No.

ME-
TB45AE

SHOPMANUAL

TCMCORPORATION
 A SAFETYPRECAUTIONS
MAINTENANCE&REPAIR
Takes
pec
iala
tte
nti
onwhenj
ack
ingupt
het
ruc
k.F
ixi
tsa
fel
ybyu
sin
gstandso
rwoodb
loc
ks.

Confirmt
hes
afe
tyo
fth
esu
rro
und
ing
. Useropesh
avi
ngane
xtr
alo
admarginwhenl
if
ti
ngheavy
o同e
cts
.

Makesureb
olt
s，n
uts，p
ipe
sandw
ire
sarecompletelyremovedwhenu
sin
gpowert
ool
stod
is-
mountp
art
s.

Toc
arr
yheavya
rti
cls，
e uset
ool
sormachines. Nevera枇emptt
odosow
ithhand.

YourTCMmachiner
equ
ire
sTCMgenuinep
art
s. OesignateTCMgenuinepa吋swheno
rde
rin
g
p
art
sfo
ryourmachine.

Usec
lea
nto
olsands
ele
ctac
len，du
a stf
reep
lac
ewhens
erv
ici
ngh
ydr
aul
icdevicesando
the
r
p
rec
isi
onp
art
s.

Makesureb
att
eryt
erm
ina
lsaredisconnectedwhens
erv
ici
nge
lec
tri
csystemp
art
sorw
eld
ing
.
(
Fir
stremovet
hen
ega
tiv
ete
rmi
nal，
andthent
hep
osi
tiv
eon
e.)

P
art
icu
lara
tte
nti
onshouldbep
aidt
okeepo
ils，gasesandflammablesawayfromt
heworkshop.
Tidyupandf
ixt
hedisassembledp
art
sandt
ool
s.

As
ignp
osto
rca
uti
onboards
hou
ldbes
etupt
oarousea
tte
nti
onf
orp
roh
ibi
tio
nofengineo
rle
ver
o
per
ati
onw
hil
ese
rvi
cin
g.
00notattemptt
oremoveanycomponentsw
hil
eth
eenginei
sru
nni
ng.

Neverstandbeneathau
pra
ise
dfo
rko
rca
rri
age
.Blockmachineandc
arr
iag
ewhens
erv
ici
ng.

Keept
hes
erv
ici
ngt
ool
salwaysi
ngoodo
rde
r. Checkthemr
egu
lar
ly，andhandlep
rop
erl
y.

I
nap
oor
lyv
ent
ila
tedroom(workshop)，neverope
悶tet
heenginef
oral
ongw
hil
e.

TC
Nt
 FOREWORD
T
hismanuali
swr
itt
ent
ogi
vet
hei
nfo
rma
tio
naboutmaintenanceproceduresf
ort
hemodelTB45g
aso
lin
e
engine，
whichi
smountedonourf
or
kl
if
ttr
uck
s.I
tiscompiledbasedont
heworkshopmanualp
ubl
ish
edby
NISSANMOTORCO.，LTD. Ther
ela
tio
nsh
ipoftheenginemodelsandoura
ppl
ica
blet
ruc
ksi
sasf
oll
ows
:

Enginemodel A
ppl
ica
blet
ruc
kmodel
TB45 FG35T2 FG40T2 FG45T2

T
hisshopmanualc
ons
ist
sofe
igh
tse
cti
onsasshowni
nth
efo
llo
win
gta
ble，whichg
ive
sth
eupdated
symbols.

S
ect
ion Symbol
ENGINEGENERAL (EG)
ENGINETUNE-UP (
ET)
ENGINEMECHANICAL (EM)
ENGINELUBRICATION (
LU)
ENGINECOOL
lNGSYSTEM (CO)
ENGINEFUELSYSTEM (
FL)
ENGINECONTROL (EC)
ENGINEELECTRICALSYSTEM (
EL)

December2004

TC
I¥
Yt CORPORATION
 ENGINEGENERAL

CONTENTS
PRECAUTIONSFORSAFETYANDQUAL lTY. EG・2 PRECAUTIONS. .・ ・ .
.
.
.・ ・
H ..
.
.
.・ ・..
..
..
..
..
..
.
.・ ・ ..
H...E
G・15 H H

SafeOperation ...
..
..
..
….
..
・ ・ .
.
.
.・ ・.
.
・ ・ .
.…
...
・ ・ .EG-2 H H H H PrecautionsinDr ainingEngineCoolant ・.
.・ .EG・15 H

CorrectOperation…・ ・・ ..
… ・・ -…
・..
.
H...
...
..… .EG-3
H H H PrecautionsforD isconnecti
ngF uelP i
pi g…EG-15
n
PrecautionsforRadioEquipment PrecautionsforRemovingand
Ins
tall
ation… …
…...・ ・-
岡 ・・ ..
… ・・
H ..
..
..
..
...
..
..
… EG・H3 H H H Disassembling・.
. ・・・H ..
..
..
..
.
..
..
..
・ ・H.
.
.
.・ ・
H .
.
・. . .
EG・15 H H

HOWTOUSETHISMANUAL. ..
.
..
.
.・ ・.
..
.
・ ・..
・ ・ .EG・4 H H M PrecautionsforI n
s p
ection，Correcti
on， and
Descr
iption. .
.
.
.・ ・.
..
..
.
・ ・・・
H .
.
.
.・ ・.
..
.
..
・ ・ .
.
.
.
H.
・ ・ .EG・4 H H H H H Replacement. .
..
.
・ ・ .
.・ ・ .
.
H……
...
・ ・ .
.
..
.
・ ・・・ H..EG・15 H H H H

Def
initio
no fTerms……………...・ ・ .
.…
..
.・ ・.
.盲
目 ..EG・4 H H PrecautionsforAssemblyandI ns
talla
tion …EG・15
Def
initio
no fUnits.・ ・ .
.…
..
..
..
..
..
.・ ・.
H.
.
..
..
.
.・ ・ ...G・
E 4 H H CautionforUseo fPowerTools … …・・・
・ ・・ .
..EG-16 H H

Descr
iption・.
. ・・・
H .
.
・ ・
H .
.
.
..
・ ・
H ..
.
.
.・ ・.
..
.
.・ ・・・
H .EG・5 H H H H H PrecautionsforLiquidGasketApplication….EG-16
ComponentP artsLocation.・ ・.
.… ・・-…… ..EG・ 5 H H H PartsRequiringAngleT ighten
ing.・ ・ .
.
.
.・ ・ ..EG・17 H H

TROUBLEDIAGNOSIS. ..
..
..
..
..
…・ ・・ .
.… ・・・ ...G・
E 7 H H H H H PREPARATION . ..
.
.
.・ ・ -一一・… ・・・・
H ...
一一・. ....E
G・18 H H H H

ECMT roubleDiagnosis .
・ ・ .
.
.
.・ ・.
.
・ ・ .
.
..
・ ・ ...G・
E 7 H H H H Specia
lS erviceTools. ・ ・..
.
.
・ ・ .
..
.
..
・ ・・・ .
. ..G・
E 18 H H H H H

ECMA bbreviati
onsList.・ ・.
..
.
・ ・..
.
..
.
・ ・ ..
… ..EG・10 H H H ServiceParts…・ ・・
H .
.
..
.
・ ・ .
..
.
.
・ ・
H .
.
..
・ ・..
..
.
.・ ・ ..EG・20H H H H

ECMGENERALSERVICEINFORMATION. ....EG
-11 SERVICEDATA…… ・・・・ -
H…
・ ・・・・-一一・ .
H H . .
EG
H・21 H H H H

ConnectorTerminallnspection .
・ ・ .
.
..
.
・ ・ ....
EG・11 H H Peri
odicalI n
spection. .
..
.
..
.
.・ ・..
.
.
・ ・ -
・. ...
...
....E
G・21 H H

Inspe
ctionf o
rE l
ectri
calSystem .・ ・.
..
.
.・ ・ .
. .
EG・12 H H Standard，RepairL imit・
.. ・・・ .
..
.
..
・ ・ .
.
… ・・ .EG・23 H H H H H H

Contr
olU nitandE lectr
onicComponent・ .
. ・ .EG・13 H Tighte
ningTorque… ..
.・ ・ .
.
… ・・ .
.
..
.
.・ ・・・ .. .
EG・
H 24 H H H H H

SST・ .
.・H.
.
・ ・H..
….
...
..
..
.・ ・.
..
.
.・ ・.
.
..
.
・ ・. ・・ ...
H.E
G・14 H H H H
PRECAUTIONSFORSAFETYANDQUALITY

• Thef oll
owingprecaution
smustbec a
ref
ullyobservedfo
rs af
e
anda pp
ropriat
es ervic
ew or
k.
• Only theq ua
lifi
ed and d esig
na t
edp erso
n n
el must pe吋orm
inspe
ctions，re
pairsanda dju
stments.
• Alwayskeept heworkplacec lean，andstor
et hetool
sneatl
yin
thespeci
fiedplace
s .

SafeOperation
• 00 n o
tr u
n an engine i n
sidet he workshop w i
thoutprope
r
ven
tila
tion(ex
.nov enti
lati
onducts).
• Keept heworkshopw e
llv e
ntilat
edandf reeofanyflammable
mate
rials
.S pecialc ar
es hould bet a
ken whenflammableo r
poisonousmaterial
ssuchasg aso
li n
ea rehandled.
• Oiscard waste oi
la fte
ro il changes o r pa吋s treatm
entin
accordancewithlocallawsandr egul
ation
s.
• Be c ar
efulo f burns and i njur
y when w orking on high
-
temperatur
ep ars，r
t ota
tingpa同s， orsli
dingpor
t i
ons.
• Ensurethatadequatev e
ntil
ationisprovidedfordisch
argi
ngany
OO43
EGM
hazardouse mi
ssionswhenw o
r kinginapitore nclos
edarea
.
• 00n otworkunderneathav ehiclesupp
o r
tedo n
lybyaj ack
.
Alwaysuses a
fetystandsattheprescr
ibe
dp oi
ntstosupp
ortt h
e
veh
icle
.
• Supporttiatthep r
escribedpoint
sandl ockt
iinp o
siti
onw it
h
saf
etyd ev
icesbefor
el i
ft
ingth
ev e
hicl
e.
• Bec are
fulthatthevehicl
ebodydoesn otbecome0何 b al
ance
andfal
lwhenremovingaheavycomponentsuchast heengin
e.
• 00n otsmoked u
rings e
rvicework.
• 00n otwearanyr ingsandn ec
klaceswhenw orki
ng.These
o同ectsmaycausee l
ectr
icshor
t.
EGMOO44

• Be
forest
arti
ngrepa
irwork th
atreq
uir
es no b
atter ，
y power
a
lwaysturn OFF theig
nit
ionsw
itch，and disc
onnectthe
ne
gat
ivebat
teryc
abl
e.

EGM0045

• 00n ottouchanym etalport

ionsi m
mediatel
ya f
tertheengin
eis
stopped.Othe附 isetheheatedmetalsmaycauseb ur
ns.00n ot
attemptto remove any c ooli
ng system parts such as th
e
rad
iatorcapw h
ilet h
eengineisho .
t
• To pe吋orm r epair work sa
fely and eff
icie
ntl
y，always use
appr
opriate commercial s
ervicet o
ols and spec
ifiedSpecia
l
ServiceTool
swhereverr eq
uired.

EGMOO46

EG-2
PRECAUTIONSFORSAFETVANDQUALITV

C
orr
ectOperation
• Makes urethatyouu n
ders tandthesymptomsb ef
o r
es ta
rtin
g
trou
bled i
agnosi
s.
• Check c or
rect i ns
tal
lation s t
atus p r
ior to r emoval o r
disassemb
ly. Make s uret hatt hey do notinterfe
rew itht he
fun
ctionoft hepa吋st h
eya rea pplie
dtofimatchingmarksa r
e
requ
ired.
• Oncet heya reremoved，alwaysr eplac
ep art
si ndicate
das" do
notr euse
"w ith newo ne
s.T hisi n
clu
des:oils eals，gaskets，
packings，O-rings，lockwashers，c o
tterpins，ands el
f-Io
ckin
g
nut
s.
• Replace inner and outerr a
c e
so ft aperedo rn eedler ol
ler
bearingsasase .
t
• Arrangedisassembledp artsino rderand p re
ve n
tthemf r
om
beingmixed-up.
• Clean o rf l
ush disassembled p artsp r
iort oi nspecti
ono r
assembly.
• UseGenuineNISSANp artsforreplacemen.
t
• Usea uthoriz
edgreaseands ealer
.
• Releaset hep r
es s
ureb efored isc
onnectin
gp ressurizedpipin
g
orhoses.
• Bes uret ocheckf orleakagea fterrepai
ringfuel，ol，c
i o
olant，
exhaust，orvacuums yste
ms .

Precautionsf
orRadioEquipment
Ins
tallat
ion
Check t h
ef o
llowing when inst
all
ing a commercial/ham rad
ioo r
m o
bilep hone.Ifmountingp os
itionisnotchosenc aref
ull，t
y heu n
it
mayi nte
rfer
ew iththee l
ect
roniccon
trolsystem.
• Separatet h
eantennaasf a
rfromt heECMasp ossib
le.
• Routeanantennaf eederlin
eatleast20cm( 7.8
7in)apartfrom
thecontro
lu ni
th arn
ess.
• Adjust an antenna and f e
ederl i
net oe l
iminateradio wave
inte
rferen
ce.

EG-3
 HOWTOUSETHISMANUAL

D
esc
rip
tio
n
T
his manual exp
lain
s how t op e
rfo
rm" re
mov
al， i
nsta
lla
tin，
o
dis
ass
embl払a ，
ssembly i
nsp
ect
ionandadj
ust
men
t"and"di
agnos
is".

D
efi
nit
iono
fTerms
WARNING Inst
ructi
onsand precaut
ionst h
atmayl eadtof at
al
hazards and/ors e
riousi nj
uri
esi fn ot observed
pro
perly
.
CAUTION I nst
ructi
ons and precaut
ionst ha
tr eq
uires pec
ial
att
entio
nandmayl eadtoproblemsa nd/oracc
idents
as w el
l as damages t o t he v e
hicle and/or
components.
NOTE 8upplementary i
nform
ationtof ac
ili
tat
et hes er
vice
work.
8tandard Indi
catestoler
anc
esforinspe
ctionandadjustmen.
t
Repairli
mi
t:Indi
cates maximum orminimumv aluesa l
lowedfor
insp
ectionanda叫ustmen .
t

D
efi
nit
iono
fUn
its
Theu ni
tsandnumeri
calv aluesinthi
s8tandarda re81uni
ts，and
thosegive
nin()i
nthis8tandardarebasedont h
ec o
nve
nti
onalun
it
systemandareappendedforinform
ativeref
erenc
e.
Example:目 :
59・78Nem( 6.0・8 0kg-m，
. 43・58f t
-I
b)
81(M
etr
icsystem， yard-p
ou n
ds ys
tem)

MAINUNITCHANGES
Measure 5
1 C
onv
ent
ion
alu
nit Conversion勉c
tort
o51

A
cce
ler
ati
on mls 2 G 9.80665

Torque，moment Nom kg-m 9.80665

Force N k
gf 9.80665
Pressure kPa kg/cm2 98.07

kPa mmHg 0.133322

Powere
ffi
cie
ncy kW P5 0.735499
W kca
l/h 1.16279
Volume cm3 cc

5
pri
ngconstant N/mm g
k/mm 9.80665
F
uelconsumption ・
g/kWh* /P5o
g h 1.3596

*Thec
onv
ent
ion
alu
nitcanbeusedf
or8.
1

EG-4
HOWTOUSETHISMANUAL

D
esc
rip
tio
n
CAUTION :Att heb eginningo f each secti
on，t hep recaut
ions
exclu
sivetot h
es ecti
ona redescri
bed.
Pr
epa
rat
ion
:A ttheb e
gi n
ningofeachs ec
tionandd urin
gt hetroub
le
diagno
sisi tems，theSSTs，gauges，ando thert o
olsto
be preparedb eforeo pera
tiona red es
cribed. Some
commercials ervi
cet oos，assumedt
l obea vail
ablein
anyworkshop， areo m
itted.
De
scr
ipt
ion
: To p erform c orrect o pe
rations， o peratio
nal
procedures， n otes， SSTs， and o ther s erv
ice
info
rmationared es
cribed.
CAUTION D escr
iptionso fv isu
ali n
specti
ons and c lean
ingo f
removed p ar
t s a re g ene
rally o mi
tted. Please
remember t h
a t actual operation
s r equir
e t hese
processe
s.

