specified

Brush
It a brush swornalmosto hewear imito r b€yond' eplace
all he brushes.
WEABLIMIT
Standard:1 7mm 0.67 n)
Minimum: l.smm (0.453 n)
STANDARD

Field coll
1. Usean ohmmetero check ontinuityetweenhe M ter-
minalw ireand hebrushes. eplacehe yokeassemblyf
there s no contnuity.

2. Usean ohmmetero check ontinuityetweenhe M ter:

minalwireand heyoke.Replaceheyokeassemblyf there
is continuity.
3. Checkl the ieldcoil s oose.R eplacehe yokeassembly
if it is.

01EOG) O73
G-30
 

STARTINGSYSTE
Armatur€
1. Usean ohmmetero checkcontinuityetweenhe com-
mutator nd hecore.B eplacethermaturetthere con-
tinurty.

2. Usean ohmmetero check ontinuityetweenhe com-

mutator nd heshaft. eDlacethermatureltherescon-
tinuity.

3. Place he armaturen V-blocks,nd measurehe runout

witha dial ndicator.
epairt witha lathe
lfthe unouts notwithin pecification,
or replacehearmature.
Runout:0.05mm 0.002 n)

4. Replacehearmaturet theouteldiamele' f hecomrru'

tator s almos( t or less han he rnlnlmum
5. t thecommutatorurfaces dirty,w ipe t witha cloth; f it
is rough, epairt witha latheor tinesandpaper'
Gdnd lmlt:31.4mm 1.23 n)

6. ll thedepthof hemoldbetween egmentssalmost t or

less han he minimum,ndercuthe grooveso he stan-
darddepth.
Depth : 0.5-0.8mm (0.02-0.03 in)
Minimum:0.2mm 0.008 n)

G-31
 

CLUTCH
- 2
rNDEX.............................................,.,......
- 3
ouTL|NE..,,,....,.,...,........,.........................
spEctFtcATtoNs....................................- 3
TROUBLESHOOTTNG U|DE...........,....,..... - 3
cLuTcH PEDAL.....................................,. - 4
ADJUSTMENT...............................,..,.,...- 4
REMOVALINSPECTION INSTALLATION., 5 -
CLUTCH ABLE,..............................,....... - 6
REMOVALINSPECTION INSTALLATION..- 6
GLUTCH NtT.....,..........-........................ - 7
PREPARAT|ON..,....................................- 7
REMOVALTNSTALLATTON .....................- I
CLUTCH OVER,........-............................ 1
-11
tNSPECTtON......,...................................
-r1
cLuTcHDtsc ...................,.....................
tNSPECTrON.,.....................,.,.,,............. -r1
RELEASE OLLAR.............. .............,....,.,. -i2
tNSPECTtON.......................................... -12
PTLOT EAR|NG.......-.............................. -'2
1 N S P E C T t O N . . . . . . . . . . . . . . . . . . . - . . . . . . . . . -. 1
. .2. . . . . . . . .
FLYWHEEL........................-..................... -l2
rNSPECTtON................,......................... -12
 

INDEX

INDEX

TFANSAXLE ERVICE,
SECTION

CLUTCH WITCH EFVICE.

SECTION

'|. Clutch edal 5. Clutch over

Inspection A djustment. ... ..pageH- 4 Removal/n stallatron...... pageH- 8
Bemoval Inspection I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . a. .g. .e. H - 1 1
I n s t a | | a t i.o. .n. . . . . . . . . . . . . . . . . . .a. .g. e
.H. . . . .5 6. Clutch isc
2. Clutch able Removal/n stallation. ..........ageH- I
Removal/nspection Inspection....................... . ..---..ageH-11
Installation... .. ...... .... ageH- 6 7. Pilotbearing
Removal nstallalion . . pageH- 8
3. Release ollar
Removal/n stallation...... ..... pageH- 8 lnspectron.. PageH-12
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g . .e.H. .-. 1. .2. . . 8. Flwheel
Removal/nstallalion .. pageH- I
4. Release ork
Removal/nstallation.... -.- . .. pageH- 8 Inspection.................. pageH-12 . .

H-2
 

U IDE
OUTLINE. ROUBLESHOOTING H
OUTLINE

Enghe/Transarle Itodel B3
B5Mfi

Diaphragmprng
S€t load N (kg, lb) 2 943 (300, 60)
Oulerdameler mm n) 180 O
lnnerdiameter rnm jn) 12514.92)
Clutchdisc
Pressurelate mm (ln) 3.2 0.126)
Rywheelside mm (in) 3.0 0.118)
Type
5.83
Clutch pedal
Fullsvoke mm s.433)
Helsht Wlh carpet) 196,207 \7.72-8.15)

UTDE
TBOUBLESHOOTING
Problem PoaslbleCause Page
Slipping Culchdisc acingwornexcessiveiy H- 8, 1t
Cbbn disc acing urface ardened r oiled H 8
Pr€ssurelatedamaged H -8
Diaphfaqmprangamaged r weakened H -8
Insuflcientlurch edalp lay H -4
cturch edat licking H -5
H -8
Faulty db€n- Excessiveunoul or damaged lulch disc H- 8, 11
gagoment Cldchdiscsplnes usled i worn Rernoveust or repace H-8
H 8
Diaphragmpringweakened H-8
Excessivelutch pedalplay H-4
Clulch vibraies Clutchdisc oiled H-8
Torsion ubbersweakened H-8
Clutchdisc tacinghardened r damagod H 8
Clutch disc lacing ivels oose H-8
Diaph€gm springweakened H-8
Pressure lale damagedor excessive unout H-8
Flwheel surfacehardenedor damaged H,8
loose or worn engrnemoum Tighlenor replace Feler o Secuons , J
Clutch pedal Pedalshan nor prop€rly ubricated
3licking
CLutchelease oilff damaged H- 8, 11
Poor ubricalon f r€leaseollar leeve H-8
Torson ubbercwsakened H-8
Excessive rankshalt nd play neier to Section B
Pilorbearing worn or damaged H- A, 12
Wornpivot pointsoi reease ork H 8

H-3
 

CLUTCHPEDAL
CLUTCHPEDAL
ADJUSTT'ENT
clurch Pedal Height
Insp€cilon
1 Measurehedistancerom he upper urlace f he podal
pad o the carpet.
(Wlth carPet)
196-207mm (7.72-8.15 in)

2. lf necessary,djust he pedalh eight

I Adiustment
1. Disconnectheclutch witch onnector.
2. Loosenocknut@ and urnclutch witch@ untilthe eight
|s Correq.
3. Tightenocknut@.
Tlohtenlnq oroue:
-Nfl
il-rg {i.l-t.a m-kg, 1o-13 ft-lb)

4. Afteradjustment, easurehe pedal reeplay.

Clutch Pedal Free PlaY

lnsoection
1. Depressheclutchpedalby handuntilclutch esistance
is felt.
Pedal ree play:9-l5mm (0.35-0.59 in)
2. lf necessary,diust he pedal reepla,.
3. Verifyhat hedisengagementeight from he uppersur-
faceof he pedal o thecarpet)scorrectw hen he pedal
is fullydepressed.
Minimumdisengagement elght: 85mm (3.35 n)
(Wlth caryet)

Adiuslmenl
i.-iili t'f'" "r"."" r"""r asshownn he igureThen urn he
adjusting ut @ until he ecommendedlearance @ be
h^/;enhe oin and he releaseever s obtained.

Slandard learance: ,95-2'05mm (0.02-0.081 in)

6ye
-7\\
2. MeasureheclutchPedalP laY.

H-4
 

CLUTCHPEDAL
REIIOVAL INSPECTIONINSTALLATION
1. Removen the ordershown n the igure.
2. Inspectall pads and repair or replaceas necessary.
Note
. Apply lilhium bas€d greaas to the bushlng and pins b€tore installation.

3. lnsiall n the revers€order of removal.

4. After nstallation, erify he clutch pedal ree play. (Refer o page H-4.)

\q '€

1.Adjusting ut 6. Bolt
2. Clutch able 7. Bushing
3. Pedalpad
4. Nut L Spring
5. Lockwasher 10.Clutch edal

H-5
 

CLUTCHCABLE
CLUTCHCABLE
REIIOVAL / INSPECTION INSTALLATION
1.Removen the ordershown n the igur€.
2. lnspectall parts and repair or replaceas necessary.
Note
; Apply firhlum based gtease lo lhe pln and lhe release leve] bslore installation'

3. nstalln the reverse rderol removal

4. Alter installation, erity he clutch pedal ree play.(Refer o page H-4.)

\-,-
\\

1. Adiusting ut 4. Clutch able

2. Pin Inspector damage
3. Clip ageH-4
Adjustment................................

H-6
 

CLUTCHUNIT H
CLUTCHUNIT
PREPAFATION
ssT

49 E301 €0 49 E301 61
Brake,ing gear engine olation Body
49 E301 60)

49 E301062 49 SE01310A

Collal engine otation Cente ng lool,

(Parlol
49 E301 60)

49 1285071 49 1285073
Puer,Jle€dle -G: b€aring Chuck beanng
ead ol
49 1285 71)

H-7
 

CLUTCHUNIT
REI'OVAL INSTALLATION
Note
. Dq not rcmove the pilor bealing It not necesaary,

1. Removen the ordershown n the igure, eferringo RemovalN ote

2. Installn the reverse rderof removal,eferringo InstallationNote.

t5-r03 p.a-r0.5, 7r-761

ra-2a o

1.Transaxle 8. Clutchdisc
service " " section J .... ageH- 9
Removal ote....................
2. Return pring aSe -1-1
lnspection...................................
3. Releaseollar ageH-10
Insiallationote..........................
ageH-12
Inspection................................... 9. Pilotbearing
4. Reamer olt . ... pageH- 9
Removal ote....-.............
5. Releaseever .. . ..pageH-1?
Inspection......................
6. Releaseork Installation ageH-10
o te..........................
7.Clutch over 10.Flywheel
Removal ote.... .. ... . . pageH- 9 Removal ote.. ............ paqeH- 9
ageH-11
Inspection................................... ageH-12
Inspection...................................
ageH-11
Installationote.......................... ageH-10
Installaiionote..........................