ComponentP
art
sLo
cat
ion
The
incl
udesi nf
ormat
ionf orr emov
al，i n
sta
lla
tin，d
o isa
ssemb
ly，and
assembly(tig
hten
ingto閃 ue，greasepoin
ts，non-re
usabl
epart
s)as
we
llaso th
eri n
forma
tionimporta
ntforrep
airwork
.

C
ams
haf
tsp
roc
ketsi
de

~Q
本 2O
-ri
ngi
nst
a1i
ngg
roo
ve
J
R"，
Hw~~~~~~haft p
u11
ey
CII asher

EGM0090

EG・5
 HOWTOUSETHISMANUAL

ComponentPar
tsLocation(
Con
t'd
)
COMPONENTSYMBOLS

Symbols Desc
円pt
ion Symbols D
esc
rip
tio
n

悶 T
igh
ten
ingt
orq
ue @ Notreusable

E Shouldbel
ubr
ica
tedw
itho
i
l
ヲ
崎 S
ele
ctpropert
hic
kne
ss.

国 Searingp
oin
t

EGM0048

EG-6
TROUBLEDIAGNOSIS

ECMTroubleDiagnosis
CAUTION:
• Thef ollowi
ngt r
ou b
led iagnosisproceduresa redesigned
toident
ifyt het ro
u bl
ecausese f
fici
entl
y.Whenperforming
diagnoses，carefullyobservet hefollowinginstr
u c
tions.
• Befores tar
tingat roube diagnosis，c
l aref
ullyr ead and
understandt hec ontentsin" BasicInspectio"，
n "Diagnosis
ChartbySymptom"and" Tro
ubleDiagnosisFlowchart ヘ
• Afte
rt her epair work ，always verify thatthe trouble is
elim
inated.
• Fort hel ocationso ft hepartsand harness connectors，
ref
ert o "Component P artsL oca
tion"i nt her el
e v
ant
sect
ion.
• Toperformasimplei nspect
ion，util
izethecircui
tdiagrams.
Toi ns
p e
ctt hec i
rcuitforcontinui
tyi ndetai
lsi ncludingthe
sub-harnesses， 同 de川
nt
i町
旬 the r elevant connectors and
harnessla
'
町lyO
utsr
恒 eferri
ngtot he“Wiri
加
• Beforei nsp
ect ingac ircu
itf o
rc ontinu
ity，alwaysturnthe
ign
itionswitcht oOFF.
• Beforemeasuringv o
ltageataconnector ，alwaysmeasure
thebatteryvoltage.
• Afte
rf inishi
ng diagnoseso ri nspections，alwaysensure
tha
ta ll removed harness connectors a re reconnected
cor
rectl
y.

EG・7
 TROUBLEDIAGNOSIS

ECMTroubleDiagnosis(
Con
t'd
)
SYMBOLS

Symbols D
esc
rip
tio
n Symbols D
esc
rip
tio
n

DISCONNECT

lu
Checkaft
e
measured
rd
isc
onn
ect
ingt
heconnectort
obe
⑥ Procedurew
ithSST

ι
CONNECT
Checkaft
e
measured
rc
onn
ect
ingt
heconnectort
obe
⑮ Procedurew
ith
outSST

(
t
..
.吋 I
nse
rtkeyi
ntoi
gni
tio
nsw
itc
h.
宙 A
lCs
wit
c s"ONへ
hi

。。吋 Removekeyfromi
gni
tio
nsw
itc
h
固 A
lCs
wit
chi
s"OFF
'¥

お
G Turni
gni
tio
nsw
itc
hto"OFF"p
osi
tio
n.
定f Connectt
oba
tte
rypowersupplyd
ire
ctl
y.

~ Turni
gni
tio
nsw
itc
hto"ON"p
osi
t旧n
品L D
riv
eco
ndi
tio
n

~ Turni
gni
tio
nsw
itc
ht T"p
o"STAR osi
tio
n
間1 Disconnectb
att
eryn
ega
tiv
ete
rmi
nal

~cc Turni
gni
tio
nsw
itc
hfrom"OFF
，・ t
o"ACC"p
osi
tio
n
駈 Brakep
eda
ldepressed

~OFF Turni
gni
tio
nsw
itc
hfrom"ACC"t
o"OFF"p
osi
t旧n
立
; Releasebrakep
eda
l

@
3 N
Turni
gni
tio
nsw
itc
hfrom"OFF"t
o"ON"p
osi
t旧n
金
銭 Depressa
cce
ler
ato
rpe
dal

G
SF Turni
gni
tio
nsw
itc
hfrom"ON"t
o"OFF"p
osi
tio
n
議
建 Releasea
cce
ler
ato .
rpedal

む Don
ots
tar
tengine，o
rcheckw
ithenginestopped Showsconnectort
co
ntr
oluni
tst h
a
ermi
n
thaves
a
e
l
v
e
so
r
fECMo
a
lte
rmi
na
ro
l
t
s
he
r

(
2
三
五
5 S
tar
tengine，o

Applyp
ark
in
rcheckw

gbrake
ithenginer
unn
ing
.

a
c
も園 CT
C
on
8
…
t
rol ne伽

五
CÝ~H
Releasep

Checka
ft
a

e
rk
ingbrake

renginei
swarmedups
uff
ici
ent
ly.
La-
一
-
~
国j Voltages
hou
ldbemeasuredw
ithav
olt
met
er

国J Ci
rcu
itresist
a
anohmmeter.
nc
eshouldbemeasuredw
ith

日
iJ C
urr
ents
hou
ldbemeasuredw
ithanammeter
EGM0049

EG-8
 TROUBLEDIAGNOSIS

ECMTroubleDiagnosis(
Con
t1d
)
SYMBOLSFORHARNESSCONNECTOR
FEMALECONNECTOR
Whenaharnessconnectori sviewedfromA(t
ermi
nalsi
de)，the
Connectorsymbol oute
rframeoft heconnectorsymbolisind
ica
tedwithas i
ngl
e
li
ne
.I nad
diti
on，t h
ed irec
tionindic
ato
rshows" TS"(Te
rmina
l
Side
)indes
cript
iontypef on.
t

S
ing
lel
ine

D
ire
cti
onmark

圃
Femaleconnector
EGMOO50

• Whenaharnessconnectori sviewedfromB(harnesssid
e)，
the
Femaleconnector Connectorsymbol oute
rframeo ftheconnectorsymboli sindic
ate
dw it
hdouble
li
nes
.I nadditin，t
o hedir
ectio
ni n
dica
torshows"HS"(Harness
Side
)i ndesc
riptiontypefo.
t
n
• Termin
a lassignmentsofaconnectorviewedfromA andBa re
mir
rorimages， ind
icati
ngjus
tast heyaresee
n.
Doublel
ine

D
ire
cti
onmark

圃
EGM0051

MALECONNECTOR
TheiIust
rat
ionmethodi sthesameast hatfo ，
rafemaleconnector
A
theblac
kg uidebox，however，indicatesamaleconnector(
thewh
ite
guideboxafemaleco n
nector
).

圃
∞
EGM 52

T
SINGLEUNIT(CONTROLUNI)
Asing
lecont
roluniti
sviewedo
nlyfromA，andt
hei
llu
str
ati
oni
sas
C
ont
rolu
nit
shownint
hef i
gur
e.

Connectorsymbol
圃
∞
EGM 53

EG-9
 TROUBLEDIAGNOSIS

ECMAbbreviationsL
ist

A
bbr
evi
ati
ons D
esc
rip
tio
n A
bbr
evi
ati
ons D
esc
rip
tio
n

A
lC A
irc
ond
iti
one
r INT I
nta
ke
A
IT Automatict
ran
smi
ssi
on LH L
eft
ALT A
lte
rna
tor LED L
ightemittingdiode
ASSY Assembly LLC L
ong
-li
fec
ool
ant
BAT B
att
ery Mf
T Manualt
ran
smi
ssi
on
C
/P Crankshaftp
ull
ey OHV Overheadv
alv
e
C/U C
ont
rolu
nit OS Oversize
C
yl C
yli
nde
r P/S Powers
tee
rin
g
ENG Engine PTO Powert
ake
-of
f
EXH Exhaust RH R
igh
t
F
/L F
usi
blel
ink RR Rear
FR F
ron
t TAS T
hro
ttea叫u
l stscrew
I
/P I
dle
rpu
lle
y T
r T
ran
sis
tor
IGN I
gni
tio
n US Undersize

EG-10
 ECMGENERALSERVICEINFORMATION

ConnectorT
erm
ina
lIn
spe
cti
on
CONNECTORINSPECTIONPROCEDURE
I
nci
rcu
iti
nsp
ect
ion，i
nap
pro
pri
atec
onn
ect
orp
rob
ingw
il
l cause
con
nectordamagesa nd/o
rp oorconne
ction
.Thep robesprov
ided
w
iththecir
cui
ttest
ermaybet o
olargetoprobec
onnectorte
rmin
als
w
ithou
tdamaging t he
m. Always use a
lli
gat
orcli
ps and "
T"pins
a
ccordin
gtof o
llo
wingthepro
cedur
e .

INSPECTIONFROMHARNESSSIOE
Foras t
andar
dc o
nnect
orw
ith
outanyw
ate
rpr
oof
ing，use寸"p
ins
fromt
heh a
rnesss
ide
.
CAUTION:
• For a connector witha r ea
r cover，such as ECM
connectors，
removether ea
rcoverb e
for
et h
einsp
ection.
• Fora waterproofconnector，do notprobetheterminals
fromtheharnesssid
e.Ooingsomaydamagethes eal
.

一
ー
EGMOO54

INSPECTIONFROMTERMINALSIOE
1. Femalete
rmin
al
• Female c
onnect
orter
minal
s have a s
mal
ln o
tchd
iff
ere
nce
ins
ide
.Ins
erta"T"p
inalo
ngt h
este
ptoinspe.
t
c
CAUTION:
P
in
Femalet
erm
ina
l
・ 00notinsertanyobjectstoafemaleconnectorterminal
o
the
rthanthecorrespondingmaleconnectort
erm
ina
l.

∞
EGM 55

• I
ncaseo fafema
lecon
nec
torterm
ina
lwi
tho
utanyn
otc
hes，
removet
her
eta
ine
rbe
for
eprob
ing
.

∞
EGM 56

EG-11
 ECMGENERALSERVICEINFORMATION

ConnectorT
erm
ina
lIn
spe
cti
on{
Con
t'd
}
2
. Malet e
rmi
nal
Foramaleconn
ecto
rte
rmi
nal，a
ppl
ya"
T"p
int
oth
esu
rfa
ceo
fth
e
t
er m
ina
.l
P
in
CAUTION:
・ 00notbendterminals.

EGMOO57

I
nsp
ect
ionf
orE
lec
tri
calSystem
DESCRIPTION
• I
fthem alf
unctio
ncanbet r
aceddirec
tlytothee l
ect
ric
alsystem，
f
irs
tcheckf oritemssuchasburned -
o utfusesandf u
sib
lelins，
k
broken wire
so rl ooseconne
c t
or s，p凶l ed
-outt e
rmina
ls，and
improperconne
ctions.
• I
faf u
seo raf usi
blelin
kisblowno u t，d
eter m
inet hepos
sible
causeandr esto
rei.
tAlwaysreplacetiwit
hanewf useorfusi
ble
li
nkofthes p
ecifi
edcapac
ity
.
• Whenremovingac on
nector，don otappl
ye xce
ssivef o
rceto
th
emainbodybyg r
aspin
gandt wis
ting
.
• Don o
tpullaconn
ector0行 bytuggi
ngont heharn
ess.
• Fora l ock
-ty
pec onnector，disengage i
tsl oc
kf ir
st，the
n
dis
connecttheconnector by h
oldingthe main body ofthe
co
nnecto
r.

∞
EGM 58

• Beforeconnectin
gac o
nnecto，checkterminalsf
r orbendsor
Bend breakage
.Connecttisecu
rel
y.
• Fora l ock
-typeconn
ector，presstiunti
litsl o
ckissecur
ely
engaged.
・ Wheni n
sta
llin
gpa巾， p r
eventharnessesfromb ei
ngsnagged
oroverexten
ded.

EGM0059

EG-12
ECMGENERALSERVICEINFORMATION

C
ont
rolU
nitandE
lec
tro
nicComponent
PRECAUTIONS
• Neverreversepola
rityofbatteryterm
inals.
• In
sta
llonlypa吋ss pecif
iedforeachmode .
l
• Beforerepl
acingac ontro
lu nit，checki n
putando utp
uts ign
als
to/
fromthecontr
olu n
it，andcomponentf uncti
ons.
• When d isconnec
tingac onnecto，do not t
r w
isto ra pply
exces
siveforce
.
• Forab olt-
typec onnecto
r，loosent h
eb oltfir
st，thenho l
dt he
mainbodyo fthec on
n e
ctort odisconnec.
t
• Befor
ec onnecting ac onne
ct or，checkt erm
inalsf o
rbendso r
breakag
e.Connectt isecurel子F orab olt
-typec o
nnector，screw
i
nt heboltunt
ilt hecoloredl ugisflushwitht hesurfac
et obe
suret
iissecurelyconnected.
• Don otdrop，hit，orsub
jectc o
ntro
lunitstoimpac.
t
• Bes uretop r
ot e
ctcontr
olu ni
tsfromcondensationcausedbya
suddens hi
ftint emperatu
r e，orfromr aindro
pso rspl
ashes
.If
any water drops adhere t ot heu nit，dryt iw e
llp r
iorto
in
sta
llati
on.
• Bes uretoprotectcont
rolunitconnec
to rsfromo.
il
• Avoi
dc leaningcontr
olunitswithbenzi
ne .
• Don otopenat oporbottomc overonac ontr
oluni.
t

EGMOO62

• When usingac irc

uitt e
ste，ensuret
r hea p
propri
ated ist
ance
between te
stp robes.A l ongerd istan
ceis recommended，
becausei
fthed is
tanceistooshort，t
imaycausec o
ntactofthe
te
stprobes，resul
tinginas ho
rtc ir
cu.
tA shortc
i i
rcu
ita l
lows
bat
teryvo
ltagetobea ppli
eddirec
tlytotheco
ntro
lu n
it，re
sulti
ng
i
ndamaget oitsinte
rnalpowert r
ansi
stor
s.
• Use thespecif
ied check adapterto check i
nputand o u
tput
sig
nalsto
/fromcont
rolunit
s.

EG-13
 ECMGENERALSERVICEINFORMATION

SST
DESCRIPTION
• SSTisas mal，l
l ig
htwei
ghthandheldte
ste
r.Whenconnectedt o
th
ev ehic
le-s
ided at
al in
kc onnecto
r，ti communicates w
ith
co
ntr
olu n
itsins
tal
ledont h
ev ehic
leandp erform
sav ari
etyof
di
agnos
tictes
ts.

FUNCTIONANDAPPL
lEDSYSTEM

I
tem
s F
unc
tio
n

WORKSUPPORT Sendscommandt
oco
ntr
olu
nitt
ose
tst
atu
ssu
ita
blef
ori
nsp
ect
ionands
erv
ice
.
FUNCTIONSYSTEM CheckseachsystemasECMb
asi
cin
spe
cti
on.
SELF-DIAGRESULTS Receivess
elf
-di
agn
ost
icr
esu
ltsfromc
ont
rolu
nitandi
ndi
cat
esDTCsandnumbero
foc
cur
ren
ces
.
SELF-DIAGRESULTS DTCs(
Dia
gno
sti
cTr
oub
leCodes)recordedi
nco
ntr
olu
nit
'smemoryared
isp
lay
ed.
[MEMOR'η
DATAMONITOR Receivesinp
utl
ouゆu
tsi
gna
lsfromc
ont
rolu
nitandi
ndi
cat
esands
tor
esthemt
ofa
cil
ita
tel
oca
tin
gcauseo
f
malf
unctio
ns.
DATAMONITOR[SPEC]
A
cti
vet
est Sendscommandt
oco
ntr
olu
nitt
ochangeo
utp
uts
ign
alsandchecko
per
ati
ono
fou
tpu
tsystem.
DTCRECORDDISPLAY I
ndi
cat
ess
elf
-di
agn
ost
icr
esu
ltss
tor
edi
nECMp
rio
rtot
hemostr
ece
nt"ERASEMEMORY".
C
ont
rolu
nitp
artNo. D
isp
lay
sco
ntr
olu
nitp
artnumber.
C
ont
rolu
niti
den
tif
ica
tio
nNo. D
isp
lay
sco
ntr
olu
niti
den
tif
ica
tio
nnumber.

D
iag
nos
ticsystems Engine

WORKSUPPORT 。
SELF-DIAGRESULTS O
SELF-DIAGRESULTS[MEMORY]
DATAMONITOR O
DATAMONITOR[SPEC
] O
A
cti
vet
est O
DTCRECORDDISPLAY
C
ont
rolu
nitp
artNo. O
C
ont
rolu
niti
den
tif
ica
tio
nNo.

EG-14
PRECAUTIONS

Precautionsi
nDr
ain
ingEngineCoolant
• D
rai
nco
ola
nto
nlya
fte
rth
eenginehasc
ool
eddown.

Precautionsf
orDisconnectingF
uelP
ipi
ng
• Operationsho
uldbedonei naplacefr
eefromfir
e.
• Reliev
ef uelpressur
eb ef
oreope
rati
on.R e
fert o EC s
ecti
on，
"Releaseoffue
lp r
essur
e".
• Aft
erd is
c o
nnect
ing，plu
gthepi
petopreve
ntf u
elfromdra
ini
ng.

Precautionsfo
rRemovingand
Disassembling
• Use c or
rectS pecialS erviceToolint hes pe
cifiedp o
sitio
n.
Alwayspaya ttenti
ontos a
fety.
• Bec arefu
ln ott ol os
es urfaceaccuracyofm atingo rslidi
ng
surf
aces.
・ To preventf or
eignm ate
rial from e
nterin
gt he engine，close
openingsw i
tha ppr
opriatetapeasn ec
essary.
• Arrangedisassembledpa吋si nthe
irnormalposit
ionsinorderto
sim
plifylocat
ingt h
ecauseo fdamageo rexcess
ivewearandt o
ensurecorrectreassembly.
• Unlesso therw
ises pe
cified，loose
nb o
ltsandn utsfromo ut
side
toinsid
ei nac ri
sscrosspa抗ern.

Precautionsf
orI
nsp
ect
ion，
Cor
rec
tin，
o and
Replacement
• Thoroughly i n
spe
ct each p ar
t follo
wing the i
nsp
ect
ion
procedure，thencorr
ectorrep
laceasn ec
essary
.Ins
pec
tnew
partsinthesameway ，andr
eplacef
ine
cessary
.

Precautionsf
orAssemblyandI
nst
all
ati
on
• Alwaysuseat orquewrenchwhent i
ghteni
ngb o
ltsandn uts
.
• Unlesso th
erwises p
ecified，ti
ghtenbolt
sandn u
tsfromi nsid
eto
outsid
ei nac risscros
sp a
tter
n.T ighten them gradual
ly and
evenlyin2t o3s t
eps.
• Alwaysr eplac
eg asket，packing，oi
lseals，andO -rin
gsw it
hnew
ones.
・ Thoroughlywash，c l
e n，andb
a low-d
ryeachp ar.
tBesuret ha
t
engineoi
landc oola
ntpassagesa refreeofclogs.
• Removeanyd irtandl i
ntons li
dingandm atingsurface
s.B efor
e
assembly，applyampleamounto fengineoi
lt osli
dingsurfa
ces.
・ I
fc oo
lantwasd ra
ined， bl
e edai
rfromt hesystem.
• Aft
erassembly ，s t
artengineand i ncrea
set heenginespeed，
then check c o
olant，f u
el，o l，grease，and exhaust gas f
i or
leakage
.

EG-15
 PRECAUTIONS

Cautionf
orUseo
fPowerTools
00' nO
'tuse any pO'wert O
'O'l
s( e.
g.airratch et，impactwrench) t O'
tighte
nt h
ebO 'l
tsandn ut
s. Usetheset O'
O'l
sO 'nl
yfO'rIO
'O'seningth e
bO'l
tsandnuts.HO'wever，dO'n O
'tusepO
'wertO'O'lsinanyeventandf O'r
anypurpO'sesO 'n t
hep artss ubjectt
O'heat( ca
tal
y t，m
s u
ffler，and
O
'therexhau~t p
a r
ts)andt het ap
pingscrews.Thesep art smaya lsO'
bedamagedwhenI O''s
O enedw ithapOwert
' O
'O'
I.

Precautionsf
orL
iquidGasketApplication
REMOVINGPARTSATTACHEDWITHL laUIDGASKET
RemO've mO'un
tingnut
sandbO
'lt
s
. Usinga s
ealc
utt
er(SST)，
remO
'veliqu
i .
t
dgaske
CAUTION:
Becaref
ulnottodamagethematingsurfaces.

• I
npO's
it
iO'nswhereasealcutt
erisd
iff
icu
ltt
O'use，l
igh
tlytapw
ith
apl
astichammer ，andremO
've.
CAUTION:
・ Whenusinga screwdriver，becarefulnottoscratchthe
EGMOO66 matingsurfaces.

L
laUIDGASKETAPPL
lCATIONINSTRUCTION
1. UsingascrapeにremO 'veanyO 'ldli
qui
dgasketremainingO 'nth e
gasketa pplica
tiO'nsur fa
ceandi t
smatings urface.
• RemO ve any O
' 'ldl iq
uid gasket remaining int he gasket
ap
plicatiO
'n groOve and O
' 'n th
et hreadsO 'fbO'l
ts and bO'l
t
hO
'les
.
2
. Using I sO
'zO e，wipe t
'l he gasket appli
catiO
'n s urfa
ce and i ts
コ
ι
ι
mating s u rfacet ' r
O emOve any mO
' 'is
ture，O l
'i，and f 'r
O ei
g n
m ateria.
l
3
. Setgenuinel iq
u i
dgaskett 't
O ubepresser( c'm
O mercials erv
ic e
tO'
O'I
)
.
EGMOO67

4
. Apply a cO 'ntinuO
'u s bead O fl
' i
q u
id gasket t't
O h
es pe
cified
pO's
it
iO'na tt hesp e
c i
fi e
dd iameter.
• Applyl iquidgasketi nthea p
p l
i c
atiO
'ng r
O'
O've
.
• Applyl i
quidgasketi nsidebO 'l
thO'le
s.Alwaysr efert't
O he
d ir
ectiO
'n ss pecifiedint hete x
twhena pplyi
n gliqui
dgasket
O'utsidet hebO 'l
thO'les
.
• A ttachi n
g shO 'uld be dO'new i th
in 5 minutes a f
tergasket
a pp
licatiO'n
.
• Immediatelywipe0'行 anyp r
o trudingliq
uidgaske .
t
• 00'nO 'tre t
ig h
t e
nn u t
sandbO 'l
tsa f
terins
tall
atiO
'n.
EGMOO68
• A fterfinishingwO 'rk，wai
ta tl east30minutesb ef'r
O erefi
lli
ng
engineO 'l
iandcO'O'l an.
t
CAUTION:
・ Followanydirectionsspecifiedinthetextonthefollowing
pages.

EG-16
PRECAUTIONS

P
art
sRequiringAngleT
igh
ten
ing
When t igh
teni
ngt hefollo
wing pa巾， use an a ngle wrench
(SST).
Cylind
erheadb ol
t
Connectingrodcapnut
Speci
fiedt or
qued esc
ribedf ort he
sep artsi sn o
tt h efin
al
tig
hteningvaluebutthet ig
htenin
gt orque used befo
rea ngle
tig
hteni
ng.
• Beforetigh
teni
ng，makes ur
et ha
tt he
rea r
enof o
reignmateri
als
ont hr
eadandm atin
gs ur
face，anda ppl
ye ng
i neo.
il

EG-17
 PREPARATION

SpecialServiceTools
D
esc
rip
tio
n A
ppl
ica
tio
n Remarks

Sealcutt
er Removingpa吋sattachedw
ith
(N-KV101-11110
-0) li
qui
dgasket

EGM0069

Ringgearstopper Removingandins
tal
lin
g
(N-KVI10 ・1056S0
・) cra
nksha
ftpul
ley
1Adapter
(N-KV101・05630)
2 Stopperp l
ate
(N・KV101・05610)

O
ils e
aldri
ft I
nst
all
ingf
ron
toi
lse
al
(N-KV101・04900)

EGM0071

Anglewrench Checkingt
igh
ten
ingangle
(N・KV101・12100)

て守 EGM0072
Alreadye
sta
bli
she
d

1
.V alvespr
ingcompressor Removingandi
nst
all
ingv
alv
e
(N-KV101・09210) co
lle
t
2
.Adapter
(N-KV101・11200)

EGM0073

V
al v
eoilsealpulle
r Removingv
alv
eoi
lse
al
(N-KV101・07901)

EGMOO74

V
al v
eoilsealdri
ft I
nst
all
ingv
alv
eoi
lse
al
(N-KV101・13000)

EGM0075

EG-18
 PREPARATION

D
esc
rip
tio
n A
ppl
ica
tio
n Remarks

Enginestandassembly Overhaulingengine
(N-ST0501・SOOO)

Engineattachment
(N-KV101・06500)

Enginesub-attachment
(N-KV111・04800) Alreadye
sta
bli
she
d

Camshaftbushingtoolset Removingandi
nst
all
ingcamshaft
(N-KV111・045S0) bushing
1.Bar
(N・KV111・04510)
2.Guidep l
ate
(N-KV111・04520)
3.Adapter

4
(N-KV111・04530)
.Dr
ift ぞ
d
(N-ST1524-3000) ヂ
3

P
ul l
eypulle
r Removingc
ran
ksh
aftp
ull
ey. Alreadye
sta
bli
she
d
(N-KV111・03000)

O
ilfil
te
rwrench Removingo
ilf
il
te
r Alreadye
sta
bli
she
d
(N-KV101・15801)

EGIfuelpressureindi
cat
or Formeasuringf
uelpressure
(N-ST1959・0000) gauge

Heatedoxygensensorwrench Removingandi n
sta
lli
ngheated
(N-KV101・13700) oxygensensor

G D EGM0083

EG-19
 PREPARATION

D
esc
rip
tio
n A
ppl
ica
tio
n Remarks

M
ai n
t泡nanceto
ol Forsystemi
nsp
ect
ionand
1
.DIAGNOSISKIT d
ia g
nosis
(N-SKVEE-GY010)
2.S0FTWARE
(N-SKVEE-GY100)
CheckadapterV F
orcon
trolu
niti
npu
Vou
tpu
tsi
gna
l

。(N-EG1755・0000)
orSMJ150 p
・incon
nec
tor
)
i
nsp
ecti
on

Harnessadap
te r
(N-EG17550200)
・
(15
0・p
into121-
pinc
onv
ers
iona
dap
ter
)

EGM0085

Form o
ldingcoi
l Checkingenginespeed
Adapterharness
(N-EG101・17500
)

EGM0086

ServiceParts
Pistonoversize
0
.5m m(
0.0
20in)08[
0.5m m(
0.0
20in)oversize]
1
.0m m(
0.0
39in)08[
1.0m m(
0.0
39in)ove陪 ize]
Mainbearingundersize

:
Unitm m(
in)

S
ize Thickness

STD 2.000(
0.0
787
)
US0
.25(
0.0
098
) 2.125(
0.0
837
)
US0.50(
0.0
197
) 2.250(
0.0
886
)
US0
.75(
0.0
29喧
) 2.375(
0.0
935
)
US1
.00(
0.0
394
) 2.500(
0.0
984
)

EG-20
 SERVICEDATA

P
eri
odi
cal
lns
pec
tio
n
To maintain the i
nit
ial performance of the TCMFORKL
lFT，
makesuretoperformappropriatemaintenanceandservicework.

PERFORMINSPECTION
Makesuretope同ormtheperiodical inspectionsattheappropriate
times，according to the month basis orthe operating hour basis，
whichevercomesf i
rs.
t
Refert
othef
oll
owi
ngnotesf
orvaluesi
n()
.

E
ngi
nesystemi
nsp
ect
ion(
exc
eptLPGf
uels
yst
ems
)

A
pplicab
le Monthso
fuse 2 3 4 5 6 7 8 9 10 1
1 1
2
N
o. I
nsp
ect
ioni
tem
s cont
rol O
pera
tio
nhours
system 2 4 6 8 10 12 14 16 18 20 22 24
(
x100hou
rs)
I
ntak
e/exh
aus
tv al
vec
lea
ran
ceE
lec
tro
nic A A A A A
E
lec
tron
iccon
tro
ls c
ont
rol
s
2 E
ngi
ned
riv
ebe
ltt
ens
ion E
lec
tro
nic
c
ont
rol
s
3 E
ngi
neo
i
l E
lec
tro
nic (
1) R R R R R R R R R R R R
c
ont
rol
s
4 O
ilf
il
te
r E
lec
tro
nic (
1) R R R R R
c
ont
rol
s
5 E
ngi
nec
ool
ant E
lec
tro
nic R
c
ont
rol
s
6 A
irc
lea
nere
lem
ent E
lec
tro
nic C C C C C C C C C C C C
c
ont
rol
s
7 Sparkp
lug E
lec
tro
nic
c
ont
rol
s
8 PCVvalve E
lec
tro
nic (
1)
c
ont
rol
s
9 PCVhose E
lec
tro
nic
c
ont
rol
s

EG-21
 SERVICEDATA

P
eri
odi
cal
lns
pec
tio ・
n(Contd)
N
o. I En
gir y蜘
肘 ni明 e伽 1( 同
LPGmode

I
Gasl
eak
agefromp
ipi
ngandp
ipi
ngE
lec
tro
nic (2)
j
oin
ts c
ont
rol
s
2 I
Damaget
opi
pin
gandp
ipi
ngj
oin
ts E
lec
tro
nic
c
ont
rol
s
3 T
ari
nva
por
ize
r E
lec
tro
nic D D D D D D D D D D D D
c
ont
rol
s
4 I
gni
tio
nno
zzl
e E
lec
tro
nic
c
ont
rol
s
5 LPGf
il
te
r E
lec
tro
nic C C C R
c
ont
rol
s

CAUTION:
(1
)Ifthevehicl
eisbeingusedindustyandd i
rtyenvironments，th
emaintenanceworkshouldbeperformed
morefreq
uentl
y.
(2
)A ft
erreplac
ingtheLPGtank，applysoapsudstot hepipingj
ointst
ocheckf o
ranygasl ea
kag
e.
Meaningso =
fsymbols:I Ins
pectio
n.Repairorreplaceifnec
essary.
R=Replacement
A=Adjustment
C=Cleaning
D=D rai
ning
T=T i
ghtening(R
eti
ghten
ing)

EG-22
 SERVICEDATA

Standard，
RepairL
imit
F
ueli
nuse Gasolines
pec
ifi
cat
ion Unleadedg
aso
lie，
n octaner
ati
ng:9
1ormore
LPGs
pec
ifi
cat
ion 100P
Engineweight(
wit
hotw創 e
u r，w
itho
il
)kg(
Ib
) Approx.290(
639
)
F
iri
ngo
rde
r 1・5・3・6・2・4
Compressionpressure Standard 1，
187(
11.
87，1
2.1，172)/200
kPa(
ba，kgf/cm2，
r pSi
)/r
pm Repairl
imi
t 892(
8.2，
9 9
.1，129)/200
D
iff
ere
ncel
im
itamongc
yli
nde
rs 98(
0.8，1
9 .0，14)/200
D
ist
ort
ionl
im
itm m(
in
) I
nta
kem
ani
fol
d 0
.2(
0.0
08)
0
.3(
0.0
12)
Exhaustm
ani
fol
d
C
yli
nde
rhead 0
.2(
0.0
08)
C
yli
nde
rbl
ock 0
.1(
0.0
04)
Engineolamount1(Impq
i t) Whenr
epl
aci
ngo
ilo
nly A
ppr
ox.7
.3(
6・3
/8)
(SLclas
s)
Whenr
epl
aci
ngo
ilandf
il
te
r Approx.7
.6(
6・3
/4)
Sparkp
lug M
anu
fac
tur
er/
typ
e/g
ap m m(
in
) NGK
lBPR4ES/0.8・0
.9(
0.0
31・0
.03
5)
Resistanceonh
igh
-te
nsi
onc
abl
e (
kn) #
1:Approx.2
.7# 2
:Approx.2.8#3:Approx.4
#
4:Approx.5 #
5:Approx.5.
2# 6
:Approx.6.1
I
gni
tio
nadvanced
evi
ce E
lec
tro
nic
all
yco
ntr
oll
edi
gni
tio
nadvance
Onboardi
dlespeed (
rpm
) 650士 50(No
rPp
osi
tio
n)
Onboardi
dli
ngpacespeed(Whenfeedbackc
ont
roli
sstopped) (
rpm
) 650(No
rPp
osi
tio
n)
D
ens
ityo
fCOa
tid
lespeed/Densityo
fHCa
tid
lespeed (%/ppm) 0
.1o
rle
ss/
50o
rle
ss
I
gni
tio
nti
min
g(Whenfeedbackc
ont
roli
sstopped) (BTDC./rpm) 10:
:1
l /650
V
alv
eclearance m m(
in
) INT/EXH Hot 0.35(
0.0
138
)/0
.35(
0.0
138
)
Thermostatopeningv
alv
etemperature(
Sta
rt-F
ullopen) 。C(下) 82-95(180・203)
Engined
riv
ebe
ltd
efl
ect
ion Newb
elt A
fte
radjustment L
imi
t
[Measuredbypre
ssin
g A
lte
rna
torb
elt 10・12 13・15
16(
0.6
3)
wit
h98N( 10kg，2
2Ib
)] mm(in) (
0.39・0.
47) (
0.51・0.
59)