H-8
 

CLUTCHUNIT
Rgmoval Note
Outch cover and disc
1. nstallhe ssT.
Caution
. Put 8pacs6 between he (49E30l 060)andlhecyl-
inder block, setling dimeaion@ as shown in the
figure o l3mm (0.51 n). (Except83 ATX)
2. Loosen achboltone urnat a time n a crisscrossattern
untilspringensions released.hen emoveheclutchcov-
er and disc.

Pilot bearing
Removehe pilotbearingwith he SST f necessary.

Flywheel
Note
. After removlng he lly'rvheel, nspeci or oil leakage
pasl the crankshatt rear oil seal,
lf ngcess€ry, eplace he oil seal.
(Rete. o Seclion B.)

1. Hold he lywheel ith he SST.

2. Removehe bolts n thesequencehown n the igure n
steos.
3. Removehe lywheel.

H-9
 

CLUTCHUNIT
lnstallationNote
Flvwheel
1 hemove he sealantrom he lwheel bohholesn thecrank'
shattand rom he lYwheelolts

Caution
. ll all the previous sealant cannot be removed flom
a bolt, replace the bolt.
. sealant lf a new bolt is used.

2. Set he lywheel nto he crankshatt

3. Apply sealant o the tlywheelboltsand install hem
4. Hold he lvwheel ith heSST.
5 Tiohtenhe boltsn woor hree tepsn heorder hown

ti"otrt.nino
gHos'l*tno*r",
ig.a-to.s m'kg' 7l-?6 ftJb)

Pllot bearing
Note
. Insiall he pilol beafng flush with the tlywheel.

Instailhe newbearingwitha plastic ammer.

Clutch disc
'1.
Cleanheclutch iscsplines ndmaindrivegearsplines
2- Lightly reasehe splines ithmolybdenumrease.

3. Set he clotchdisconto he lywheel iih he SST.

@E@
01EoHX{]7
H-l0
 

CLUTCHUNIT.CLUTCHCOVER,CLUTCHDISC
Clutch cgver
'l. Installhe SST.
2. Align he dowelh oleswith he lywheel owels.
3. Tightenhebolts venly ndgraduallyn hepatternhown.
Tlghtening orque:
18-26 Nm (1.8-2.7 m-kg, 3-20 ft-lb)

CLUTCHCOVER
INSPECTION
Note
. trlinorscoringor burningshould be removedwlth
emerypaper.
'1.Inspecthe contact urface f he clutchdisc or scoring,
cracks, nd burning.R epair r replace s necessary.
2. lnspecthecontact urface f the clutch elease earing
for wearandcracks.
Replacehe clutch over f crackedor worn.

CLUTCHDISC
INSPECTION
Note
. Use sandpaperl the trouble 15mlnor,

1. nspecttheining uriaceorburning ndoilcontamination.

Replaceheclutch isc f t s badlyburned r oilsoaked.
2. Inspector loose acing ivets nd rubbers.
Replaceheclutchdisc f either s loose.

3. Measurehe hicknessf he ining t a rivet eadon both

sideswithvernier alipers.
ReDlace heclutch isc f ts hicknesss esshanminimum.

Minimum hickneaa: .3mm 0.012 n)

4. Measureheclutchdisc unoutw itha dial ndicator.

Replaceheclutchdisc f runout s excessive.

Runout:0.7nm (0.027 n) max.

H-l1
 

RELEASECOLLAR,PILOT BEARING'FLYWHEEL
RELEASECOLLAR
INSPECTION
Note
. The clutch Eleaae collar s a sealedbearlngand
musl not be washed in solvent.
Turn he bearingwhile pplyingorce n the
It the bearinqsticksor has excessive esislance, eplace t.

PILOTBEARING
INSPECTION
Turn he bearingwhile pplyingorce n the axiald irection
lf the bearing ticks r hasexcessiveesistance,eplacet

t FLYWHEEL
INSPECTION
Note
. Minorscoringor burningshould be removedwith
emery paPer.
1. nspecthecontact urface f theclutchdisc or scorang,
cracks, nd burning. lepair r replace s necessary.

2. nspecthe ringgear eeth o. wearanddamage l neces'

sarv. eDlacehe lwheel.
3. '/easurehe lvwheelu noutw itha dial ndicator' eplace
the lywheelf runouts excessve-

Runout:0,2mm 0.008 n) max,

H-12
 

MANUALTRANSAXLE
tNDEX..................................................,,..
- 2
ouTLtNE........,..........,..,....,...,..................
- 3
spEctFtcATroNS,...................,........,......- 3
STRUcTUFALtEW,.........,....,..,.............. - 4
powERF1OW,...........,..........,..,...,..........- s
TROUBLESHOOTTNG UTDE......,..............- 6
TRANSAXLEtL,,,,.,.................,.....,.,.,..... - 7
- 7
tNSPECTtON......................-......,,,,.........
REPLACEMENT........-.....-.,.................., - 7
- I
TRANSAXLE....,............................,...........
PREPARATtON................................,..,.,..
- 9
REMOVA1.................-...---.............,.... -r r
-r4
DtSASSEMB1Y..................................,.....
tNSPECTtON.................--..................,...
-27
ASSEM81Y..................,......,,..................
-30
|NSTALLAT|ON ......,..,J-56
DtFFERENT|AL................,.,...,...................
-59
PREPARAT|ON.,.,....,.........,....,..,.............
-59
DISASSEMBLY I NSPECIIONASSEI\,lBLY.. -50
SHIFTMECHANlStrl...--...-.................,..... -64
-64
ovERHAU1...........,....,.,........................,
 

J INOEX
INDEX

GFADE : API SEFVICEGI-4

BACK.UPUGHTSWTTCH NEUTRAL AIITCH VISCOSIIY:ALL SEASON
SEFIVICE, ECTIONT SEBVICE,SECTIONF D€xrend'[or M2C3ilF
aBovEr8.c (ocD
saE75W-80
cAPAclry: 2.5lllsls 2.6us qt, 2.2 mp

1.Transaxle 2. Differential
R e m o v a 1 . . . . . . . . . . . . . . . . . . . . . . .a. g . .e. . -. .l .1. . . . . . . DisassemblyI nsp€ction
D i s a s s e m b 1 y . . . . . . . . . . . . . . . . .a. .g. .e. .-.1. .4. . . . . . Assembly . pageJ-60
i n s p e c l i o n . . . . . . . . . . . . . . . . . . . . .a 2 7
. .g. .e. . . . . . . . . . .3. Shiftmechanism
A s s e m b | y . . . . . . . . . . . . . . . . . . . . . .a. .g. .e. .-.3. .0. . . . . O v e r h a u | . . . . . . . . . . . . . . . . . . . . . . .a. g
. .e. . -. .6.4. . . . .
I n s t a | I a t i o n . . . . . . . . . . . . . . . . . . . .a. g. .e. . -. 5 . Transaxleil
. .6. . . . . .4.
Inspection..--................................ age - 7
R e p | a c e m e l t . . . . . . . . . . . . . . . . . .a. .g. e . . .-. .7. . . . .

J-2
 

OUTLINE J
OUTLINE
SPECIFICATIONS
----__ ____
- ------- Engine B3
Item
85M-B

e chanism
Synchronlzation Forward:Synchromesh Bev€rse:S€leclivesliding
3 454
2n d 1.944
3rd 1.392
Gear atio 1.030
5lh 0.810
3.583
4.058
Speedomelere ar atio o.9112123)
(Driv€n earnumber/Drlveearnumber)
Grade
Dexrono]Ir M2C3&F
ol
Above -18oC (0"F) SAE 75WAO
Capaclty liters USqt, lmp qt) 2.5 12.6, .2:)

J-3
 

J OUTLINE
STRUCTURALIEW

lst '11.Secondaryth gear

1 Primary gear 6- Primary everse ear
2. Pdmary nd geat 7. Secondaryst gear 12.Secondaryeverse ear
3. Primary rd g;ar B.Secoloary2nd gear 13 FleveIsedlergear
a. Primary tn gear 9. Secondary rd gear 14 Ditferedial
5. Primary th gear 10.Secondary th gear

J-4
 

OUTLINE J
POWEBFLOW

rsT 2ND

3RD 4TH

5T H

J-5
 

J UIDE
TROUBLESHOOTING
TROUBLESHOOTINGUIDE
Page

shilt lever won't shlfi sllcking shiit ever ball J-€4

smoothly or is hatd Stcking change conllol rod oinl J-64
ro shlfi Benl change conlrol od J-64

Too much play n Wornchange onlrcl od bushing J64

shilt lever Weakshift everballsprlng J64
Worn shitt everball seat J-64

Difficull to shltl J64

No Oreas€ transaxleonlrol J64
lnsuificieniil J 7
Deteiorationof oil quality
We or play ot shlft ork or shlft rod
Worn ynchronizer g J,21,24
Womsynchrcnizero neor gear J 21,24
Bao conlacr l syrchro_i7Fringandconeol gea' J 21,24
Excessiveongiludinslay ol gears J 21,24
J 21,24
Womsynchronlzereysping J-21. 24
Excessiv€ rirnary halt gear bearlngpreload J-38
lmpropeiy djusled hange uLde late
Won't stay h gear Benl change conlrol rod J-64
Wom change conlrol od bushing J-64
W€ak shit lever balL pring J-64
Tishten J-64

Wofn clutch hub sleeve

Worn slidingsudaceol gear or shait J 21,24
Worn steelslldinggrooveol conlroL nd J 1 4
J-14
Excessivehrusl clearance

Loos€ engrnemounl Tghten J-56

J-7
Deierloralioni oil qualty J-7
J 21, 2 4
Womsliding urlace i gearor shafl J 21,24
Danragecl ear eeth J-21.24
Fore n materlal gears J-21.24
Damaged itferentiaLe aror excessve acklash J-60

J-6
 

TRANSAXLEOIL J
TRANSAXLEOIL
INSPECTION
Note
. Park he vehicleon level ground.