A
lte
mat
orb
el
t

EGMOO87

EG-23
 SERVICEDATA

TighteningTorque
STANDARDBOLTTIGHTENINGTORQUE
<Hexagonhead><Nol
ubr
ica
tio
n :
> Uni ・
tN m (kg-m，
ft
-Ib
)
N-m(kg-m，i
n-I
b)*

4T 7T 9T
Normals
ize P
itc
h
d P N
on-
flang
ed N
on-
flang
ed
Flangedb
olt N
on-
fla
nge
dbo
lt Flangedb
olt Flangedb
olt
bol
t bol
t

M3 0
.5 0
.6 0
.7 1.1 1.3 1.6 1.9
(
0.0
6，5
)* (
0.7，6
0 )* (
0.1，1
1 0)
台 (
0.1
3，11)
* (
0.6，1
1 4)
* (
0.1
9，16)
*
M3.5 0
.6 1.
0 1.2 1.7 2.1 2.5 2.8
(
0.0，9
1 )
* (
0.2，1
1 0)
* (
0.1
7，15)
* (
0.1，1
2 8) 合 (
0.2
5，22)
* (
0.9，2
2 5)
*
M4 0
.7 1.5 1.7 2.5 2.9 3.5 4.
2
(
0.5，1
1 3)
* (
0.1
7，15)
* (
0.2
5，22)
* (
0.3
0，26)
* (
0.3
6，31)
* (
0.43，37
)*
M5 0
.8 2.9 3.5 5.0 5.9 7.2 8.5
(
0.0，2
3 6)
* (
0.3
6，31)
* (
0.5
1，44)
* (
0.6，5
2)* (
0.7
3，63)
* (
0.8
7，76)
*
M6 1
.0 5.0 6.0 8.4 10 11
.8 14.
7
(
0.1，4
5 4)合 (
0.6
1，53)
* (
0.6，7
8 5)
* (
1.0，87
γ (
1.2，8.
7) (
1.5，1
0.8
)
M8 1
.25 12
.7 14.
7 20.6 24.5 29.4 35.3
(
1.3，9.
4 (
1.5，1
0.8
) (
2.1，1
5) (
2.5，1
8) (
3.0，2
2) (
3.6，2
6)
1
.0 13
.7 15.7 21.6 26.5 31.4 37.3
(， 1
1.
4 0
) (
1.6，1
2) (
2.2，1
6) (
2.7，2
0) (
3.2，2
3) (
3.8，2
7)
M10 1
.5 24.5 29.4 41.2 49 58.8 69.6
(
2.5，1
8) (
3.0，2
2) (
4.2，3
0) (
5，3
6) (
6.0，4
3) (
7.1，5
1)
1
.25 25.5 30.4 43.1 51 61.8 73.6
(
2.6，1
9) (
3.1，2
2) (
4.4，32) (
5.2，3
8) (
6.3，4
6) (
7.5，5
4)
M12 1
.75 42.2 51 70
.6 84.3 98
.1 118
(
4.3，3
1) (
5.2，3
8) (
7之 52
) (
8.6，6
2) (
10，72
) (
12，8
7)
1
.25 46.1 55.9 77.5 92.2 108 137
(
4.7，34) (
5.7，4
1) (
7.9，5
7) (
9.4，6
8) (
11，8
0) (
14，101)
M14 1
.5 73
.6 87.3 127 147 177 206
(
7瓦 54
) (
8.9，6
4) (
13，9
4) (
15，108) (
18，130) (
21，152)
M16 1
.5 108 137 186 226 265 324
(
11，8
0) (
14，101) (
19，137) (
23，166) (
27，195) (
33，239)
M18 1
.5 167 196 275 324 392 471
(
17，123) (
20，145) (
28，203) (
33，239) (
40，289) (
48，34)
M20 1
.5 226 275 382 451 549 657
(
23，166) (
28，203) (
39，282) (
46，333) (
56，405) (
67，485)
M22 1
.5 304 363 510 608 736 883
(
31，224) (
37，268) (
52，376) (
62，448) (
75，542) (
90，651)

CAUTION:
・ Exceptspecialparts.
• Theboltapplicabletothel
isthasthefollowingnumberembossedonthehead.
ModelNumber
4T '
" 40rnone
7T "
' 7
9T "
' 9

CAUTIONFORUSEO FPOWERTOOLS
00 not use any power tools ( e.g.a r ratchet，impact wrench) to
i
tighten the bolts and nuts. Use thesetools onlyforloosening the
boltsandnuts.However ，donotusepowertoolsi nanyeventandf or
any purposes on the parts subject to heat (catalyst，muffler
，and
otherexhaustparts)andthetappingscrews.Thesepartsmayalso
bedamagedwhenloosenedwitha powertoo .
l

EG-24
 SERVICEDATA

TighteningTorque(
Con
t'd
)
MAINTIGHTENINGTORQUE
* :Partswithtighte
nin
gsequence
1
)- :Tightenseparatelyi
nseveralt
urn
s.
Unt :Nem(kg-m，
i f
t-I
b)
・
N m (kg-m， in
-Ib)
*

P
art
snameo
rlo
cat
ion T
igh
ten
ingt
orq
ue

A
dju
sti
ngscrewLockn
ut 16・22(
1.6・2之 12・1
6)
A
ltern
ato
rAdj
ust
ingbars
ide 17
.5・2
3.7(
1.8・2
.4，13・1
7)
Bra
cketsi
de 5
0.0・6
7.6(
5.1・6
.9，37・5
0)
O
ilpand
rai
npl
ug 54・59(
5.5・6
.0，
40・4
3)
Sparkp
lug 1
9.6・2
9.4(
2.0・3
.0，14・2
2)
*I
nta
kem
ani
fol
d 1
5.7・1
8.6
(1.
6・1
.9，12・1
4)
会 A
irhorn 22・37(
2.2・3
.8，16・2
7)
Exhaustm
ani
fol
dcover 6
.37-7.45(
0.6
5・0
.76，
56・6
6)*
* Exhaustm
ani
fol
d 27・3
1(2
.8・3
.2，
20・2
3)
Exhaustm
ani
fol
dconnector 59・78(
6.0・8
.0，
43・5
8)
*O
ilpan[
M6] 6
.3・8.
3( 0.
64・0.
85，56・7
4)*
[M
8] 15
.7・20.
6( 1.
6・2
.1，12・15
)
O
ils
tra
ine
r 16・19(
1.6-1
.9，12・1
4)
* Rockerc
ove
r 0
.89-2
.9(
0.1・0
.3，
9・2
6)*
Rockers
haf
tbr
ack
et 1
5.6-2
1.6(
1.6・2
.2，12・1
6)
*C
yli
nde
rheadb
olt 1 3，
)29.4( 22)
2
)61.7(
6.3，
46)
3
)0(0，0
)
3，
)29.4(
4 22)
5
)69・
ー 74・(Ang
let
igh
ten
ing
)
C
yli
nde
rheada
ddi
tio
nalb
olt 6.4・ 7
.5(
0.6
5・0
.76，56・6
6)*
C
ran
ksh
aftp
ull
ey 1
81・1
91(
18.
5・1
9.5，134・1
41)
*F
ron
tco
ver 1
5.7・2
0.6(
1.6・2
.1，12・1
5)
Camshafts
pro
cke
t 132・142(
13.
5・1
4.5，
98・1
05)
Chaint
ens
ion
er 6.
4・7
.5(
0.6
5・0
.76，56・6
6)*
D
ist
rib
uto
r 9
.35・1
1(0
.95・1
.1，
82・9
5)*
Camshaftl
oca
tin
gpl
ate 6.4-7
.5(
0.6
5・0
.76，
56・6
6)
合 F
lyw
hee
l 147-167(
15・17，108-123)
* Mainb
ear
ingcap 162・172(
16.
5・1
7.5，119・1
27)
Connectingr
odn
ut 1
)38・40(3.
9・4.1，
28・3 0)
)40・-45・(
2 Ang
letigh
ten
ing)
Enginec
ool
antd
rai
npl
ug 34・44(
3.5・4
.5，
25・3
3)
Waterpump 1
5.7・1
8.6(
1.6・1
.9，12・1
4)
Enginec
ool
antt
emp
era
tur
esensor 20・29(
2.0・3
.0，14・2
2)
PCVvalve 20-29(
2.0・3
.0，14・2
2)
*F
ueltube 1
)9.
3-2 0
.6( 0
.9・21，
. 78-18
2)*
2
)20.6・26.
5( 2
.1・2.7，15・2
0)
S
tar
termotor 4
1.2・52(
4.2・5
.3，
30・3
8)
Heatedoxygensensor1 40・60(
4.1・6
.1，30・4
4)

EG-25
 ENGINETUNE-UP

SECT馴 ET
CONTENTS
VALVECLEARANCE. ..
..
.
..
..
・ ・..
.
.
・ ・ .
.
..
.
司 ・・ .
....
..E
T・2 H H H H ENGINEOIL・ . ・
H .
.
..
..
..
.
..
・ ・ .
.
H…
・・ ・・ .
.
・ ・ .
..
.
.
H.
..
.
..
・. ..
.E
HT-5 M

Inspe
ction….
..
・ ・ .
.
.
..
・ ・
H ..
.
.
・ ・・・ .
..
.
.
H.
・ ・ ..
..
...
.…
.ET ・2H H H H EngineOilInsp
ection….
..
・ ・ .
.
..
.・ ・
H..
….
..
..
・ ・ .
...
.ET・5 H H

Adjustment・.
.・
H..
・ ・-
且 ・・ ..
.
.
.・ ・
H ..…
….
...
.
H.
...
・ .・ET
H ・3 H H EngineOilReplacement…..
.・ ・..
.
.
.・ ・..
….
..
・ ・
H .
..ET・6 H H

ENGINEDRIVEBEL T・. ・ .
..
..
..
..
..一
..
.・ ・.
H.
.… ・・ .ET・4 M H H Oi
lF i
ltrReplacement…
e ……..
.・ ・ .
.
..
.
・ ・ .
.
..
.
・ ・ ..
.ET・7 H H H

Inspec
tion……..
.・ ・..
.
.
.・ ・
H.
..
.
.・ ・・・ ..
..
..
.
..
..
・ ・
H .
.
.ET-4 H H H H COMPRESSIONPRESSURE… …・・…・ ・・-一一・ . .ET・9 H H

BeltTensionAdjustment .
・ ・-
圃 ・・ ..
.
..
・ ・ .
.….
.ET ・4 H H H H SPARKPLUG. ..
..
.
..
.・ ・
H.
.
..
.
・ ・ .
.
.
.・・
H.
..
.
・ ・ .
.
..
.
.・ ・..
.
a..
.E・，10
T H H

RemovalandI nsta
lla
tion..
...
.
...
..
..
..
.
..
..
.・ ・..
....E
T -
10 H

Inspe
ctionAf
terRemoval . .
.
.
.
.・ ・ .
.…
..
.・ ・・・ ..ET-10H H H H
 VALVECLEARANCE

• Wheneverr oc
kerarmandr o
ckersha
ftassemblyareremoved
andinsta
lld，
e o
rsymptomsduet ochangesinvalv
ecleara
nce
asar e
sul
tofa gin
g(p
oorst
arti
ng，rou
ghidle，
unusu
alnoi
se)a陪
obvio
us，checkanda叫u stvalveclear
ancewiththefol
lowi
ng
pro
cedure:

I
nsp
ect
ion
1
. Stopt heenginea f
terwarmingu p.
2
. Remover ockercover.
3
. Rotate t hec rankshaftp ulle
yc lo
ckwis
e( as viewed from
c r
ankshaftpulleyside)anda lignorangenotchwiththetim
ing
i n
dicat
or( p
rotru
sion)ont hefron
tcover.
4
. Makes urethatthereisval
v eclear
anceinint
ake/e
xhaus
tsideof
N o. 1cylin
der.( N
o. 1c ylind
erisa tTDConi t
scompression
Cコ 鋭 的k e
.)
• I
fnot，rot
atethec ra
nkshaftpulle
yonemoret ur
n.

IN :
Intake
EX:Exhaust
ETMOO65

5
. Re
fertot h
ef ig
ure，andmeasurevalveclear
ancefort
het
abl
e
i
tembeloww i
thac ir
cleu
singafee
lergauge
.
Standa吋:
0
.35m m( 0.0
138in
)(Hot，in
take
Jexhaust)
CAUTION:
Make sure t hat the standard under hot c
ondit
ionis
appropriatei
fadjustmentismadeundercoldc ond
iti
on.

Cy
lin
der

V
alv
e

1c
ylin
deratTDCo f
i
tscompression
s
tro恥e

NOTE:
Fi
rin
gor
der
:1・5・3・6・2・4

6
. Turncranksh
aft360degreest
ose
tNo
.6c
yli
nde
ratTDCo
fit
s
compressionst
rok
e.

ET-2
VALVECLEARANCE

I
nsp
ect
ion(
Con
t'd
)
7
. Measure v
alvec
lea
ran
cea
tpo
int
s marked w
ith0 i
nth
e
fo
llow
ingt
able
.

C
yli
nde
r

Valve

6c
ylind
eratTDC0 1
i
tscompression
st
roke

NOTE
:
・I
fNo
.1c
yli
nde
risn
ota
tTDConi
t
scompressions
tro
kei
nst
ep
4，t
iisacc
eptabletomeasurethei
temwi
thN
o.6c yl
ind
erat
TDC on it
s compression s
tro
ke(st
ep7)wit
hou
tr ot
ati
ng
cr
ank
sha
ftpull
ey.
8
. A
dju
stw
itht
hef
oll
owi
ngf
iou
tsi
det
hes
tan
dar
dva
lue
.

Adjustment
• Adju
stt hesame measuring p o
intsi nt h
esamec on
ditionof
"In
spect
ion"withthefoll
owin
gp roc
ed u
re:
1
. Loosenvalveclearanc
ea dj
ustin
gscrewl o
cknu.t
2
. Turna dju
sting screw int hel ooseningd ire
ctio
nu singa
scr
ewdri
ver.
3
. Ins
ertas tand
ardfeele
rgaugei nbetweenr ockerarmandv a
lve
stem end s ur
face，and t hent i
ghtenu nt
iltic ontac
tsw i
th
adj
ustin
gs cre
w.
4
. Tigh
tenl oc
kn u
tw hi
les e
curingi
tu singas cre
wdriversoasn ot
torot
ateadjus
tingscrew.
ロ:16・21N-m(1.6・2.2kg-m， 12・15f t-
Ib)
5
. Cranke n
g i
nes ev
eraltimes，checkv alv
ec learan
cea gain，and
makes uretha
ttiiswit
hinthestandard.

ET-3
 ENGINEDRIVEBEL
T

I
nsp
ect
ion
・ Inspectionshouldbedoneonlywhenengineiscoldorover30
minu
tesaf
tert
heen
ginei
ss t
opped
.
Measuret
hebel
tde
fle
cti
onbya p
plyi
ngl
oado
f98N(
10k
g，22
A
dju
sti
ngb
arb
olt
I
b)to~ asshowni
nthefi
gur
e.
Waterpumpp
ull
ey CAUTION:
Fir
sts e
tthet ensiont othestandardwhenmeasuringb e
lt
tensionimmediatelya ft
ert hebel
tisi ns
tall
ed.Rotatethe
crankshaf
t more than two t urnsino rdertoe limin
ate
A
lte
rna
torb
ol
t(2
) varia
n ceint heb e
ltd eflecti
on between p叫 l
eys
. Then
measureanda d
justt ensio
nt othestan
dard.
• Visu剖 I
ycheckb el
tsf o
rwear ，damage，andcracksoni ns
ide
A
lte
mat
orb
elt C
ran
ksh
aftp
ull
ey andedges.
∞
ETM 67
• Retightenifbel
td eflect
ionistoolow( exc
essiv
et en
sion)
andtooh igh(outsideretight
eningli
mi
t).

:
Unitm m(in)
8
elld
efl
ect
ion
¥Localion I
開 henpressedbyaf
orc
eof98N(
1 g，
0k 2
2Ib
)]
¥
、 I
8el
lsp
eci
fic
ali
on
item¥
、￨ L
imit
H Iadment￨

A陶 r
nat
orb
eltI
Low-edgeb
(FMtype)
e
lt
。;
(;
11
7)
￨
(。;
日 9
) I
16(
0.6
3)

CAUTION:
・ Tighten slightly stronger than used belt when belt is
replacedwithnewone， becausenewb e
ltwil
lnotfull
yseat
inthepulleygroove.
• Adjustthet ens
iont othevalueafte
radjustmentwhenused
bel
tt en
s i
onexceedsr etighteni
ngl i
mit
.
• Makesuret hatb e
ltisc orre
ctlyengagedw it
ht hepul
ley
groovewheni ns
tall
ing
.
• Adjustthebeltbya pply
i n
gt ensin，
o b
utdon otrot
atepul
ley
ineachp ulle
ystopc ond
ition.
• 00nott ightenwithexcessivetension
.
• 00nota llowoilorwatert ogetont hebe
lt.
00nott wistorbendt hebeltstron
gly.

B
eltTensionAdjustment
Loosenalter
natorbol
tanda d
just
ingba rb
olt，anda叫u
stthem
wi
tha l
ter
natorins
tal
lin
ga ng
le.
Tig
htenadjusti
ngb a
rboltanda l
tern
ato
rb o
l.
t
Adj
ustingb arbol
t:
目: ・
18・23Nm(1.8・2 .4kg-m， 13・17ft-I
b)
A
lternat
orb olt
s( 2
):
悶:50・6 7N.m( 5.1・6.9kg-m，37・49侃 ・Ib)

ET-
4
 ENGINEOIL

EngineO
ilI
nsp
ect
ion
OILLEVELANDCONTAMINATION
CAUTION:
• For
kli
ftmustbel
eve
lwhencheckingo
ill
eve
l.
• Checkoill e
velbefor
es t
artingengin
e.Stopengineandl eavet
i
atleast 10minutesfiengine has been s t
arted
. Then check
lev
e.
l
Checkfit h
eoillev
eliswith
int herangeshownont hele
ft
.

w
• Checkengineo i
lforwhitecontaminati
o no
rc on
siderabledi
r.
t
瓜しr--nI-「三 • f
Ioil hasw hiteorp al
ec o n
t a
mination，t
imaybecaused by
mixingwithenginecoolan.
tRepairthesuspectparts.
マ
Adjus
toilleve
lfit
iisoutsidetherange.

Makes
uret
hatt
heo
ill
eve
lisbetween"
L"and"
H"

ETMOO68

OILLEAKAGE
Checkt hefoll
owingpa同sforengineo
illea
kage.
• O i
lpan
・ O i
lpand rainplug
• O i
lp ressu
res wit
ch
・ O i
lfil
terbracke
t
• O i
lfil
ter
• Lowers i
deo fcyl
ind
erblockback
• M atingsurfacesofcy
lind
erb l
ockandcyl
inderhead
• M atingsurfacesofcy
lind
erheadandr oc
kerc o
ver
• Fron
tc over
• Aroundc ra
nkshaftp
ulley

OILPRESSURE
1
. Checko
illev
e.
l
2
. Removeoi
lp re
ssureswitc
handconnectanoilpressur
egauge.
3
. Makesuretha
tt heprop
eroilpre
ssu
recorrespondingtoengine
speedi
sobtainedaf
terwarminguptheen
gine.
NOTE:
・ Oilpressureisdisplayedhighishwhenlowoiltemperature.
ENGINEOILPRESSURE
Enginespeed(rpm) AtI
dle 2，
000

kPa(
ba，kg/cm2，p
r si) I
Approx.49(
0.9，
4 )I
0ム 7 Approx.118(
1.8，
1 1.
2，17)
o
rmore o
rmore

4
. In
sta
lloi
lpress
ureswi
tchaft
ercheckingtheo
ilpressur
ewi
thth
e
fol
lowin
gproc
edure
.
1
) Removeo ldse
alan
tont h
es wi
tchande n
gine.
2
) ApplyThreeBond1201 orequivale
nttot h
et hrea
dsandth
en
tig
hte
n.
目 :13・17N.m( 1
.25・1.75kg-m， 9・12f t
-Ib
)
CAUTION:
• Bec are
fulnottogetburnedwhenengineorengineo
ili
s
heate
d.

ET-5
 ENGINEOIL

EngineO
ilReplacement
NOTE:
Perf
ormin
spe
ction"aft
erre
fi
lli
ngo
i
landa f
terre
plac
ingo
il"a
fte
r
re
placi
ngo
ilf
il
te
rfiengineoi
landoi
lfi
lt
erhavebeenrep
lace
d.

PERIODICREPLACEMENTINTERVAL
Replacew
itht
hefollo
win
gper
iod
:
OlgradeSJ，
i SL:1monthoreve
ry200hour
s
(5
0hoursfo
rfi
rstt
imeo
nly
)

REPLACEMENTPROCEDURE
CAUTION:
e Bec ar
efu
lnott
ogetburnedwhenengineo
rengineo
ili
s
heat
ed.
1. Warmupengine， andcheckthatt
hereisnooi
lleakag
e.
2
. Stoptheengi
ne.Leavetifo
r10m i
nutes.
3
. Removeo i
lfi
ll
ercap，andremovedrai
np lugo
foi
lpan.
4
. Drai
ne ng
ineoi.
l
5
砂 In
sta
lldra
inplug.Re
fi
llwithnewengineoi.
l
Dra
inplugt ig
hteningtor
que:
ロ
:54・59Nem(5.5・6.0kg-m， 40・43ft
-Ib
)

ETMOO70

OILLEVEL
U
nit fl
: (mpq
t)
H
-Ie
vel Approx.7
. 6・3
7( /4)
L
-Ie
vel Appr
l .
叫 6.7(
5・7
/8)
Onlyr
ef
il
llev
elwhenchangingoi
l
Approx.7
.3(
6-3
/8)
(Whendrai
nedfromd
rainplug
)
Re百II
lev
elwhenchangingbot
ho i
lli
ft
erando
il
A
ppr
ox.7
. 6・3
6( /4)
(Whendrain
edfromdrainp
lug)

INSPECTIONAFTERREPLACINGOIL
1
. Checkoi
lfil
te
rf o
rengineoilleakagewhenr e
pla
cin
goi
ldrai
n
plu
gandoilfi
lt
eraft
erwarmingupe ng
ine.
2
. Check o
ill e
velw iththe engine oi
li ns
pec
tionpro
ced
ure
desc
rib
eda b
ove.

ET-6
ENGINEOIL

O
ilF
ilt
erReplacement
COMPONENTPARTSLOCATION

O
il刊t
er
ETM0071

PERIODICREPLACEMENTINTERVAL
Replacewi
tht
hefoll
owi
ngperi
od:
Oi
lg raeSJ，
d SL
:3monthso reve
ry600hour
s
(
200hour
sf o
rfi
rstt
imeo
nly
)

REMOVAL
Removeo
i
lfi
lt
eru
sin
gano
i
lfi
lt
erwrench(
SST
).
CAUTION:
• Bec aref
ulnottogetburnedwhenengineorengineo i
lis
heated.
・ Use a shop clot
ht o absorb engine oi
l leakage when
removing.
・ Bec are
fulnottos
pil
lengineoi
lont h
eengined riv
ebelt
.
• Completelywipe0何 anyengineo i
ls pi
lledont heengine
andv eh
icle
.

ET-7
 ENGINEOIL

O
ilF
ilt
erReplacement(
Con
t'd
)
INSTALLATION
1. Completely remove any for
eig
nm a
ter
ials on th
ea t
tac
hin
g
surfacesofoi
lfil
te
r.
2
. Applyengineo iltothefu
llcir
cumfe
r e
nceofanoi
ls e
alonanew
o
ilfi
lte
r.
3
. Screwi nt h
eo i
lfil
terbyhandunt
ilitcont
actsoi
lfilt
erbra
cke
t
suげ:ae，
c andthenadda not
he 3o
r2/ fatur
n.
NOTE:
・ Tighteningtorqueis15 20N-m(1.5 2.1kg-m，11
・ ・ ・15f
t-
Ib
).

4
. Checkf
orengineo
ill
eak
agea
fte
rwarmingupt
hee
ngi
ne.
ETMOO73

ET
・8
COMPRESSIONPRESSURE

1. Warmupt h
eengines u
ffi
cie
ntl
y.
2
. Releaset hef u
elp r
essur
e.( Ref
ertoECs e
cti
on，"Relea
seo
f
fu
elpressureへ
)
3
. Turni g
nit
ionswithOFF
c .
4
. D isc
onnecta i
r hose from th
rot
tle body and move t
iouto
f
po
sit
ion.
5
. Removea l
lsparkplugs
.
CAUTION:
・ Blowsparkplugcleanwithcompressedairwhenremoving
i
t.
6
. In
stal
lar evc o
unterorelect
ronicsystemdiagno
sistester(SS
T).
(RefertoEC ・11，"Insp
ectionofi d
lespeed，ign
iti
ont im
ing，and
ai
r-fu
elr a
tio
"inECs e
ctio
n.)
7
. Removei nj
ecto
rharnessc onn
ector.
8
. Attach an adapte
rt oA lle
n compression gauge (commerc
ial
serviceto
ol)ands ett
itothee ngi
ne.
9
. Depressa ccele
ratorpedalful
lyT司urnig
nit
ionswit
cht o"START"
andcrankt heengine
. Recordt hecompressionp ressur
eand
theenginespeeda ft
erthegaugei nd
icat
ionsta
bili
zes.Repeat
themeasurementoneachc yl
inder
.
CompressionpressurekPa( bar，kglcm2，psi)
/rpm
Standard:
1，
187(
11.
87，
12ム 172)厄
，00
Repairl
imi
t:
892(
8.2，
9 9ム 1
29)
/20
0
Differencel i
mitamongc ylinders:
98( 0.98，1.0， 14)/200
• Checkb atteryfort hespeci
f i
cg rav
ityf
ie nginespeedi snot
wit
hint hes t andard，and measure a gain under normal
cond
itions.
• Check v alvec leara nc
e and components around t he
combustion chamber ( v
alve，v alves e
at，p istons，p i
ston
ring
s，c y
linderb ore，cylind
e rhead，c yl
inderheadg ask
et)fi
compression p ressu rei sn otw ith
int hes tan dard，and
measureagam.
• Addas mallamounto fengineo i
lf romsparkp l
u gholeif
compression p r
es sureo f some c ylin
dersi sl ow，and
measureagam.
• I
ti sp ossiblet hatp is
tonr ingi s worn o r damaged f i
compression p ressur eis improvedbya ddinge n gin
eo i.
l
Checkp istonring，andr ep
l ac
etifinecessar
y.
• Theremaybeav alvem alfunctioni
fcompressionp ressure
isnotimprovedbya d dingen g
in eoi.
lCheckv alve，andt hen
replacevalveo rcylinderheadf inecessar
y.
• I
fcompressionp re s
s u陪 sofa djace
nttwoc ylinde陪 arel o
w，
andifp ressurescannotbeimprovedbya ddinge ngineol，
i
gasketisleaking.Replacec ylinde
rheadgaske .
t
1
0.I n
sta
llremovedp arts.

ET9 圃
 SPARKPLUG

RemovalandI
nst
all
ati
on
Useasparkp l
ugwrench(commercialse
rvi
cetoo
l).
Blowcompresseda
iraroundsparkp l
u .
t
gwhenremovingi
・
目:20・29Nm(2.0・3 .0kgf-m，15・21ft-
Ib)

I
nsp
ect
ionA
fte
rRemoval
Visu剖Iychecke lectr
odefordi
rtanddamageandi
nsul
ato
rfo
r
bur
n i
ng.
• Checki ftheelectr
odegapi swit
hinth
estan
dar
dusin
gap lu
g
gapgauge.
Standard:
08・0
. .9m m( 0.0
31・0.035in)
• Adjusti
fo u
tsidethestand
ard.
• Replacefinecess
ary.

ETMOO75

ET-10
 ENGINEMECHANICAL

SECTION EM
CONTENTS
IINTAKEMANIFOLD・ .
.・ ..
，…
..
.・ ・..
…・
・ ・・ ...
.
H..
. ..
.EM
-2 H H H CYLINDERHEAD. ..
.
.
.・ ・.
.・ ・.
..
.
.
・ ・ ..…
… ・・ -….EM・ H11 H H H H

ComponentP art
sL oca
ti n…
o .
..
・ ・..
.
.
.・ ・.
..
.
.
・ ・ .EM・2 H H H ComponentP a
rtsL oca
tion...
.
.
.・ ・.
..
.
.
・ ・ ...
.....EM
-11 H H

RemovalandI nst
all
atio
no fIntakeManifol
d..
.EM-3 RemovalandI ns
tall
atio
no fCylind
erHead
RemovalandI nst
all
atio
no fAirHorn8 0t・
l . ...EM・3 Assembly… ・・
H -…
...
・ ・
H . ・・ .
.
.
.・ ・.
..
.
..
・ ・..
… EM・ 11 H H H H H

I ns
pecti
on… ・・..
・ ・
H ..
….
...
.・ ・-…… ・・
H H .
..
.
..
・. . .
EM・3 H H H C yli
nderHeadAssembly… ・・ -…
...
・ ・ .
.
… ...EM-14 H H H

EXHAUSTMANIFOLD・ .
.・ .
.
・ ・..
・ ・ ...
..一一一一 ..EM-4
H H H TIMINGCHAIN . .
..
.
・ ・ .
.
..
..
.
..
.・ ・..
..
..
..
.
..
..
.
H.
..
.
・ ・ .. ..EM-
19 H H

ComponentP art
sL oca
ti n・
o . ・ .
.
.
..
・ ・ .
.
..
.
..
.・ ・ .EM・4 H H H ComponentP a
rtsL oca
tion・. ・・・ .
.…
..
.
・ ・ ..EM・19 H H H H

RemovalandI nst
all
atin…
o .
..
・ ・ .
.
.
.
・ ・ .
.
・ ・・・ .EM-4 H H H H H Removal… … ・・H.
.
・ ・ .
.…
・ ・・ ..
… ・・
H .
..
.
..
・ ・ ..
H .
EM・19 H H H H H

OILPANANDOILSTRAINER. 一一一
...・ ・ -…
…. . .
EM・5 H In
stall
atin…… ・・
o ..
・ ・・ .
.
..
.
・ ・H.
.…
..
.・ ・
H .....
. ..
.EM-2
2 H H H H

ComponentP art
sL oca
ti n.
o .
.
.
..
・ ・..
… ・・ .
.
・ ・ .EM・5 H H H H REMOVALANDINSTALLATIONOF
RemovalandI nst
all
ation..
..
..
.
..
・ ・ .
.
..
..
.
..
..
..
・ ・ ..EM・5 H H ENGINE. .
…
.
目.
.
日
山
'
ROCKERCOVER. .
.一
..
..
..
.・ ・ .
.
..
.
..
・ ・-一一一一 ・・ .EM・7 H H H a Removal. .
….
口
.
.…
.
日.
.
…
..
.
.…
.
日
..
口
….
口
.
.日
…
..
.
日
….
一
..
.
….
日
.
.日
…
.日
.
.
.…
.
..
…
.
..
…
.口
冒
.
….
日
..
.
…
.日
.
..
…
.
日.
.
….
日
.
.…
.
..
.
…
.日..EM-26
ComponentP art
sL oca
ti n・
o . ・ .
.
.
..
・ ・ .
.…
..
.
・圃 -
・EM・ 7 H H a In
stall
atin.
o .
…
.日
.
.…
.
日.
冒
….
日
..
…
.日
.
.日
…
.口
..
日
….
日
..
…
.日
.
.…
.
..
…
..
.
日…
.
日.
…
….
.
.・ ・ .
.…… .EM・ 28 H