1 Disconnecthespeedometerableandremovehespeedo
meterdriven ear.
2. Verifyhat he oil evel s betweenhe F and L.

3. Installhe speedometerriven ear.

Tightening orque:
7.8-12 Nm (0.8-t.2 m-kg, 5.8-8.7 tt-lb)
4. Connecthe speedometera ble.

REPLACEMENT
'1.Disconnect able nd emovehespeedo-
hespeedometer
meterdriven ear.
2. Removehedraan lugandwasher.Drainheoil ntoa suita-
o
l-----.--
ble container.
3. nstall newwasher nd he drainplug.
Tightenlng orque:
24-35 N.m 2.4-3.5 m-kg, 7-26 finb)

4.Add henecessarymount f hespecilied il hroughhe

speedometerr iven earhole.
Specifiedoil
Grade:API serviceGL-4
Viscosity:AlFseasonDexron@n r M2C33-F
Above -t8"C (0"D SAE75W-80
Capacity:2 .5 liters (2.6 US qr, 2.2 mp qt)
5.Veritvhe oil evel.
6. Install he speedometerriven gear and connect he
speedometera ble.

Oil seal
ReplacementOn-vehicle)
1.Jack up the vehicle nd supportt withsafety tands.
2. Drain he ransaxle il.
3. Removehe rontwheel.
4. Femovehe splash hield.
5. Separatehe rontstabilizerr om he owerarm.

J-7
 

J TRANSAXLEOIL
Cautlon
. Do noi damage he dust boots.

6. Removehe clinch oltand pull he ower rmdownward

to seDaratehe knucklerom he owe.arm ball oint.
7 Loosenhenutando6connecthe ie-rod ndwilh heSST

Caution
. Ilo not subiect he tdPod olnl to shockwhen remov'
ing lhe driveshaft.
8. Disconnect rom he ransaxley pryingwith
hedriveshaft
a bar nsened etweenhe outer ingand he ransaxle.
9. Suspendhe driveshaft itha rope

10.Removehe oil sealwitha screwdriver.

Note
. Tap n until he oil seal nstaller ontacts he case.
. Coat he gil seal ip wilh ttanaaxleoil.

11 Tap he newoil he ransaxleasewith heSST

12.Replacehe driveshaftndclipwitha newone- nserthe

driveshaft ith he splitol the ciip acingupward
13.Pull uton hedriveshatt o veritvhat t sheld irmlynplace.

J-8
 

TRANSAXLE J
TRANSAXLE
PBEPARATION
ssT

49 GO17 AO 49 G01750 1

Suppon,englne Ba r
(Parlof
49 GO17 A0)

49 G017 49 G017 03

Suppod Hook
{Pan of
49 G0175A0) 49 G017 AO)

49 0107 6804 49 DO172A2A _g adiuslmenl f

Engine tand sh,ms€ecro,se,
,fffiililp bearing reload
../-t

49 G0190A0 49 F40138 4
adjuslrnent f
Collar
(Panof
49 DOIT2A2A)

49 G019 01 49 F40138 5

Body Ba r
(Panol
49 G019 A0) 49 Do17 MA)

49 G019 02 49 F4013818
adjustrnent t
Siay SelectorC6o preload
{Parrol (Padof
49 GOrg A0 ) 49 F401 814)

49 G019003 4 9G 0 1 9 1 9

F:'"Tr888 -
9 Gor90A0)
Bolt set
49 Do17 A2A)

49 DO17 01 49 8001 795

J-9
 

J TRANSAXLE

49 FTot 361 49 BO270024

beanngpreload
(Partot
49 DO172A2A)

49 G030 795 4 9 0 1 8 05108

beaing prcload
measuing

49 DOIT 241 49 G03079 7

beaflng Body
beanng (Partol
49 G030795)

49 F40133 1 49 G030 796

Body b€aring Body

(Partol (Pad of
49 D017 A1 ) 49 G030 795)

49 DO17 01 49 0839 425C

/A\ bearng
Attachmenl gezl
w|, beanng
(Padof
4 9D 0 1 7 A 1 )

49 0710520 49 0A62 428

bearlngpullef
(Pan oi
49 0839 425C)

49 0636 145 49 0a39 426

beaflng

(Partol
49 0839425C)

J-10
 

TRANSAXLE J
REMOVAL
1.Disconnecthe negative attery able.
2. Raisehe vehicle n a vehicle oist.
3. Drain he ransaxle il ntoa suitable ontainer.
4. Removen the ordershown n the igure, eferringo RemovalN ole.

{!e

CLIP,

01A0JX{02

1.Wheel nd ire 10.Driveshafts

2.Splashhield age -12
Bemovalote.............................
3. Battery, attery arrier 11 Starter
4. Speedometera ble 12.Enginemounting ember
5.Clutch able age -12
Bemoval ote..................... ........
6. Back-upightswitch onnector 13.Exhaust ape racket
7. Neutral witch onnector Stifiner
8. Extensionar 15.Transaxle
L Controlo d age -13
Removalote.............................
16.Engine ount o.2

J-1 1
 

J TRANSAXLE
Removd Note
DrlvEhaft
- 1 . 1. Removehe ball ointclinchbolt.

Caution
. Wrap a rag around the ball ioint dusi boot to pro'
lect h trom damage.
2. Pry he owerarm rom he knucklewitha pry bar.

Cautlon
. Do not shock the tripod ioint when removing the
dtiveshaft.
3. Seoaratehe driveshaftrom he ransaxley pryingwilh
a bar nserted etweenhe outernng and he ransaxle.
4. Suspendhe driveshaft itha rope.

EnginemountinEmember
1 Suspendhe enginewith he SST

2. Removehe bolts ndnuts hown, nd emoveheenglne

mounting ember.

J-12
 

TBANSAXLE J
Tranaaxle
1. LoosenheSST €ngine uppon)and ean heengineo
ward he transaxle.
2. Support he transaxlewith a jack.

3. Removehe ransaxle ounting olts.

4. Removehe ransaxle.

J-l3
 

J TRANSAXLE
DISASSEi'BLY
Precaution efore isassembly'
i. 6t""n tn" ttuna""f. xteriorhoroughlyilha steamleane. cleaningolvent olvent,nddry
-i. di;;; il";,.d;"J pirti (except"-ateb earings)andseatingudacesith leaning
checkhat here re
ir,and
iitiilii,irr""llO iii Cteinouiatt rotes ndplsiageswitha compressed
no obskuctions.
3.Wear yeprotectionhenusing ompressedir o clean omponefis
HousingParls
ijGo"inOt" in the ordershown n ll"e eferringo DisassemblyNote'

BEPIACE

"-/Wr \-,.,@
a'. \
\af
xqrqk'
/(t
REPLACE
@ \
FEPLACE @ g

o
BEPLACE

BEPLACE

J-l4
 

TRANSAXLE J
1.Transaxle 26.Rollpin
age -16
Disassemblyo te....................... 27.Rollpin
2. Return pring 28.Shift ork sth/Rev)
3. Clutch ever age -27
1nspeciion....................................
4. Clutch eleaseork 29.Shift od (sth/Rev)
5. Clutch elease ollar Disassembly age -16
o te.......................
age -27
fnspection.............-...................... 30. nlerlock in
6.Engine ountN o.1 31.Shift od end(sth/Rev)
7. Drainplug 32.Ueversedlergear
8. Plug, pring, teelb all 33.Feversedlershaft
9. Back-upightswitch 34.Follpin
10.Neutral witch J5. l.tn
11.Speedometerriven earassembly 36.Lever etspring
12.Transaxleaseassembly 37.Reverseever haft
'13.Retaininging 38.O'ring
14.Crank evershatt 39. Reversehitt ever
15.Crank everassembly 40. nterlock in
16.Baseplateunit Disassembly age -16
o te.......................
17.Plug,spring, teelb all 4'1 Interlock in
18.Roll in Disassembly age - 16
o te.......................
19.Roll in 42. Primary haftgearassembly
20.Shift ork (3rd/4th) 43.Secondaryhaftgearassembly
age -27
fnspection.................................... 44.Difi rential ssembly
21.Shift od (3rd/4th) 45.Clutch ousing ssembly
age -16
Disassemblyo te....................... 46.Follpin
22.Shift od end (3rd/4th) 47.Speedometere arsleeve
23.Rollpin 48.O-rin9
24.Shifl ork (1sv2nd) 49.Oil seal
age -27
1nspection.................................... Disassembly age -16
ote ......................
25.Shift od (1st/2nd) 50.Driven ear
age -16
Disassemblyo te....................... 51.Magnet

J-15
 

J TRANSAXLE
DisaasemblyNote
Transaxle
Mount he ransaxlen theSST.