RemovalandI nst
all
ation・
..・..
・ ・・ .
.
..
・ ・ -… ..EM-7 H H H H Insp
ection・. ・..
.
.
.
H・ ・.
..
.
・ ・..
..
.
.
・ ・・・ ..
….
.
.・ ・
H .EM・28 H H H H H

ROCKERARMANDROCKERSHAFT CYLINDERBLOCK" ….
..
・ ・ .
..
..
..
.
..
.・・.
.
..
・ ・・ .
.… .EM・ 29 H H H H

ASSEMBLY...・・・・
H -一
一 ・・
H .
..
.
..
.
・ ・H.
..
.
..
.
・ ・ .
.
.
.・ ・ .EM
H ・8 H M H H ComponentP a
rtsL oca
tion...
.
..
.
.・ ・.
..
.
..
・ ・..
… EM・ 29 H H

ComponentP art
sL oca
ti n.
o ・ ・・・ .
..
.
.
・・ -… ..EM-8 H H H a Disassembly・.
.・..
・ ・..
.
..
.
・ ・ ..…
…
a….
..・ ・ .
.
H..
.....M・
E 29 H H

RemovalandInst
all
ation..
..
.
.
・ ・ .
.
.
..
・ ・..
.
.
・ ・ .....EM
-8 H H H Sel
ective
-FitServiceParts・. ・ .
.
…・ ・・ .
.
.
.・ ...EM・33 H H H

DisassemblyandAssembly .・ ・・・ ..
….
..
・ ・ ..EM・9 H H H H Insp
ectionAfterDisassembly・. ・ .
.
..
.
..
.
・ ・ .. ..M・
E 33 H H

1nspect
ion・. ・.
.
.
..
・ ・.
..
.
.・ ・
H .
.
.
..
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.
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.
..
.
.
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EM・9 H H H H A ss
embly....
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.
.
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.
.
.・ ・
H ..
….
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..
・ ・ .
.
..
.
.
・ ・ ..EM・
H46 H H H
INTAKEMANIFOLD

ComponentP
art
sLo
cat
ion

A
irhorn

EMM0521

EM-2
 INTAKEMANIFOLD

RemovalandI
nst
all
ati
ono
fIn
tak
eMa
nif
old
PREPARATION
- Dr
ainenginecoo
lant
- O
illev
elgauge
- W
iring，d
iscon
necti
ngli
nes，
moving

RemovalandI
nst
all
ati
ono
fAi
rHorn8
0lt
REMOVAL
Loosenb
olt
sint
her
eve
rseo
fth
eor
dershowni
nth
efi
gur
e.

INSTALLATION
T
ightenb o
ltsev
enlyi
ntwos tep
sintheo r
dershown i
nth
e

。 EMM0394
f
igu
re.
同 1 st
:9・10N-m(
2nd:18・2
O
.
1N-m(
9・1
1.
1kgm，
.
8・2.
圃 6.
5・7
2kg-m，
.9f
t
13・16f
-
t
I
b
I
・
)
b)

I
nsp
ect
ion

CHECKINTAKEMANIFOLDDISTORTION.
Check dis
tort
iono
f mounting s
urf
acei
n6d
ire
cti
onsu
sin
g
str
aight
edgeandfe
elergauge.
Li
mit
:0 .2m m(O.
008in)

MASSAIRFLOWSENSOR
R
efe
rto"Massa
irf
lowsensorsystem"i
nECs
ect
ion
.

LPGINJECTORHOLDER(LPGANDCOMBINEDUSE)
R
efe
rto"LPGin
jec
torsystem"and"LPGa
ssi
sta
ncei
nje
cto
rsystem"
i
nECsec
tio
n.

ELECTRICTHRO
甘 LECONTROL
Referto" Thr
o抗lepo
sitio
n sensor system" and "
Thr
ott
lec
ont
rol
motorsystem“inECsec
tion.

EM-3
 EXHAUSTMANIFOLD

ComponentP
art
sLocation

悶 N'm (
kg-
m. fト I
b) 0
:N
ot削 帥 l
e E
xha
ustm
ani
foI
dco
ver
園 N'm (
kg-
m. in-Ib) 悶 59-78 (6.0-8
.O.4
3-5
8) EMM0530

RemovalandI
nst
all
ati
on
PREPARATION
• Disassembleexhaustfro
nttube
Exhaustmanif
oldc ove
r

REMOVALANDINSTALLATIONOFEXHAUST
MANIFOLD
1
. Removal
・ Loosennutsinthereverseoftheordershowninthefigure.
9 2. In
stal
lati
on
• In
sta
ll yoke w
ithf l
atsidefaci
ng exhaust m
ani
fold.(Re
fert
o
"ComponentP ar
tsL o
catio
n".
)
• Tigh
tenn ut
sint h
en ume
ricalorde
rshowni nthefi
gur
e.

CコCrankshaftpulleyside
EMM0397 INSPECTION
1. Exhaustmanif
oldd
istor
tion
• Check dist
ort
ionof mounting s
urf
acei
n4 d
ire
cti
onsu
sin
g
str
aighted
geandfee
lerg auge
.
Li
mit:0.3m m(0.012in)

EM-4
 OILPANANDOILSTRAINER

ComponentP
art
sLocation

D
rai
npl
ug O
αH
旬 容
凶
Ip
O
ilpanb
olt(M8)(
20) 悶 54・59(5.5・6.0)
~: 悶 15.7 20.6(1.6-2.1)
o:
Liquidgasket
5
宍7
戸
・

Notr
eus
abl
e

悶:N.m(kg-m，ft-Ib) B
olt
hol
e

EMM0522

RemovalandI
nst
all
ati
on
PREPARATION
D
rai
nengineo
i.
l

。 C悶 附 叩 ￨leys1de
Viewfromo
i
lpanl
owe
r
l•
REMOVALOFOILPAN
Loosenbol
tsinther
evers
eoft
heo
rde
rshowni
nth
efi
gur
e.

⑬⑪①①①①①⑬ • Useas e
alc u
tte
r(SST)
.

if::1
⑬
⑫①①①①⑬⑪ ⑬
EMM0400

EM-5
 OILPANANDOILSTRAINER

RemovalandI
nst
all
ati
on(
Con
t'd
)
INSTALLATIONOFOILPAN
ApplyacontinuousbeadofThreeBond1207C(N-KP510
・
$一一一~与『LE--G
F 、 00150)t
ot h
ep osi
tion
sshowninthefi
gur
e.
Tight
enbo
ltsinthenumeri
calorde
rshowninth
efig
ure
.

INSTALLATIONOFOILPANDRAINPLUGWASHER
。
}ーー
ー- 0
、ーー
ーー- 0
I
nst
alli
twithbendings
idef
aci
ngo
i
lpa
n.(
Ref
ert
o"Component
P
artsLoca
tionへ)
3
.5-4
.5m
n
(
0.1
38-0
.17
7in
) dia
EMM0531

EM・6
 ROCKERCOVER

ComponentP
art
sLocation

T
oPC
Vva
lve

② ￨に二

R
ock
erc
ove
r

。
圃
N
恥

N
'
附
叫
0tr

匂
m(
k
e
釦

g
E
u叩
刊-
m.川
1n
叫
1-
-ω
肋
川
1b)
。
自
制 e
t

EMM0532

RemovalandI
nst
all
ati
on
PREPARATION
• Movehigh
-ten
sio
ncore
• Wi
ring，
disco
nnec
tin
glins，moving
e

REMOVALANDINSTALLATIONOFROCKERCOVER
1
. Removal
Loosenscrewsinth
erevers
eoftheord
ershowni
nthefigu
re.
2
. In
stal
lat
ion

位
二三ゴ
コ
Make s ur
et ha
tg ask
eti sn otmiss
ingfromr o
ckerc ov
er
mountin
gg ro
ove.
Tigh
tenscrewsinth
en um
erica
lorde
rshowninth
efigu
re.
1
CAUTION:
・ Tighteningtorqueofthefirstscrewmaydecreaseafter
t
igh
ten
inga
lls
cre
ws.R
eti
ght
ena
llscrews.
〈
コ C問 削
EMM0403

EM-7
 ROCKERARMANDROCKERSHAFTASSEMBL
V

ComponentP
art
sLocation

巴 E
時 i
neo
iI

問:N'm (kg-
m
， f
t-I
b)
乙
三うr
ans川
k ey
EMM0533

CAUTION:
Apply newengineoi
ltothep
art
s marked i
nth
efi
gur
e
befor
ei n
sta
lla
tio
n.

RemovalandI
nst
all
ati
on
PREPARATION
• Rockercov
er
• Adj
ustin
gvalv
ecl
ear
anc
e(a
fte
rin
sta
lla
tio
n)

REMOVALAND INSTALLATION OFROCKERARM

ANDROCKERSHAFTASSEMBL Y
A
dju
sti
ngscrew
1. Removal
• Loosenlockn
ut，andthe
nful
lyloosenvalv
ec le
ara
nceadj
usti
ng
scr
ew.
・ Loosenbol
tseve
n l
yinsev
era
ls et
psf romout
sidet
ocen
ter.
Carryeachbr
acketwi
thmounti
ngb o
lts
.
CAUTION:
・ HoldNo.8bracket(end)onlysoasnottodropi
twhen
c
arr
yin
g.

EMM0405

EM-8
 ROCKERARMANDROCKERSHAFTASSEMBL
V

RemovalandI
nst
all
ati
on(
Con
t1d
)
2
. I
nsta
lla
tio
n
T
ightenbol
tse
ven
lyi
nse
ver
als
tep
sfr
omc
ent
ert
oou
ters
idei
n
t
hisord
er.
CAUTION:
• Makesuret h
atv al
veclearanceadj
u s
tingscrewiss e
curely
inserte
dt opushrodhead.
• Performi ns
talla
tionwithvalveclearancea d
just
ingscrew
ful
lyloosenedsoas nott obea 符:ec
tedbyv alvesprin
g
ωCran附 a
代pu
lle
ysi
de tensi
on.
• Adjustvalveclearanc
ea f
terinst
all
ation
.
EMM04ω
Referto" Insp
ectionandadjustmento fvalvecl
earance
"in
ETsection.

INSTALLATIONOFPUSHROD
R
ota
tepushrodaf
terins
ert
ing，andth
enmakes uretha
tpush
r
odt
ipi
ssecu
relyi
nser
tedint
ov a
lvel
if
te
rspheres
urfa
ce.

DisassemblyandAssembly
DISASSEMBL
Y ANDASSEMBL
Y OFROCKERARM
ANDROCKERSHAFTASSEMBLY
Removeeachp
arti
ndi
vid
ual
lyandav
oidm
ixi
ng.
In
st
al
lthemtoth
eor
igi
nalpo
sit
ion
.

INSTALLATIONOFSPRINGWASHER
I
nst
al
lwitheachconvexs
urfac
efa
cin
gfl
atwashers
ide
.(R
efe
r
t
o"ComponentPa
rtsLoc副 i
onへ
)

INSTALLATIONOFROCKERARM
Assembleroc
kersha
ftwit
hb ol
th o
les i
defaci
nge ngi
nefro
nt
sid
eando i
lholef
aci
ngdownward.(Re
ferto"ComponentP
arts
Loca
tionへ
)

I
nsp
ect
ion
CHECKINGFORROCKERSHAFTBEND
• H
oldb o
thendso fr ock
ers h
aftw
ithV-bloc
ks，andthensetdia
l
i
ndi
cato
ront hecente
r.
• R
otatet h
er ockershaftin one d
irec
tio
n by hand and r
ead
i
ndi
cati
onont hedia
li n
dic
ato
r.
H
alfofthereadin
gist herock
ersh
aftbend.
Standard
:
0.
15m m( 0
.0059in)orless
Lim
it:
0
.3m m( 0.012in)

EM-9
ROCKERARMANDROCKERSHAFTASSEMBL
Y

I
nsp
ect
ion(
Con
t'd
)
ROCKERARMOILCLEARANCE
1. Rockers ha
fto u
terdiameter
Measureo ut
erdiameteraroundrock
erarmmountingu
sin
ga
micromete
r.
Standard:
19.988・20.000m m( 0.
786
9・0 .
787
4in)dia.

2
. Rockerarmi
nne
rdiameter
• Measurer oc
kerarmsha
ftho
lei n
nerd
iamet
erusi
ngani
nsi
de
mic
r ometer
.
Standard:
20.020・20.
038m m(0.
7882・0.7
889in
)dia
.

EMM0410

3
. Howt
oca
lcu
lat
ero
cke
rarmo
ilc
lea
ran
ce
• (Clearance
)
=( Rockerarmi nn
erdiame
ter)ー( R
ockershaftoute
rdiame
t e
r)
Standard:
0.020・0.050m m( 0.0
008・0 .0
0 2
0i n
)
Limit
:
0.15m m( 0.
0059in)
• Replacer ock
erarma nd
/orrockersha
fti
fo u
tsidethere
pairli
mi.
t
Refertostandardsfo
rtheo u
terdiameterandi n
nerdi
ameter.

CHECKINGPUSHRODBEND
Holdb othendso fpush rodw i
thV-b
locs，andthens
k etdi
al
indic
atoront hecen
ter.
Rotatepushr odinoned ire
cti
onbyhandandrea
dindi
cat
ionon
thedialind
icat
or.
Halfofther e
adingisthepushr odb
end.
Limit
:
0.2m m( 0.00
8i n
)

EMM0411

EM-10
 CYL
lNDERHEAD

ComponentP
art
sLocation

固 Cylinder headbolt (26)一一-JI

~R伽

巴 E
ngi
neo
iI
~ :N
otr
eus仙

画 N'm (
kg，
m
- in-Ib)
EMM0534

CAUTION:
• Apply newengine o
ilt
othe pa同s marked i
n the f
igu
re
beforein
sta
lla
tio
n.

RemovalandI
nst
all
ati
ono
fCylinderHead
Assembly
PREPARATION
• Drainenginecoolant
• Exhaustm a
nifol
d
• Inta
kem ani
fold
• Hight e
nsioncore
• Rockerc ov
er
• Rockerarmandr ocke
rs haf
tassembly
• Pushr od
・ Wiring，dis
conne
ctingl i
nes，moving
• Alt
ernatoradj
ustin
gb ar

EM-11
 CYL
lNDERHEAD

Removal and I
nsta
lla
tio
nofC
yli
nde
r Head
・
Assembly(Contd)
REMOVAL AND INSTALLATION OF CYL
lNDER
HEADAUXIL
lARYBOLT
1
. Removal
Removeb efo
rel o
osen
ingcyl
ind
erheadbo
l.
t
2
. In
stal
lat
ion
In
sta
llaft
ertigh
teni
ngcyl
ind
erheadbo.
t
l

REMOVAL AND INSTALLATION OF CYL

lNDER
HEADBOLT
1
. Removal
*
w
，

Crankshaftp
ull
eys
ide
uvee
o

ea
o偽
NHhm
ehm

Loosenb o
ltsinthere
verseoftheord
ershowninth
efigu
re.
md
ptt

nHaunH

ー
円
uaanua

合
r

2
. In
stal
lati
on
唱

e Lubr
icatethreadsands ea
ts u
rfaceofeachcy
lin
derheadb o
lt
wi
thnewe ngi
n eo
i.
l
23
e Tight
enb o
ltsinthenume
ricalorde
rshowninthefi
gur
ew i
ththe
fo
llowin
gs t
eps.
CAUTION:
・ Instep3)，loosenallboltsinthereverseoftheordershown
i
nthefigure.
1
) T
ighte
nt o29. ・
4N m (
3.0kg-m，22f
t-
Ib
)
2
) T
ighte
nt o61. ・
8N m (
6.3kg-m，46f
t-
Ib
).
3
) F
ull
yl oo
s e
nt ・
o0N m ( 0kg-m，
0in-
Ib
).
4
) T
ighte
nt o29.4Nem(3.0kg-m，22f
t-
Ib
).
5
) T
ighte
nt o69'to74・

EMM0414

Checktigh
teninganglewithana nglewrench(SST)o rap r
otra
cto
r.
00notsimplyestimatetigh
teni
ngangle.
e T ight
e ・
n64・ 74N m ( 6.5・7.5k g
f-m，47・ 54ft-
Ib
)ins te
p5 )f
i
checkin
gt igh
teninganglei
sdiff
icu
l.
t
e Applya n
ticorro
siveo rengineoilafterins
tal
lat
iono n
toe i
tir
e
heads urf
aceso fcyl
inderheadbolts(3，5，11，13，19，21inthe
fig
ure
)t h
atexposer ockercove
re x
ter
ior.