Shlft rod
Wiap heshift oOwitha ragand urn t withplierswhilepull
ing t out.

lnterlockpln
Removehe nterlock in witha magnet.

Oll seal
iem-dvetrespeeaometerrivengearoil sealasshown n he
figure.

J-16
 

TRANSAXLE J
Clulch Housingand TaansaxleCaseComponents
Caution
. Do not remove an oil seal lf not necessary,

1.Disassemble n the ordershown n the igure, eferringo DisassemblyNote.

2. nspect ll partsand repairor replace s necessary.

REPLACE
BEPLACE

SELECNVE

AEPLACE

1.Batfle late 13.Oilseal

2. Bleeder '14.Bushing
3. Rollpin 15.Clutch ousing
4.Change rm 16.Oil passage
5.Change od assembly 17.Adjustmenthim
18.Funnel
7. Oilseal change od) Disassembly age -19
o te.......................
Disassemblyo te.......................
age -18 lO Ra./i^^ ^' d6r /r^6
8. Oilseal primary haft) Disassembly age -20
ote ......................
Disassemblyo te.......................
age -18 20.Adjustmenthim secondaryhaft)
9. Bearing uter ace secondaryhaft) age -20
Disassemblyo te.......................
Disassemblyo te....................age -18 21.Bearing uter ace ditferential)
10.Funnel Disassembly age -19
o te.......................
Disassembly age -18
ote ...................... 22.Adjustmenthim
11.Oilseal ditferential) 23.Oil seal differential)
Disassemblyo te.......................
age -18 age -18
Disassemblyo te.......................
12.Bearing uter ace differential) 24.Transaxlease
Disassemblyo te.......................
age -19

J*17
 

J TRANSAXLE
DisassemblyNote
Oil seal (change od)
Caution
. Do not damage he cluich housing'

Removehe oil sealw itha screwdriver.

Oil seal (dlfterential)

\r Caution
. Do ngt damage he clutch housing.
l<,
Remove he oil sealwitha screwdrver'

Oil seal (p maryshafl)

Cautlon
. Do noi damage he clutch housing.

Removehe oil sealwitha screwdriver'

Funneland bearingouter race (secondary hatt)

Noie
. Remove he bearingouter racewith a acrewdriver

I ) naerta screwdrive. etween he clutch housing

and bearlngouter race.
2)Pry the bearlngouter race flee.
Removehe bearing uter aceby ifting ut he unnel nd
race together.

J-l8
 

TRANSAXLE J
Funnel
Removehe unnelw ithpliers.

Bearlngouter race (differential)

1. nstallhe SST o the bearing uter ace.

2. Turnover he clutchhousing.
3. Removehe bearing uter acewitha su,tableprpe.

Bearingouler raaeand adiustmentshim (difierential)

1. nstallhe SST o the bearing uter ace.

.'-/l l\).r-
.< -t,'.-,t )-P

2.Turn ver heclutch ousing.

3. Tap heSSTwitha pipe hroughhedriveshattole o re-
move he bearino uter ace.

J-19
 

J TRANSAXLE
Bearing outel race and adluslment shin
(seqondaryshalt)
i. puttout tre beaiing uter aceas shown n the igure.
2. Removehe adiustmenthim

J-20
 

TRANSAXLE J
PrlmaryShaft Assembly
1.Measurehe hrust learancest all gearsbetore isassembly,eferringo Preinspection.
n the ordershown n the igure, eterringo Disassembly ote.
2. Disassemble

FEPLACE

E FEPLACE

1.Retaininging 10.Synchronizer ing

2. Bearingsth) Disassembly ote ...................... age -22
Disassemblyo te....................... age -22 Inspection....-............................... age 27
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. .e. .-.2. .8. . . .11.3rd
.. gear
3.Spacer Disassembly ote ...................... age -22
4.Steel all Inspection.................................... age -28
5. sth gear 12.Bearing
Disassembly ote ...................... age -22 Disassembly o te....................... age -22
Inspect ear eeth or damage,w ear,and I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. e. . . 2
. .8. . . . . .
cracKs 13.Primary haft
6. 4th gear Inspection.................................... age 28
Disassembly ote ...................... age -22 14.Synchronizerp ring
Inspection.................................... age -28 '15.Clutch ubsleeve 3rd/4th)
7. Synchronizer ing 1nspection.................................... age -27
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. .e. .-.2. .7. . . .16.Synchronizer
.. ey
8. Retaininging 17.Clutch ub (3rd/4th)
9. Clutch ub assembly3rd/4th)
Disassembly ote ...................... age -22
Inspection.................................... age -29

J-21
 

J TBANSAXLE
Preinspection
3rd qear thrusl clearance
1 M;-asurehe clearance etween rd qearand 2nd gear'

Clearance: .06-0.41mm (0.002-0.016 n)

llaximum : 0.46mm 0.0'18n)
2. lf heclearancexceedshemaximum,heck hecontact
surfacesfthe3rdgear,2nd ear, ndclutch ub 3rd/4th).
Replace ornor damaged arts

4th qear hrust clearance

t. MEasurehe clearance etween th gearand the ball
bearing.
Clearance: .22-0.52mm (0.009-0.020 r)
Maxlmum:0,57mm 0.022 n)
2. lf theclearancexceedshe maximum,heck hecontact
surfaces f the 4th gear,ball bearing, nd clutchhub
(3rd/4th). eplace ornor damaged arts

Disassembly Noie
Bealing (sth)
1 Place he primary haflg ear n a vrse

Noie
. Use protectfuePlates n the iaws ot lhe vlse'

2. Removehe bearingwith he SST.

4ih gear and 5th geat

1 lnsrallhe 4th oearwrth he SST.
Cauilon
. Hold he shaft one handso that t doesnot all'

2. Flemovehe 4th gearand sth gearwith he SST

Clutchhub assembly 3rd/4lh), ynchronizering (3td)

and 3rd gear
Caution
. Hold he shaftwith one handso that t doesnot all.

1. Bemovehe retaininging.
2. Removehe clutchhubassembly3rd/4th)'ynchronizer
ring 3rd)and 3rd gearwith he SST

J-22
 

TRANSAXLE J
Bea ng
Note
. Use protectlve plalea In ihe laws ol the v|se.

Removehe bearingwith he SST.

J-23
 

J TRANSAXLE
Secondary Shaft Assembly
1. Measutehe thrust learance f 1st gear,2nd gear,and sth gear, elerringo Preinspectlon.
2. Disassemblen the ordershownin the igure,referringo Disassembly ote.
NEPLACE

N€PLACE

1. Bearingnne. ace 5th) 12.Synchronizer ing

Disassembly ote ...................... -25 age Disassembly o te....................... age -26
Inspector damage nd rough otation 1nspection.................................... age -27
2. Retaininging 13.Clutch ub assembly 1sv2nd)
3. Washer Disassembly o te....................... age -26
4. Clutch ub assembly5th) Inspection.......-............................ age 29
Disassemblyo te............... ...... age -26 14.Synchronizer ing
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. .e. .-.2. .9. . . - . . Disassemb|y................................ age -26
5.Synchronizering 1nspection.................................... age -27
a g e
fn s p e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . -. .2.7. . . . .15.2nd
. gear
6. sth gear Inspection.....................-.............. age -29
a g e
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .9. . . . 16.Synchronizer
.. p ring
ing 17.Clutch ub sleevesth)
8. Bearingnner ace 1st) Inspection.................................. a]e J 27
Disassembly age
ote ...................... -26 18.Synchronizer e y
lnspector damage nd rough otatpn 19.Clutch ub (sth)
L Pinion ear 20.Synchronizerp ring
Disassembly o te....................... -26 21.Clutch ub sleeve1st/2nd)
age
Inspect ear eeth or damage,w ear,and fnspection....::............................... age -27
cracks 22.Synchronizer e y
10.1stgear 23.Clutch ub (1sv2nd)
Disassemblyo te....................... age -26 24.Secondaryhaft
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. .g. .e. .-.2. .9. . . . . . I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . .a. g
. .e. . . 2
. .9. . . . . .
11.Retaining i ng

J-24
 

TRANSAXLE J
Prelnspectlon
lsi gear hrust clearance
1. Measurehe clearance etween stgearand he pinion
gear.

Clearance: .22-0.62mm (0.008-0.024 n)

Itaximum:0.67mm 0.026 n)
2. lf theclearancexceedshemaximum,heckthe ontact
surfaceslthe stgear,pinion earofthesecondaryhaft
gear, ndclutch ubassembly1sv2nd). eplace ornor
damaged arts.

2nd gear hrusi clearance

1. Measureheclearanceetween nd gearandsecondary
3rd gear.
Clearance: .06-0.2lmm (0.002-0.008 n)
Maximum: .26mm 0.010 n)
2. lf theclearancexceedshemaximum,heck hecontact
surtaces l the2nd gear, econdaryrd gear,a ndclutch
hubassembly1sy2nd). eplace ornor damaged arls.

slh gear lhru9t clearance

1. Measurehe clearanceetween th gearandsecondary
4th gear.
Clearance: .06-0.2lmm (0,002-0.008 n)
Maximum: .26mm 0.010 n)
2. lf theclearancexceedshemaximum,heck hecontact
surfaces f thesth gear, econdaryth gear,andclutch
hub sth).Replace arts.

Disassembly Note
Bearing nner race(5th)
Caution
. Hold he shaftwith one handso that t doesnot all.