EM-12
 CVL
lNDERHEAD

Removal and I
nsta
lla
tio
nofC
yli
nde
r Head
Assembly(Co
nt'd)
INSTALLATIONOFCYL
lNDERHEADBOL
TWASHER
Washeri ns
tal
lin
gd ir
ecti
onisno
tsp
eci
fiedf
icyl
inde
rheadbol
t
ang
le-tight
ensinstep5).
In
sta
llitinthedire
ctionshowni
nth
efigu
rei
fitdoesno
tang
le-
ti
ghteninstep5)

4
レ
Cylinderheadside

EMM0416

INSTALLATIONOFCYL
lNDERHEADGASKET
F
ron
tcover
• A
fte
rappl
yin
gThreeBond1207C(N-KP51000150)t
胴 oth
e
L
iqu
idg
ask
eta
ppl回 t
ionp
oin
t
p
osi
tio
nshowninthef
igu
re，i
nst
allc
yli
nde .
t
rheadgaske

EM-13
 CYLINDERHEAD

CylinderHeadAssembly
COMPONENTPARTSLOCATION

弊れ
丹
14 山
h刊
山
口…
…
一
I
v
v
川……
es
回e
刷山……￨川a
回瑚

。
図 L
iqu
idg叫 e
t
由 ¥ ¥

固 E
ngi
neo
iI
Not r
eus仙
I
'
l
"'("n~
'
'
悶 N.m (
k刊 f
ト I
b) EMM0535

CAUTION:
• Apply newengineoi
ltothep
art
s marked i
nthef
igu
re
beforein
sta
lla
tio
n.

DISASSEMBL
Y
1. Compresst h
ev alves pr
ingw i
tha v alvespri
ng compressor
N-KV101・
09210
(55T)，andremovet h
evalvecol
letwit
hamagneticdrive
r.
2. Removev a
lvespringret
ain
er.
3. Removev a
lvesprin
g.
4. Pushth evalvestemt owardthecombustionchambersideand
removev a
lve.
• Checkv alv
eg ui
dec lear
ancebeforeremova.
l
• Checkt heloc
ation，andstorei
ndiv
idu
all
y.

EMM0419

EM-14
 CYL
lNDERHEAD

CylinderHeadAssembly{
Con
t'd
}
5
. Removev alv
eoilsealusingaval
veoi
ls ea
lp u
lle
r( S
ST)when
remov
lng.
6
. Removev al
ves p
ringsea
ts.
7
. Referto(EM s ec
tion
)“
，Valveseatcontactinspe
cti
on"when
removin
gvalvesea.
t
8
. Blowcompresseda i
raroundsparkpl
uganduseas pa
rkp l
ug
wrench(commer
cialservic
etoo
l)whenrem o
vingsparkplu
g.

INSPECTION
1. Cy
lind
erheaddis
tor
tio
n
• Removeoi
l，sca
le，gaske
t，s e
ala
nt，andca
rbo
nde
pos
itsf
rom
su
rfac
eofcyl
ind
erheadu si
ngas cr
ape仁
CAUTION:
・ 00 not allow gasket fragments to enter oil or engine
coolan
tpassages.
• Checkf latn
essofc ylin
derhead lowers
urfa
ce. Measure
di
stortionin6d ire
ctionsshown i
nt hefi
gue，
r ats ev
eral
poin
tsi neachdir
ectio
n.
Limit:0.
2m m( 0.00
8in)

2. BulbDimensions
• Measured imens
ion
satthep
oin
tsshowni
nth
efi
gur
eus
inga
micr
ometer.
Standard U ni
t:m m(
in
)
I
nta
ke Exhaust
a :
118
.15(
4.6
5) 118β(4.677)
b :
3.1・3.5( 0
.122・0.138) 3.
1・ 3.5( 0.12
2・0 .1
38)
c :
1.15・ 1.
45( 0
.0453・0.0571) 1.35・ 1.6
5( 0.05
31・0 .06
50)
D( diam
eter):
47.0・4 7
.2( 1
.850・ 1
.8583) 38.0・3 8.
2( 1496・ 1
目 .5
04)
d( di
amete
r):7.965・7 .9
80( 0.
3136・ 0.
3142) 7.945・7.960( 0.31
28・0 .31
34)
α(degree) :45・1'-45・
5 45' 45"15'-45"45'

EMM0422

五
百d

EMM0423

• V
alv
efa
cei
sco
rre
cte
dus
ingv
alv
esu
rfa
ceg
rin
der
.

EM-15
 CYL
lNDERHEAD

CylinderHeadAssembly(
Con
t'd
)
Stemedgesurf
acei
scor
rectedus
ingoi
lst
one
.
Keep cor
rec
tio
nsto a minimum due t
os ur
fac
ere
duc
tio
n.
Replacef
iou
tsid
eth
erepai
rlim
i.
t

CORRECTIONREPAIRl
IMIT
Facecorrec
tionl e
ngth
:
Inta
kev a
lve:
0
.5m m( O
.020in
)orles
s
U
I 二工コ0:旧 Exhaustv al
ve:

r
m
dt
0.
5m m( O
.020in
)orles
s
Stemedgesunacec orre
cti
onlen
gth
:
L
rT1
1 Inta
kev al
ve:
0.
2m m( 0
.008in
)
Exhaustv al
ve:
EMM0425 0.
2m m( 0
.008in
)

3
. V
alv
egu
idec
lea
ran
ce
• Checkb eforeremovingt heval
veguide
.
• Makes uret hevalv
estemd ia
meteriswit
hinthestand
ard.
RefertoOIVal
vedirec
tioninspect
ion(pre
viouspag
e)O
I.
• Pusht hev alveoutt o
wa rdthecombustionchamber.Measure
runoutw h
ile pushingt hestem edges urfacetowardthedia
l
in
dicat
or.
• 1/2ofthed i
alindic
atorreadingisth
ev al
veg u
idecleara
nce.
Standard:
Inta
ke:
0.020・0 .053m m( 0.00
08・0 .00
21i n
)
Exhaust:
0.040・0 .073m m( O.00
16・0 .0029in)
Repairlimit
:
Inta
ke:
0.1m m( 0.004in)
Exhaust:
0.1m m( O.004in)
• Replacec yl
inderheadfitiexceedsthelim
i.
t

4
. V
alv
ese
atc
ont
act

。
• T
hisi
nsp
ect
ionmustbedonea
fte
ren
sur
ingt
hatt
hedimensions
。
ft
hev
alv
egu
ideandt
hev
alv
ear
ewi
thi
nth
est
and
ard
.Th
is
insp
ectio
nmustbedonea ft
ere n
su r
ingt ha
tt h
edimensionso
f
thevalv
eg uideandt heva
lvearewithinthestanda
rd.
O
.K • Checkv alveconta
ctbya pplyi
ngDICATOLPL ・1t ovalv
esea
t
conta
ctsurfac
e.

O.O~G
• Makes uretha
tc on
tactsurfa
cesa reconnectedal
la rou
nd.
• Reseatt hevalveandchecka gainfis e
atingcondit
ionisno
t
corre
c.
tReplacec yl
inde
rheadf is eat
ingc on
ditio
ncannotbe
corre
ctedbyr es
eatin
g.
EMM0427

EM-16
 CVL
lNDERHEAD

C
yli
nde
rHeadAssembly(
Con
t'd
)
5
. V
alvespri
ngsquareness
Se
tt hevalv
espringa g
ains
tas qu
are
.R ot
atethespr
ingand
r
ecordthemaximumgapbetweens pr
ingupperendandthe
s
quare
.
Lim
it:
1
.9m m( 0.0
75i n
)(Inn
er)
2
.1m m( 0.0
83i n
)(Outer
)

一・一
V
e附c
alt
r
ia
lsq
uar
e

C
ont
act EMM0428

6
. F
reel
eng
thandcompressionl
oado
fva
lves
pri
ng
・ Checkwithavalvespringtester.
Standa
rdmm( i
n)
Inner Outer
Freel eng
thm m( in
):
42.72(1.6
819) 48.02(1.
8905)
Lengtha tins
talla
tionm m(in
):
35.0(1.
378) 40.0(1.5
7)
Loada tinst
allat
ionN( kg，I
b)
:
105・115 219・240
(10
.7・1 17，
. 23.6・25.8
) ( 22
.3・24.4，49.2・53
.8)
EMM0429
Valveopeningl engthm m(in
):
24.7(0.
972) 29.7(1
.169)
Valveopeningl oadN( g，
k I
b)
:
292・319 584・638
(29
.8・3 25，
. 65.7・71.7
) ( 59
.6・65.1，131.4・143
.5)
Iden
tifica
tionpain
t:
Green Green

ASSEMBLY
1. I
nst
al
lvalv
es p
ringsea
ts.
• I
ns
tal
lv al
ves prin
gs eat(out
er)with rounded si
defaci
ng
u
pward.
2. I
nst
al
lvalv
eoilsea
ls.
• I
nst
al
lvalveoi
ls ea
lt othedimen
sio
nss peci
fiedinthef
igu
re
u
singavalveoi
lseald
rif
t(SS
T).

EMM0430

EM-17
 CYLINDERHEAD

CylinderHeadAssembly(
Con
t1d
)
3. I
nst
allv
alv
es.
•4.Applyengineo
In
sta
llvalvesp
i
r
lt
in
ov
g
s.
alv
es tem.

• Facet
pain
henarrowerp
tmark)towardc
i
y
t
c
l
hs
in
de
id
rh
eo
e
fv
a
d.
a
lvesp
ring( w
ithiden
tifi
cat
ion

5
. I n
sta
llvalvespringret
ainer
s.
6. Compress t hev a
lves pri
ngw ithav alves pr
ing compressor
(SST)，andinst
allthevalvecoll
etwithamagneticdr
iver
.
• Tapv
af
teri
a
l
n
v
s
estemt
t
all
ingva
i
l
pw
v
i
ec
t
hap
o
lle.
t
la
stichammert oensureap roperfi
t

EMM凶 u 7
. I
u
n
s
s
t
e
)
a
l
.
lwaterconnector( ga
soline
)o rplug (LPGo rcombined

• ApplyThreeBond1386Bo
connectthec
onnec
tor
.
requiva
len
ttot
het
hre
ads，
andthen

8
. In
sta
llsparkplu
gfit
ii
sremoved.

l
de
nt
if
ic
at
in∞l
o o
r
EMM0432

EM-18
TIMINGCHAIN

ComponentP
art
sLocation

EMM0536

CAUTION:
・ Applynewengineoiltothepartsmarkedinthefigureprior
t
oin
sta
lla
tio
n.

Removal
1
. Removet hefollow
ingpar
ts.(
Ref
ert
oth
eap
pro
pri
ates
ect
ionf
or
eachp r
epara
tion.
)
• Engined riv
eb e
lt
• Waterpumpp ulle
y
・ O i
lpan
• Rockerc over
• Rockerarm
• Rockershaf
tassembly
• Pushr od
• C ylin
derhead

EM-19
 TIMINGCHAIN

Removal(
Con
t'd
)
2
. Makes urethatNo. 1c ylin
derisa tTDCon i tscompression
s tr
okew i
tht hefollow
ingp rocedur
e :
1
) R otatet hec ran
kshaftp ulleyc lockwis
e( as viewed from th
e
f r
ont
) and a lign orange n o
tch w ith thet iming i n
dic
ator
( pr
otrusi
on)ont hef r
ontc o
ver.
2
) Makes urethatdistri
butorroto
risf aci
ngt h
ed i
rect
ion( f
ron
tside
)
asshowni nt hefigu
re.
• Turncrankshaftp u
lley360degreesi nt hedire
ctionshown
i
nt hefigur
eifther oto
risf a
cingr ea
rs i
de.
3
. Removed istr
ibut
or.
4
. Removec ran
kshaftp ul
leyw i
tht hefollo
wingprocedure.
1
) Removes t
artermotor.
2
) Securec rankshaftbyi n
stal
linga r i
nggears topper(SST)to
s t
artermountingh ole
.
• Use a pproximately 10 m m spacer between p lat
e and
sto
pper.
3
) Loosen c rankshaftp ull
eyb olts，and t hen remove cranksh
a f
t
pul
leywasher.
4
) Screwc ranksha
f tbol
tbyhandu n
tili
ts tops，andt henrota
teit2
or3t ur
nsb ack.
5
) P os
itionap ulleypull
er(SST)t ocrankshaftpull
eyw i
thM8b olt
s
(
2).
6
) Setp ul
lerb o
ltt oa p ulleyp ul
ler，and then tightenitunti
lit
conta
ctsw i
thc rankshaf
tp ull
e ybol.
t
7
) T ighte
nM8b olts(2)temporarilyinst
all
ed.
8
) T ighte
np u
llerb olta ppro
x i
m atel
y2 t urnsa f
terf eel
ingt ha
t
EMM0437
st
ickin
go fcrankshaftpulleyisreleased
.
9
) Removet hepulleypulle
r，placeitt ofron
ts urfa
ceo fcranksh
a f
t
pul
ley，and t apitw ith a hammer. Release s t
ickin
go f cone
bush
ing.
10
) Removeconebushingu singlong-nosep lier
s.
11
) Removec ran
ksha f
tp u
lle手
12
) Removekeyf orconeb ushing.

EM-20
TIMINGCHAIN

Removal(
Con
t'd
)
5
. Removefron
tc ov
erbol
tint h
er ev
ers
eoftheor
deron EM
se
cti
on，andthe
nremovefr
ontcov
erusi
ngas
ealc
utte
r(S
ST).
CAUTION:
• Bec a
ref
ulnott
odamagemountings
urf
ace
.

6
. Removek eyforconeb ush
ing.
7
. Removeo i
lpumpd r
ivespacer
.
8
. Removec ran
kshaftsprocke.
t
9
. Removek eyforcranks
haftsprock.
et
1
0.Lif
tandremovef ro
ntsealonf r
ontcove
ru si
ngas
cre
wdr
ive
rifi
t
needst
ober epl
aced.
1
1. RemoveO-ri
ngo fcrank
shaftpul
leywashe
r.
CAUTION:
・ 00notreuse0・ring.
1 2
. Removecamshafts p
rocketbol.
t
• Ins
erta s c
rewdriv
erwrappedi nashopc lo
tht
ot heholeon
camshaftsprocke，securecamshafts
t p
roc
ketbyatta
chi
ngt he
t
ipo fs c
rewdriv
ert o camshaft l
oca
tin
gp l
ateb
olt，and th
en
loosenthebo.
t
l

1
3. Removec
hai
nte
nsi
one
randc
hai
ngu
ide
.
CAUTION:
・ Holdthesleevewithafingertopreventitfrompoppingout
whenremoving.

1
4. Removedis
tri
but
ord
riveg
ear
.
1
5. Removecamshaftspr
ock
etandc
ran
ksh
afts
pro
cke
tto
get
her
wi
thtim
ingcha
in.

EM-21
 TIMINGCHAIN

Removal(
Con
t'd
)
⑨ Keyfor∞nebushing ⑥ O
ilpumpd
riv
espacer

Crankshaftp
ull
eywasher

Crankshaftp
ull
eyb
olt

④ Keyf orcrank
sha
ft
sprocket
NOTE:Assemblyorder

⑧+⑧+⑥+⑨+⑤

CAUTION:Alwaysapplyengineo
il
whenassembling

Crankshaftp
ull
ey
EMM0438

I
nst
all
ati
on
NOTE:
Camshafts
pro
cke
t • In
stal
lin
gc o
ndit
ionandmatchingmarkl o
cati
onofeachpar
tare
Matchingmark(Stamp) shownint h
efigu
re.
1. In
sta
llthekeyf orc r
anks
haftsprock
etafte
rmakings ureth
at
cra
nkshaftkeygrooveandcamshaftkeypoi
ntst
raig
htup
.

Matchingmark
Matchingmark
(Darkbluei
Ink
)
(Cuto
ut)

EMM0440

EM-22
 TIMINGCHAIN

I
nst
all
ati
on(
Con
t'd
)
2. In
sta
llcamshaftspr
ocketandcra
nks
hafts
proc
ketalig
ningwit
h
matchingmarkontimi
ngchai
n.
• Ins
erteachsproc
kettothesh
afti
ntur
nandinsev
era
ls te
ps.