1. Set he SST o the sth gear.

2. Removehe bearing uter acewitha suitable ipe.

Pipe diameter:20mm 0.79 n)

J-25
 

J TRANSAXLE
Clutch hub assembly (sth)
Nole
. Remove he clulch hub assembly sth) as lollows
ll necessary.
1- nstallhe SST as shown n the igure.
2. Removehe clutch ub assemblysth)usinga press

Bearlng nner race (lsl), pinion gear' l3l gear

Caullon
. Hold the shaft with one hand so that lt does not tall.
'1. Set he SST o the 1stgear'

2. Removehe b€aringnner acewitha suiiable ipe

Plpe diameter:20mm 0'79 n)

Clutch hub assembly lsu2nd), synchronizer ing

Note
. Remove he cluich hub assembly 15u2nd) s tol-
lows if necessary.
1.lnstallhe SSTas shownn the igure
2. Removehe clutch ubassembly1s 2nd)using press

J-26
 

TBANSAXLE J
INSPECTION
Inspect ll partsand repair replace s necessary.
Clutch release ollar
Inspectheclutch eleaseollar or roughnessr noisewhile
turning.

Synchronizer ing
Note
. Set he synchronizering squarelyn he gean hen
measurearound he clrcumlerence,
1. \,leasurethelearanceetweenhesynchronizer
ingand
lianksurface f the gear.
Standard learance: .5mm 0.059 n)
Minimum: .8mm 0.015 n)

2. Inspecttheynchronizer
ing eeth ordamage, ear, nd
cracks.
3. lnsoecthe aoersurfaceor wearor cracks.

Shift tork, clulch hub sleeve

1. Measurehe clearanceetweenhe shift ork andclutch
hub sleeve roove.
Standard lealance
(1st/2nd):0.100-0,358mm 0.004-0.014 n)
(3rd/4th) 0.150-0.458mm 0.006-0.018 n)
(5th) : 0.150-0.458mm 0.006-0.018 n)
Maximum 1st/2nd): .408mm 0.0i6 in)
(3rd/4th):0.508mm 0.020 n)
(sth) :0.508mm (0.020 n)

J-27
 

J TRANSAXLE
Pdmary Shatl
3FD GEAB Note
. ll the prlmary shaft is replaced, adiust the bearing
pretoad. Reler o PageJ-39.)

1. nspecthe primary haft unout

Maximum unout: 0.0lsmm (0.0005 n)
2. Inspecthe splinesor damage nd wear.
3. Insbecthe gear eeth or damage'w ear,a ndcracks

4. Inspecthe oil passageor blockage.

3rd gear, 4th gear

'1.l\,leasure
h e clearance etweenhe shaft nd gears
mm .n )
B A Shaftsrde Ge side
(outerdiameleo (inner iamelet
32.945-32.970 33.000-33.025
3rd gearsideA (1 297- 1 298) (1.299-1.30O)
2A.545-28.570 2A.6@-24.621
4th geff side B l1 126-1 127
0 .123-1 125)

2. Inspecthe synchronizero nes or weat.

3. Inspecthe gear eeth or damage,w ear'a ndcracKs.
4. Insbecthe Contacturfacesf the synchronizeringand
the 3rd/4th ear or wearand cracks

Bearing
Insoecthe bearingor damage r rough otation.

0rFoJx063
J-28
 

TRANSAXLE J
SeaondaryShafl
Nole
. ll the secondaryshatt is replaced, adiust the bear-
ing preload. Reter o pageJ-39.)
1. nspecthe secondaryhaft unout.
Maximum unout: 0.015mm 0.001 n)
2. Inspecthe splinesor damage nd wear.
3. Inspecthe gear eeth or damage, ear,a ndcracks.

4. Inspecthe oil passageor blockage.

1st gear, 2nd gear, sth geal

1. Measurehe clearance etweenhe shaft nd he qear.
mm (in)
Shalt ide Gear ide
(olter diameled (nnerdiameter)
32.945-32.970 33.000-33.025
112971 .294) (1 299-1 .30O)
39.945-39.970 40.000-40.025
2nd gearsideB (1 573-1 .574) (1.575-1.576)
sth seff side C
28.545 28.570 24.604-24.62-l
11124- t 125J lt.126-1.127)

2. Inspecthe synchronizero nes or wear.

3- Inspecthe gear eeth or damage, ear,a ndcracks.
4. Inspecthe contact urfacesl the synchronizeringand
the l st/2nd nd sth oear or wearandcracks.

Clutch hub aaaembly

1. nspecthe clutchhubsleeve nd hub operation.
2. Inspecthe gear eeth or damage, ear,a ndcracks.
3. Inspeclhesynchronizerey or damage,wear,andcracks.

J-29
 

J TRANSAXLE
ASSEIIIBLY
Precaution
i. lil-O;i;a. and gasketsmustbe replaced ith he newones ncludedn the overhaul it'
2. Verityhatall pansarecompletelyleanbeforeassembly
"3. Assehbboanswithin10 minutes fterapplying ealant
;ffi;il "A;;ti;cure at leastgo minuies ftEr ssembrve{oreillinghe ransaxle nhoil'
4. A bearing uter aceand bearingnner acemuslbe replaced s an assemDly olEoJx.o6s

Clutch hub assembly

Note
. Synchlonizer ing diametelsare as follows.
mm (ln,
--_=_-
@
1st 55.7 2.r93)
?nd 55.7 {2.193)
3rd and 4lh 49.7 r.954
5th 43.7 172O)

. Synchronizer ey dlmensionsare as tollows.

o @
1sv2nd 17.000.669) 4 2 5 0 .r6 7 ) 5.00 0. 97 )
3tdl4th 14.00 0.551) 4.25 0.164 5.00 0.197)
14.00 0 . 5 5 1 ) 4 25 0.16n 5.00 0194

1. nstallhesvnchronizereyspringsn theclutchhubwith
thehooksn hegrooveso hold he hree ynchronizereys
In p|ace.

inggrooves ith hesynchronlzer

2. Align he synchronizer
SYNCHRONBEB RING key duringassembly.

SYNCHRONIZEFEY

J-30
 

TRANSAXLE J
secondaryShaft Assembly
Assemblen the ordershown n the igure, eierringo AssemblyNote.

BEAFINQNNEFRACE,

YIETAINING
FIING,NE W
@
@E
AEAFINGNNER

'1-Secondaryhaft 14.Relainingi ng
2.Clutch ub (1sv2nd) 15.1stgear
3-Synchronizerey age -32
Assemblyote............................
4. Clutch ub sleeve 16.Pinion ear
5.Synchronizereyspring age -32
Assemblyote............................
6. Clutch ub 17.Bearingnner ace 1st)
7. Synchronizerey Assemblyote................ ... page -32
8.Clutch ub sleeve 5th) 18.Retaininging
9.Synchronizereyspring age -33
Assemblyote............................
10. ndgear 19.5th ear
age -32
Assembly ote............................ 20.Synchronizer ing
11.S ynchronizer ing 21.Clutch ub assemblysth)
Assembly ote......................age
......-32 .. page -33
Assemblyote........................
12.Clutch ub assembly1sl2nd) 22.Washer
Assembly ote......................age
......-32 23.Retaininging
13.Synchronizering 24.Bearingnner ace sth)
Assembly ote......................age
......-32 age -33
Assemblyote............................

J-31
 

J TRANSAXLE
Assembly note
2nd gear,synchronlzer ino
1. Asaemblehe 2nd gear o the secondary shown
in the igure.
2. Assemblehesynchronizer ing.

Clutchhub as€embly lsu2nd), synchronizer ng

1.Assembleheclutch ubassemblyo hesecondaryhaft

I as shown n the igure.

ing.
2. Assemblehe synchronizer

&
Caution
.lnstall the clutch hub assembly lsi/2nd) wlth a
presa It necessary.
. Align the synchlonizerdrg gloove and leverse gear

Y key groove when installing.

1st gear
Assemblehe 1stgear o hesecondaryhaft sshownn he
figure.
Caulion
. Align he synchronizering grooveand clutch hub
assembly ey when Installing.

Piniongear,bearing nner race (lst)

Caution
. Replace he bearing inner race lf removed.

1. Supporthe 4th gearof the secondaryhatt.

2. Inslallhe olainend ol pinion earwith he bonomup.

3. Set heSST o henewbearingnner aceasshownn he

fagure.

J-32
 

TRANSAXLE J
Rstaining lng
Cautlon
. Roplace he retalning ng ll removed.

1. nstallhe retaininging.
2. Measurehe clearance etweenhe retaininoring and
secondaryhaftgroove.
Clearance: -0.1mm (0-0.004 in)

3. l notasspecilied,electhe proper etaininging rom he

chartbelowand nstallt.
Retaining ing thickness:
mm (in)
2.0 0.079)| 2.1 0.082) 2.2 0.086)| 2.3 O.O9O)
| 24 (0.094)

Clutch hub assembly 5th)

Installhe clutchhub assembly nto he secondaryhaft.
Note
. Installthe clutch hub assembly sth) wilh a press
it necessary.

Bearlng Inner race (5th)

Cautlon
. Replace the bearlng Inner race it removed.

1.Supporthe st gearof hesecondaryhaft ndpresshe

bearingnner aceon.
2. Installtheewbearingnner aceusingthe STandpress,
as shown n the igure.

3. vleasurehe clearance etween stgearand he pinion

gear.

Clearance: .22-0.62mm (0.008---{t.024

n)
Maximum: .57mm 0.025 n)

J-33
 

TBANSAXLE
4. Measureheclearanceetween nd gearand hesecon-
dary3rd gear.
Clearance: .06---0.2lmm 0.002-0.008 n)
Itaxlmum:0.26mm 0.010 n)

5. Measureheclearanceetween th gearand hesecon'

dary4th gear.
Clearance: .06-0.21mm (0.002-0.008 n)
Itaxlmum: 0.26mm 0.010 n)

J-34
 

TRANSAXLE J
PrlmaryShaft Assembly
As.semble
n theordershown n the igure, eferringo AasemblyNote.

RETAINING
FIN6, NEW

1. Clutch ub (3rd/4th) 12.4th gear

2. Synchronizerey age -36
Assemblyote............................
3. Clutch ub sleeve 13.sth gear
4. Synchronizerey spring age -36
Assemblyote............................
5. Primary haft '14.Sleelball
6. Bearing '1st) age -37
Assemblyote............................
age
Assembly ote....................... .....-36 15.Spacer
7.3rd gear age -37
Assemblyote............................
8. Synchronizering 16.Bearingsth)
9. Clutch ub assembly3rd/4th) age -37
Assemblyote............................
age
Assembly ote....................... .....-36 17.Retaininging
10.Retaininging age -37
Assemblyote............................
11.S ynchronizer ing
age -36
Assembly ole................... .........

J-35
 

J TRANSAXLE
Asssmbly lote
Bearing lst)
Installhe bearing th a Press

--- t-

Clutch hub assembly 3rd/4th)

i. Fress he clutchhu6assembly nto he primary haft

il ,1\
OILGFOOVE

Caution
. lliqn the svnchronlzer ing grooveand clutch hub
assiemblyieys (3rd,/4th) hen Installing'
2. Align e clutch uband halt ear pline nd hen nstalling'

Synchronizer ing, 4th gear

1. Install he synchronEer ng and clutchhub assembly
(3rd/4th).

*re@69 2. Installhe 4th gear.

5th gear
Caution
. ltion tne svnctrronizeling grooveand clutch hub
ass;emblyeys (3rd/4th)whsn installlng'
'1.Align he clutchhub and primary haftsplines'
2. Press he sth gearon

J-36
 

TRANSAXLE J
Steel ball, spacer
Hold he steel allwitha finger, nd nstallhe spacer.

Bearing sth)
C€ution
. Replace he ball bearing f removed,

Installhe ballbearingwith he SST anda press.

Retaininging
Caution
. Replacehe relaining ing t removed,
1. nstallhe retaininging.
2. Measureheclearanceetweenetainingingand hepri-
maryshatt.
Clearance: -0.1mm (0-0,004 in)

3. f notasspecified,electheproper etaininging rom he

chartbelowand nstallt.
Fetaining ing
mm (in)
2.0 0.079)I 2 r (0082 | 22 (0.086)| 2.3 0.090)| 2. (0094)

Note
. The ollowing nspectlons to verity properassem.
bly ol lhe primaryshatt.
. ileasure the clearance etween he 3rd gear and
2nd geal. (Reter o page J-22.)
. Measure he clearancebetween he 4th gear and ball
bearing. Refer o page J-22.)

J-37
 

J TRANSAXLE
ClutchHousinqand TlansaxleCaseComponents
L select he adiusimenthim(s).eterrrngo BearlngPreloadAdiustmenl
2. Assemblen ihe ordershown n the rgule reterringo AssemblyNote

1-Transaxlease 13.Bearing uter ace dilterential)

2.Adjustmenthrm age
Assemblyote............................
A s s e m b l yo i e . . . . . . . . . . . . . . . . . . .a. .g. .e. .' .4. 5
. 14.Oil seal ditferential)
3. Bearing uter ace differential) age -46
Assemblyote.........................
A s s e m b l yo t e . . . . . . . . . . . . . . . . . . .a. -g.e. . . 4. .5. 15.Funnel
4. Oil seal difierential) age -47
Assemblyote............................
Assemblyote.................... ....... age -45 16.Bearing uter ace secondaryhatt)
5. Adjustmenthim age -47
Assemblyote............................
age 45 '17.Oil seal primary haft)
Assemblyote............................
6. Bearing uter ace secondaryhaft) .... age -47
Assemblyote.....................
Assemblyote............................ age -45 18.Oil seal change od)
/ FUnnel age -47
Assemblyote.............-..............
............a geJ-46
Assembly ote............... 19.Boot
8. Adjustmeni hrm . page -47
Assemblyote..........................
. Assembly ote.........................-..
age J-46 20.Change od
9. Oil passage 21.Change rm
10.Clutch ousing 22.Roll in
11.Bushang age -48
Assemblyote............................
12.Oilseal 23.Bleeder
24.Batfle late

J-38
 

TRANSAXLE J
Adiustmenishim selection
Selectheshim(s) s follows.
Primaryshaft assembly
1.Set he primary haftassemblynto heclutchhousing.
2. Installtheransaxlease o theclutch ousing nd ighten
the bolts o the soecifiedorque.
Tightening orque;
19-26 N.m 1.9-2.6 m-kg, 14-19 ftlb)

3. l\4ount dial ndicaloro the ransaxleanoer ndmeas'

ure he primary hatl hrust learance.
Clearance: -0.lmm (0-0.004 In)
Caution
. Do nol use more han three (3) shims.

4. Selectheclosesl himon the hinside rom he able or

adiustmentf the primary hatt.

Adiustmenlshim hickness:
0 30 (0.012) I 0 40 (0.016) | 0 50 10 r9 )

Secondary halt assembly

Caution
. Do nol install he secondary hafl shim.
. Applypetroleumelly o prevent he shim lom fall-
ing when installinE i.
1-Removehe ransaxleaseand nstallhe proper djust'
mentshim or the orimarv hafi.

2. nstallhe primary haft earassemblynd hesecondary

shaftgearassembly.
Do not nstallhe secondary haft hlmat his ime.
3. Shifl he gears o 4th gear.

J-39
 

J TRANSAXLE
4. nstallhe ransaxlease o heclutch ousing nd ighten
the bohs o the specifiedorque
Tiohteninq orque:
ig-zs-Hm i.s-z.s m-rs,1 4-19 t'lb)
d.F
\ic
5.Set heSSTonto he primary haft ndmeasurehestad-
ing orquewitha torquewrench
Sta inq torque:
o-ra7 N.m o-15 m-kg, o-1oB fi-lb)

6. Removehe ransaxleaseand the bearing uter ace'

7. nstallthehim emoved uring isassemblyndthebear'
I
ino outer ace.

A 6
\ ,1-

Caution
. Verifv hal the primary hatt canbe urnedby hand
atteriightenina he transaxlecasebolts'
SST measurehestartingorquewitha torque
wren;handselecthe proper him f hestadingorques
greaterhan n SteP .
Caulion
. oo not use mote than two (2) shims.

Adlustment him lhickness: mm (in)

0 . 3 0 0 . 0 1 1) 0.35 0.013) 0.40 0.016) 0.45 0.0r8)
0.50 0.020) 0.55 0.021) 0.60 {0.023)

J-40
 

TRANSAXLE J
Dltterenllal
'1.Removehe bearing uter aces rom he ransaxlease
and removehe adjustmenth ims.

Note
. Turn A and B untilthe gap (anow) n lhe tigu.e is
eliminated,
2. Installhe differentiali debearing uter ace o the SST
(selector).

3. Set he bearingouter aceanddiiferentialssemblynto he

clutchhousino.

4. Set he bearingouter aceand SSTonto he differential s-

sembly s shown n the agure.

5. Slide he ransaxleaseover he ditferentials semblv

J-41
 

J TRANSAXLE
6. Set heSST(collals) betweenhe ransaxleaseandclutch
housingn the positionshown n the igure.

7.Tightenhe SST (bolt set) o the specjfiedorque

Tiqhtenlnq orque:
ls-ze-Nm (i.9-2.6 m-kg,14-19 fi'lb)

Note
. Turn the bars until the SST (seleclor)no longer
iurns,
8. Mountthe arson parts@ and@ of heselector,nd urn
the selsctor o he gap s widened.
9. Turn n the reverse irection ntil he gap s eliminated.

10. nstallhe SST o the difterentiali nion haft hroughhe

transaxlease.

01EoJX,115

J-42
 

TRANSAXLE J
Note
@t@ . Procedurework with a pull scale.
. Procedure12 work wilh a torque wnench.

11.Turn he SSTwitha pullscale.A djusi he SST preload

adapter)until he specified reload.

@ Preload:0.5--0.7 N.m 5-7.6 cm-kg, 4.3-6.6 inlb)

Puffscafe:500-760 g (17.7-26.8 ozl

12.Turnthe STwithatorquewrench.d justheSST selec-

lor) with he barsuntil he specified reloads obtained.
Preload:0.5-0.7 N.m 5-7.6 cm-kg, 4.3-6.6 In-lb)
13.BemoveheSST.

14.Measurehe gap around he entire ircumferencef the

SST (seleqtor).
15.Selecthe properadjustmenthim(s)o be used or the
ditferentialy referringo the ableandselectingheshim
whichsnearesto nthethick ide)o he argestmeasured
clearancen the selector.
Adiustmentshim hickness:
.10 0.004) 0-25 0.010)
0.35 0.014)
0.80 0.031)

16.RemoveheSST (bolts).
17.Removehe ransaxleaseand he SST (collars).
'18.Removehebearing uter ace rom heSST selector).

t9 Installhe selected him(s) nd bearing uter ace o the

transaxlease.

J-43
 

J TRANSAXLE
20. Measurehe preloadas ollows.Set he differentialssem-
bly nto he clutchhousing.

01E0JX-121
21. nstallhe kansaxle aseonto he clutchhousing
Tlght€ning orque:
t9-26 N.m 1.9-2.6 m-kg, 14-19 ft-lb)

22. InstallheSST o hedifferentialidegear hrough he rans-

axle case.

Note
. Procadurc 23 work wilh a pull scale'
. Prccedure24 work with a iorque wrsnch.

23.Turn he SST (preload ) witha pullscale

Readjusthe SST (prsload adaptor) until he specified
preloadwhennotapply.

Preload:0 ,5-0.7 Nm (5-7.6 cm-kg,4'3-6.6 innb)

Pull scale: 500-760 g (17.7-26'8 oz)

24.Turn he SSTwitha torquewrench.

Readjusthe SST (Preload adaptor) untilthe specified

 :1
preloadwhennot aPPlY.

Pleload:0.5-0.7 l,l'rn 5-7.6 cm-kg,4.3-6'6 in'lb)

t/ 25.Removehe SST.
26. Remove he transaxle ase and then the ditferential s-
semory.
@

J-44
 

TRANSAXLE J
Assembly Noie
Adiustmer shlm and bearing outer racc (dltferential)
1. Set he adjustmenth imand newbearing uter ace nto
the lransaxle ase.

2.Afterm ountingthelutch ousing ntohe ransaxleang-

er, tap in the diffe.ential earingouterraceswith a ham-
meruntil t is lushwith he end of the ransaxlease.
Pipediametsr:59mm 2,32 n)

Oll seal (ditterential)

Caution
. Apply transaxleoil to the outet circumfercnceol the
oil seal,
lnstallhe newoil sealw ith he SST.

Adiustment shim, bearlng ouier race (secondaryshaft)

1. nstallthedjustmenth imandbearing uter ace nto he
clutchhousing.
\

2. Aftermountingheclutch ousing nto he ransaxleang-

er, tap in the difterential earingouterraceswith a ham-
meruntil t is flushwith he end ol the clutchhousinq.
Plpedlametel:47mm 1.85 n)

J-45
 

J TRANSAXLE
Adlustmentshim and tunnel (Primary haft)
1. nstailhe unnel nto he ransaxe ase
Pipediameter:40mm (1.57 n)

2. Installhe adjustmenthim(s).

Oll seal (ditlerential)

Caution
. Apply transaxleoil to lhe outer clrcumGl€nceof the
-4 r-J lr_:
oll seal.
lnstallhe newoil sealwith he SST.

Bearlngouter race (differential)

1. nstai he bearing uter ace nto he clutchhousing-

2. Afterm ountingheclutch ousing nto he ransaxleang'

--\R er, ap n the differentiale aring uter aceswitha ham-
meruntil t is flushwith he end of the clutchhousing
$,\o,-

\m#
\ Pipediameter:59mm 2.32 n)

4PY
J-46
 

TRANSAXLE J
Funneland bea.ingouter race (secondary hafl)
Note
. lnstall he tunnel which has the extra hole.

1.Setthefunnelandearinguteracentoheclutch ousing.
2.Tap hebearing uter acewitha suitableipeuntilitsful
ly seatedn the clutchhousing.
Plpe diameter:50mm ('1,97n)

Oil seal (primaryshalt gear)

Caution
. Apply transaxleoil to lhe outer qircutnlerencaol lhe
oil seal.
lnstallhe newoil sealw itha suitable ipe.
Pipe diameter:38mm 1.50 n)

Oil seal (change od)

Cautlon
. Apply transaxleoil to ihe outer circumferenceol the
oil seal.
Tap he newoil seal n until t is ullyseated.

Change rod and boot

e\ r
\
<-,2 l\ 1. nsEll he change od and boot nto he ransaxle.
\ t - 2. Fit he bootover he seal.
u .\-- -J,,-
Cautlon
. lnstall the boot wlth the air bleed downwardas
shown in the ligure.

J-47
 

,J TRANSAXLE
Roll pln
lnsiali he new rollpin as shownn the igure.

J-48
 

TRANSAXLE J
i,EMO

J-49
 

J TRANSAXLE
Housing arts
ljsemo-ten theorder hownn he igure eferringo Asaembly ote

r20-29
(2.oJ,0,1s-22)

(3.6-5.3,

t i

q
(2.0-3.0,

fl e-^
q02.-r5
{\\ (2..--3.€r
\
17__61
@

NEW

J-50
 

TRANSAXLE J
1.Clutch ousing ssembly 25.Shiti od end (3rd/41h)
2. Diff rential ssembly age
Assembly ote....................... .....53
3. Primary haftgearassembly 26.Shift od (3rd/4th)
Assembly ote............................ age -52 age 53
Assemblyote............................
4. Secondaryhaftgearassembly 27.Roll in
A s s e m b l yo t e . . . . . . . . . . . . . . . . . . .a. g. .e. .-.5. .2. age -53
Assemblyote............................
5. Reverse hitt ever 28.Roll in
Assembly ote.......... page 52 age -53
Assemblyote............................
6. Oring 29.Plug, pring 3rd/4th),teelb all
evershalt 30.Baseplateunit
Assembly ote.......... page 52 31.Crankever ssembly
tJ Htn 32.Crank ever haft
9.Roll in 33.Retalninging
10.Reversedlershaff Assembly ote......................age
......-54
'11.Reversedlergear 34.N4agnet
age
Assembly ote........................ ....-52 35.Transaxleaseassembly
12.Lever et sprrng Assembly ote......................age
......-54
13.S hiftork 1sv2nd) 36-Engine ountN o.1
Assembly ote..... age -52
...................... 37.Plug, pring 'lsv2nd, th/Bev), teel all
14.Shift od (1st/2nd) Assembly ote......................age
......-54
age
Assembly ote........................ ....-52 38.Drainplug
15.Bollp in 39.Back-upightswitch
Assembly ote.......... Page -52 40.Neutrai witch
16. nterlockin 41.Oilseal
Assembly ote.......... page -52 age 55
Assemblyote............................
17.Shift ork (sth/Rev) 42.Speedometere arsleeve
Assembly ote.......... page 53 43.OJing
18.Shift od end (sth/Rev) 44.Driven ear
Assembly ote.......... Page -53 45.Roll in
19. nterlockin Assemblyote.......... age -55
.................
Assembly ote.......... page -53 46.Speedometerr ivengearassembly
20.Shift od (sth/Rev) 47.Clutch elease ollar
Assembly ote.......... page -53 age -55
Assemblyote............................
21.Follpin 48.Clutch eleaseork
Assembly ote.......... page 53 age -55
.................
Assemblyote..........
22.Roll in 49.Clutch ever
Assembly ote.......... page -53 age -55
Assemblyote............................
23.lnterlockin 50.Return pring
Assembly ote.......... page -53 51.Transaxle
24.Shitt ork (3rdi4th)
Assembly ote.......... Page -53

J-51
 

J TRANSAXLE
Assembly Note
Primary ahalt gear assemblyand secondary shatt gear
assembly
Inslallhebdmary hattgearassembly nd hesecondaryhaft
gearassemblyogether.

Reverseshift lever, reverse lever shalt

1. Apply ransaxleil o the newO-ring nd hen nslallhe
reverseevershalt.
2. Installtheeversehift ever nd hen nstalltheeversee-
ver shaft.
3. nslallhe newpin.

Reverse dler gaar

Installhe reversedlergearand he reversedlershalt.

Shift rod (l sU2nd),shift fork (l su2nd), roll pin, interlock

pin
Caution
. The mark 0ndicated by the atrow in the llgure) and
theshin rod end mountlngbolt holemust be n the
aamedirection.
'l. ,nstallheshitt ork and he shift od.

Caution
. When nstalling he roll pin, be caretulnot to dam'
age the shlft rod.
2. Installhe new ollpin.
3. Installhe nterlock in.

J-52
 

TRANSAXLE J
Shift rod (slvRev), shitt fork (sth/Rev),
shltt rod end (5th/Fev), oll pin, inte ock pin
Caution
. lnstall he intedockpln nto he holeof clutchhous-
ing as shown in the flgure.
1. nstallthenterlock intothe hift odand nstallthehifl od.

. When nstalling he roll pin, becaretulnot to dam-

age the shift rod.

Note
Diameter Length
Shifl lork s.0 0.20) 22 9.8n
Shifl rod end (slh/Rev) s.0 0.20) 20 (0.79)

2. Installhe new rollpin.

3. lnstallhe nterlock in.

Shift rod (3rd/4th), shift lork (3rd/4th),

shift rod end (3rd/4th), oll pin
Caution
. Install he nterlockpin nlo he holeot clutchhou&
ing as shown in lhe llgure.
1 Installthen terlockin o te shift odand nstallthehift od.

Caution
. When nstalling he roll pin, be caletul not to dam-
age he shift rod.
2. Installh e new rollpin.

J-s3
 

J TRANSAXLE
Retaining ing
1. nstallhe crank everand nstallhe crank evershaft.
Caution
. Verify he in3tallinga retalning ing 6urely.
. lnstal the groove of crank ever shalt to the diftereF
tlal end.
2. Installhe new etaininging.

3. Shift he gears o 3rd gearandhold he shift odwithone

handso that t doesnol all.

Transaxle ase assembly

Note
. Tighten he bolts to the specified orque.

1.Applysealant nd nstallhe ransaxle ase.

Caution
ENGINEMOUNT No.l
. When nstalling he transaxlecase, nstall he en-
glnemountNo.l.

2. nstallhe ransaxlease o the clutchhousing.

Tlghtening orque:
i9-26 N.m 1.9-2.6 m-kg, 14-19 ft-lb)

Plug, spring, steel ball

'1. Applysealanto the
Plugs.
2. Installhe geel balls, prings nd plugs

20-2tN.morque:
Tiqhtenlnq
i2.O-3.0 m-kg, 14-22 ftlb)
sp ng Oiametermm {in) Lensh mm (n)
@ 7.2 O.2A) 22.5 (0.89)
7.2 10.28) 33.2 r.31)
o 7.2 /{0.28) 22.5 0.89)

3. Contirmhat he ransaxleperatesmoothly hen hitted.

If not, eassemblyhe ransaxle.
J-54
 

TRANSAXLE J
Oil seal
1. Place hespeodometerearsleeven a vice.
2. Tap he newoil seal nto he speedometerearsleeveus-
ing a suitable ipe.
Pipe diameter:15mm 0,59 n)

Folt pln
Installhe new ollpin as shown n the igure.

Clulch release ork, clutch releaae olol

1-
Applygrease s shown n the igure.

"=

Clutch ever
1.Applygreaseo the bushing.
2. nstallhe clutch ever o the clutch eleaseork.
Tightening orque:
35-41 Nm (3.6-4.2 m-kg,26-30 fi-lb)

J-55
 

J TRANSAXLE
INSTALLATION
1. Raisehe vehicle nd supportw ithsalety tands
2. Installn the ordershownn the ighre. eflerringo InstallationNole
3. Ado he specitied mount l the specitiedransaxlejl (Refero pageJ-7 )
a. Warmup ihe engine nd ransaxle, nd nspector oil eakage nd rasaxle peration

3r --45 (4.2-4,7, 23--.34)

€ t

huz
32-56
(3.4-s.7, &-trif"l',.'-."

6a--a,--:6

J-56
 

TRANSAXLE J
1. Engine ountN o.2 9. Extensionar
2. ransaxle lnstallation age -58
o te..........................
lnstallationote........ J-57 10.Neutral witch onnector
3. Stittner 11.Back-upightswitch onnector
4. Exhaust ipe bracket '12.Clutch able
5. Enginemountmember age -58
lnstallatlono te..........................
qno6.l^mal6r
installationNote........ pageJ-57 11 ^.h16

6. Staner ageJ-58
lnstallationote..........................
7. Driveshatt 14. Battery,b attery arrier
age -58
Installationote.......................... 15.Splashshied
8. Control od 16.Wheeland trre
age -58
lnstallationote .........................

Installation Note
Transaxle
1.Set he ransaxlen a jackand ift t intoplace.

2. nstallhe ransaxle olts.

Tightening orque
@rj&{r@ A: 64-89 N.m 6.5-9.1 m-kg, 47-66 ft-lb)
Bt 7.3-11 N.m 0.8-l.l n-kg, 5.8-8.0 ft-lb)

Enginemount member
1. nstallheboltsand nutsas shown.
Tightenlng orque
@: 64-89 N.m 6.5-9.1 m-kg,47-66 ft-lb)
@: 37-52 N.m 3.8-5.3 m-kg,28-38 ft-lb)
Caution
. BetoF install he enginemountmember, ul engine
mount No.1and No.2studs n the installlnghole.
2. RemoveheSST (Eqine support).

J-57
 

J TRANSAXLE
Ddveshaft

f\rt") Cautlon
. Verlty hat the oil seal s not damaged.
. Do not damage he oil seal.
'1. Inserthe newclipwith heend-gap t he op ot hegroove
2. Apply transaxle il around he oil seal ip lnstall he
driveshaft.
3. Verityhat hedriveshafts correctly eated y pulling n
the shaft.

4. Connecthe ower rm o heknuckle nd ightenheclinch

bolt.

<\
* Tightening orque:
43-54 N.m 4.4-5.5 m-kg,32-40 tt-lb)

Extenslon bar and conlrol rod

1. nstallhe extensionar o the ransaxle.
Tightenin9 orque:
31-46 Nfl (3.2-4.7 m-kg,23-34 fr'b)
2. Installh e change ontrolod o the ransaxle.
Tightening orque:
16-23 N.m 2-17 ft'lb)

Clulch cable
Installhe clutch able. Refero SectionH.)

Speedometer able
1. Add the sDecifiedmount i the specified ansaxle il
thoughthe speedometerr ivengear nsiallationole
2. nstallhe speedometerr iven ear.
Tightening orque:
7.8-12 Nm (0.8-1.2 m-kg, 5.8-8.7 ft-lb)
3. Connecthespeedometera ble o the speedometerr iv'
en gear.

J-58
 

DIFFERENTIAL J
DIFFERENTIAL
PNEPARATION
SST

49 8017 2A0
@ 49 DO27 02
bearins
@@@ (Partof
49 80172A0)
@@@
49 F40l 366A 49 0839 425C

oeafrng
beanng
49 80172A0)

49 0439 428 49 0862426

bearingpuller bearing uller

49 0839 425C) 49 0839425C)

49 D017 241 49 F401 3374

4 9 D 0 1 72 A l )

J-59
 

J DIFFERENTIAL
DISASSEMBLYINSPECTIONASSEMBLY
Caqtion
. Do not remove the inner race il not neoessary'
'1.Before isassembly, nspecthe backlash l sidegears' eferflngo Preln6P€ctlon
2. Disassemble n theordershown n the igure. ete(ing o Disa$embly Note'
3. Inspect ll partsand repairor replace s necessary
4. Me;sure he backlash fterassembly,eferringo Backlashol Pinlon Geara

'wa
..-'4b,
Tffi.
'1.Sidegear 6. Pinion ear
lnspector wearand cracks Inspector wearandcracks
2. Washer 7. Sidebearing nnerace
3. Rolipin ........page -61
Disassemblyo te...........
age -61
Disassemblyo te....................... Inspector wearand cracls
4. Pinion haft 8. Speedometerr ivegear
5. Thrustw asher 9. Ringgearand gearcase
Inspect or wear and cracl$

J-60
 

DIFFERENTIAL J
Preinspection
Backlashol pinion geals
Measurehe backlash s follows.
n to he ditferentials-
1. nstallhe eftand rightdriveshafts
semDly.
2. lMeasureh e backlash l bothpinion ears.
Backlash 0-0,1mm (0-0.004 in)
Maximum: .5mm 0,020 n)
3. f the backlashs notas soeciiied,eplacehedifierential
as an assemoty.

v€LocK

DisassemblyNote
Roll oin
Caution
. use prolectiveplates n the vbe.
. Insen he punch nto he roll pin hole lom the rlng
gear slde.

Securehe gearcase n viceand ap out he rollpin.

Slde bearing nner race

Cautlon
. When eplacinga bearing, eplac€ he innerand out-
er tacesas a set,
1. Removehe bearingnner ace speedometerrivegear
side)with heSST.

1EoJXj75
2. Removehebearingnner ace ringgearside)wilhheSSI.

BEABINGNNER

J-61
 

J OIFFERENTIAL
Assembly
1. nstallthe peedometerr ivegearas shownn he igure
Cautlon
. Wtlen replacinga bearing, eplace he inner and out-
er races as a set.

2. Installhe newbeanngnner ace.

(1) Installthe ewbearingnner ace speedometerrive
gearsjde)witha Press nd he SST

(2) Installhenewbearingnner ace (ring earside)w ith

a press nd heSST.

3. Set he pinion ears nd hrustw ashernto he gearcase

4. Inserthe pinion haft.

J-62
 

DIFFERENTIAL J
5. Installa newroll pin and stake he case o prevent t from
workino ut.

6. Installhe sideoearsandwashers.

Backlashof PinionGears
Recheckhe backlash l the pinion ears.
(Refero pageJ-61.)

J-63
 

J SHIFT IECHANISM
SHIFTMECHANISM
OVERHAUL
1. Disassemble n the ordershown n the igure.
2. Inspect ll parts and repairor replace s necessary.
3. Assemble n the reverse rderof disassembly,eferringo AssemblyNote

16-26 0.6-2.3, t2-t4

J-64
 

SHIFTMECHANIS]II J
1.Shift everknob 18.Washer
2. Ashtray 19.Pipe
3. Front onsole 20.Bushing
4. Boot Insp€ctor wearand damage.
5. Nut 21. nsulator
6.Washer Inspector damage ndcracks
7. Bolt 22. Bushing
8. Nut Inspector wearand damage
9. Bolt 23. Boot
10.Control od Insp€ctor damage
Inspector bending 24.Spring
Assembly ote............................
ageJ-66 Inspector damage nd weakness
11.Bushing age -66
Assemblyote............................
Inspect or wear and damage 25. Ball seat upper)
12.Nut 26.Boot
13.Washer Inspector wearand damage
14.Washer 27.Holdel
15. Nut 28. Ball seatbwer)
'16.Washer 29.Shift ever
17.Extensionar olEoJxr86
Inspector bending
age...-66
Assembly ote.........................

J-65
 

J SHIFT IECHANISM
Asso|nbly Note
Sprlng
'1.Applygreaseo the spnng.
2. Aisemble he spring s shown n the igure

Extensionbar
1.Assemblehe nsulatoro the bracket l theexension ar
and nstallhe nutsand washers.
2. Conneclheextensionar o the ransaxle,hen o he body.
Tightening orque
Tranaaxle:
5.9-8.8 N{n (0.6-0.9 m-kg,4.3-6.5 ft-lb)
Shlft lever:
31-45 Nm (3.2-4.7 m-kg, 23-34 finb)

Control rod
1. nstallhe control od.
2. Verify mooth peralion f the shiftmechanlsm
01E0JX-149

J-66