EMM0441

• Move camshaft i
ntoc
ylin
derblock when i n
serti
ng camshaft
sproc
ke.
tHoldcamshaftbytemporarilytigh
tenin
gb ol
ts，tapti
usi
ngap la
stichammer，
andthenfullyins
ertcamshaftsprocke.
t
NOTE:
• Keyf
ord
ist
rib
uto
rdr
ivegeart
oca
msh
aft
.

3. In
sta
ld ist
ribut
ord r
ivegeari sn otvisibl
eficamshafts p
roket
ins
ertio
nisi nsu
ffic
ie.
nt
• In
sta
llsot h
ati nd
icat
ionstampmarks i
deisf acingcamshaft
sproc
ketside.(Referto"ComponentP
目 a
rtsL∞
。 c剖
ati
on
げへ
1
"
E¥
.
4. In
sta
llcamshafts pr
。c
巾 k剖e
tbol比
t
..
• In
sta
ll washer withflats id
ef aci
ng camshaft s prock
ets i
de.
(Ref
erto"ComponentP artsLoca
副ti
on
げ.
l
'
へ
目¥
l
• Securecamshafts procke
剖t川i
nthesamep ro
ce dureasr emov
al，
andtighte
nb o
lts.
5. I
nst
al
lc ha
ing uideandc h
ainten
sione
r.
• I
nst
allchaintension
ers le
evewiththearro
wons
lid
ingp
ort
ion
f
acingchai
nr ot
atin
gd i
rect
ion(u
p).
6. I
nst
allo
ilpumpd rivespacertocra
nksh
aft
.
7. I
nst
allkeyforconeb u
shing.

8. I
nst
al
lfron
toi
lsealtofron
tc ov
erwhenrepl
aci
ngfr
onto
ilsea.
l
• I
nst
allw
iththea
rrowf a
cingoutsi
de.
• Presso
ilseali
nu n
tiltiisflushwit
hth
eends urf
aceoffron
t
c
overusingano
ilsealdr
ift(SST)or78m m(3
.07i
n)di
a.dr
if
t.
CAUTION:
• Make sure t
hat the circumference o
foi
lse
ali
s not
damagedandt h
ereisnob ur
r.

EMM0444

EM-23
 T
IMI
NGCHAIN
I
ns
ta
ll
at
io
n(C
ont
'd)
9. Ins
tal
lfron
tc ov
er.
• Removeo il，scae，ands
l e
alan
tc om
ple
tel
yfromfl
anges
urf
ace
andw at
erh ol
e.
• Applyac ontinuousbeadofThreeBond1207C(
N-KP
510
-
∞15町
totheposi
t i
onsshowni nth
efig
ure
.
CAUTION:
・ 00notapplytoinletloutletsidegrooveofoilpumpinletl
o
utl
et
.(2a
t * mark)

EMM0445
NOTE:
Groovesa
pumpi n
let
l
*
t markp
ou
tle
re
v
twheni
e
n
n
s
t
tl
al
l
i
i
q
u
n
g
i
.
dg
ask
etfroms
pre
adi
ngi
ntoo
i
l

I
nst
allO
-ri
ngs(
2)
.

CAUTION:
• Bec a
refultopreventO-ringfromdroppingandd
isl
oca
tin
g
wheni n
stal
lingfrontcovertocyl
inderbloc
k.

Don
otr
eus
eO-
rin
g.
• R
efert
oth
efi
gurefo
rl oc
ati
onandtig
hte
ningord
erofb
olt
s.
A
:M8XLengthunderh ead
:35m m( 1.
38in
)(4)
B
:M8XLengthunderh ead
:65mm( 2.56i
n)(8)
C
:M8XL eng
t hunderhead:80mm(3.15i
n)(1)

EMM0446

1
0.I
nsertacra
nksh
aftpulle
ygu
ide(SST)t
ocr
ank
sha
ft，andt
hen
i
nst
allc
ran
ksha
ftpul
ley
.
CAUTION:
・ Front oil seal may be damaged if crankshaft p叫胞Y is
i
nst
all
edd
ire
ctl
y.Alwaysusecrankshaftp叫 胎'
ygu
ide
.

1
1.I n
sta
llconeb us
hing.
1
2. Applyengineoi
lt oO-r
ing，andt
henin
sta
llO-ri
ngtot h
eO -
ring
groove on cra
nksha
ftp ul
leywash
er.( R
efe
rt o "Component
PartsLo
c a
tio
n".)
CAUTION:
・ 00notreuse0・ring.
1
3.I
nst
allcra
nks
haftpul
leywasher，andthent i
ghte
nc rank
sha
ft
p
ulleybol
tu si
ngar i
ng gear s
top
per (SSηfollowing t
he
p
rocedu
resabove.

EM-24
 TIMINGCHAIN

I
nst
all
ati
on(
Con
t'd
)

r
n
叩l
AU
g ~ア

C
nuF
白
K町 f
orconeb附 i
n

d
HM

団山
A

内
v
-
il--i
“aHu

何¥¥¥¥
C

e
n
LK
hH
﹁

vy

AU
v
n
au

Hu

川U
門
H
J

u
W

Keyf
orc
ra円k
sha
fts
pro
cke
t

EMM0447

1 4
.I n
sta
lldist
rib
uto
r.
• CheckTDC on compression s tro
kew i
th matching mark on
cranks
haftpul
ley
.
• Ins
ertd i
str
ibut
ors h
afttofro
ntc ov
era l
igni
ngd is
tri
buto
rshaft
matchingmark( c
irc
lestampmark)wit
hunitsid
ematchingmark
(sho
rtstampl i
ne)
.
NOTE:
・ Matchingmarkonshaftisalignedwithunitsidematchingmark
(
Ion
gstampl
in
e)byengagemento
fhe
lic
algeara
fte
rin
ser
tin
g.

EMM0448

1
5.R
ein
sta
llremovedp
art
sint
her
eve
rseo
rde
ro .
fremoval

EM-25
REMOVALANDINSTALLATIONOFENGINE

CAUTION:
• Alwayspaya ttentio
nt osafet
y.
• 00 notremoveengine u n
til exhaustsystem and engine
coolanthascompletelycooleddown.
• Supportthevehiclea tthespecifiedli
ftpoints.
• Refertoappropriatesectionsf oroperationproceduresf
or
componentsotherthanengine.

Removal
[OPERATIONOESCRIPTION]
Removet
ran
smi
ssi
on，
andremoveenginebyp
ull
ingu
p.

[PREPARATIONWORK]
1
. Releaset h
ef ue
lp re
ssu r
e.R efertoECs ect
ion，"Releaseo
ffue
l
p re
ssure".
2
. Remover a
diatordrai
np lugandd rai
nenginecoolan.t
3
. Removet h
ef ollo
wingparts
.
• Enginehood
• Ba杭ery
• Radiato，
rshroud， andradiato
rhose
• Enginedrivebelt
• Coolingfan
4
. Disconnecta ccelera
torc ablefromthro
ttl
edrumandmovei to
ut
o fposi
tion
.

EM-26
REMOVALANDINSTALLATIONOFENGINE

Removal(
Con
t'd
)
[LEFTSIDEOFENGINEROOM]
5
. Removea irductanda i
rc l
eanercase.
6
. D isconne
ct heated oxygen sensor harness c o
nn e
ctor and
ground(betweene xhau
stm anif
oldcoverandbody).
7
. D isconn
ectharnessc onnectorfromAlCc o
mpressor.
. RemoveA
8 lC compressorf romb r
acketandsecuretiont
obody
wit
har ope.
9
. D isconne
cth eate
rh ose.Plugt hehosei m
mediate
lyt opre
vent
enginecoola
ntf romdrai
ning.
1
0. Removepowers teer
ingr e
servo
irt a
nkfrombracke
tands ecure
t
iontobodyw it
har o
pe.
CAUTION:
・ Levelly secure reservoir tank. Tilting may cause oil
l
eak
age
.

[RIGHTSIDEOFENGINEROOM]
1
1.D isco
nne
ctvacuumhose(
fo
rbr
akeb
oos
terandf
ord
iff
ere
nti
al
lo
ck)onengin
es id
e.
1
2. Removefue
lh os
e.
CAUTION:
• After disconnecting hoses，plug them immediately t
o
preventfuelfromd ra
ining
.

1
3.D is
conne
cta l
l harnessc
onnect
orsone n
gines ie，andt
d h
en
moveharnessestobodysi
de.
1
4.D is
connec
th eat
erhosefrombodysi
d ，
eclamp andthe
nmoveti
t
oe ng
ineside
.
1
5. Removestart
ermotor.

[UNDERVEHICLE]
16
. Removeexhau
stf r
onttub
e.
17
.D is
conn
ectAIToi
lc ool
erpipi
ngf
romo
i
lpa
n.
18
. Remove r
earprope
llersha
fts
.
19
. Removetra
nsmis
sion.

[REMOVAL]
20
. Engage c
hai
nbl
ock hook i
nfr
ont
lre
are
ngi
nes
lin
ger
s and
.
t
suppor
CAUTION:
Bec are
fulnott
ocontacthookandchainw
ithbodyand
pipin
gwhenengaginghookins
lin
ger
s.

2
1. Removeeng
inemountin
sul
ato
rLH/RHnuts
.
2
2.P u
llupandremoveen
ginebyadj
ust
ingt
hepos
iti
onc
are
ful
ly.
CAUTION:
・ Makesurethatallwiresand pipingweredisconnected
wh
ileremoving.
• Becar
efulnottocontactw
ithbodys
idep
art
s.

EM-27
REMOVALANDINSTALLATIONOFENGINE

I
nst
all
ati
on
I n
sta
llint herever
seo rd
erofremovalandn otethef o
llowi
ng.
• 00n otallowoi
ltog etontheenginemounti nsul
ator
.Bec are
ful
nottodamaget h
eenginemounti nsu
lator
.
• Securelyins
ertposit
ionin
gstopperpinintomatingsidehol
e.
• Makes ureal
lmounti n
sulat
orsareseatedproperl弘thentigh
ten
mountb ol
tsandn uts
.

I
nsp
ect
ion
• Checkamounto fenginec ool
ant，oi
landgreaseb efo
res t
arti
ng
engin
e.Ref
illasnecessary.
• Sta
rtengineandcheckf oranyunusualn oiseandvi
brat
ion.
• Warm up engine，and t hen check engine c
ool
ant，oil and
grease，
fuel，andexhaustgasf o
rl ea
kage.

EM-28
CYL
lNDERBLOCK

ComponentP
art
sLocation

CAUTION:
Applynewengineo
ilt
othep
art
smarkedi
nthef
igu
rep
rio
r
toins
tal
lat
ion
.

Disassembly
1. Removeengineassemblyfromt h
ev e
hicl
e.
(Ref
ertoEMs ection，"RemovalandI n
sta
lla
tio
no fE
ngin
e".)
2
. Keept h
ep o
sit
ionus i
ngah ois
tsoasn ottoti
l
te n
gine
.
3
. Removeenginemountb racke.
t
4
. I n
sta
llengineassemblytoengines t
and(SST)withthefol
low
ing
proce
dure:

EM-29
 CVL
lNDERBLOCK

Disassembly(
Con
t'd
)
1
) In
sta
llenginesub-attachment(SST，A showninthefig
ure
)t o
enginemountb ra
cketmountingho
leonexhaustmanif
oldsid
e.
2
) In
stal
lengineattachment(SST，Bshowninthefi
gur
e)toengine
.
t
sub-attachmen

悶ァ。 7
7-9
8(7.
9-1
0.O
.57-7
2) C
ran
ksh
aft
(4) ビ~ p
ull
eys
ide
問 N'm (
kg-
m. ft-Ib) EMMO
揃

3
) H ois
tengineandmountt ionengines ta
nd(SST ，Cshowni nthe
f i
gur
e )
.
・ I
ti spossibl
et osetenginea tta
chmentandsub-attachment
toengines tand，andtheninst
allhois
tingenginel
at
er.
5
. D rainengineo i
lfromo i
lpand rai
np lu
g.
6
. D rainenginec oolantfromcylin
derblockdra
inp l
ug.
( Ref
e rto" Coo
lantReplacement"i nCOs ect
ion.
)
7
. Removet hefollowi
ngp a
rts
.
• Auxil
iarybrackets
・ Exhaustm anifold
••
Thermostathousing
Waterp ipe

•••
Intakemanifold
Distr
ibuto
r
Rockercover
••Rockers
Cylinde
haf
tassembly
rassembly

•••
Oilpan
Oilstrai
ner
Timingc hain
•
Oilfi
lte
rando i
lf i
lt
erbrac
ket

EMM0453

8. Removef ly
whee.
l
N
-KV
101・
05610
• Secure c
ranks
haftu
sin
gas
top
perp
lae (SST)，and t
t hen
removebo
lts
.
CAUTION:
・ Placeashopclothonflywheelsurfacetopreventdamage.
• Loosenb
olt
sdiagonallyandremovethem.

9
. Removeflywh
eelhou
sin
g.
1
0. Remover
earoi
lse
alandret
ain
era
sse
mbl
y.

EMM0454 NOTE:
・ Oilsealisintegratedwithretainer.

EM-30
 CVL
lNDERBLOCK

Disassembly(
Con
t'd
)
1 1
. Removev a
lvelif
t
er.
• Pu
lloutfromblockuppersurfa
cewithafing
e .
t
randremovei
• Removec amshaftw i
thv a
lvelif
te
rinn on-
con
tactcond
iti
onfi
remov
alisd i
ff
icu
lt，andt henremovev a
lveli
ft
eraf
tertap
pin
g
fromcra
nksha
ftsi d
eh o
le.
• Checktheloca
tion，andstor
eindi
vid
ual
ly.

1 2
. Removec ams
haft.
• Pu
llcamshaftst
raig
hto
utsoasn
ott
odamageb
ush
ing
.

EMM0456

1
3. Removep i
stonandc onne
ctingroda s
sem
bly.
1
) Set c ranksha
fta tr emovalp ist
on assembly to BDC on
compressionstrok
e.
2
) Removec onn
e c
tingr odcapandpushp isto
nandc o
nnect
ing
r o
dassemblyo utt owardcyli
nderheads id
ew it
hh andl
eofa
hammer.
• Beforelooseningconnecti
ngr odnuts，checkc o
nnect
ing
rods i
dec lear
ance.( R
efertoEMs ect
ion，吋 n
spect
ionof
connec
tingr o
ds id
ec le
a悶 nc
e".)

EMM0457

3
) Removec
onn
ect
ingr
odb
ear
ing
.
CAUTION:
• Checki n
sta
lla
tionposit
ionofeachp
art
.Arrangeremoved
valvest
opreventmixingthemup.

1
4. Remove p
isto
nri
ngu
sin
gpi
sto
nri
ngexpander(
com
mer
cia
l
se
rvi
ceto
ol)
.
CAUTION:
・ Becarefulnottodamagepiston.
• 00notexpandp i
stonr i
ngse xc
essivel
y.Itcandamage
pist
onr in
gs
• Checkp isto
nrin
gs ideclearancebeforeremovingpis
ton
ri
ng.( R
efertoEMs ec
tion，"Inspec
tiono fp
istonrin
gside
clear
ance".
)

EM-31
 CVL
lNDERBLOCK

・
Disassembly(Contd)
1
5. Removeconnectingrodfromp
ist
on.
1
) Removesnapr ingus
ingsnaprin
gplie陪 .

2
) Heatpi
sto
nt ・
obetween60and70C (140and158・
F)u
sin
ga
dr
ier
.

EMM0460

3
) Pusho utpis
tonpi
nfrompi
sto
nusin
ga roundbarw
itho
ute
r
diametero
fappr
oxima
tel
y20m m(
0.79i
n)
.
CAUTION:
・ 00notremoveconnectingrodboltfromconnectingrod.

，
EMM0523

1
6. Removemainbe
ar i
ngcap
s .
C
:JCra鵬 h胡 p
ull
eyi
n鉱 山t
ion拘 1
) Loosenbol
tsintherev
erseoft
heo
rde
rshowni
nth
efi
gur
e.

EMM0462

EM-32
 CYLINDERBLOCK

Disassembly(
Con
t'd
)
2
) Removemainb e
aringcapwhi
lesha
kingt
ile
ftr
/ig
htusin
gmain
bear
ingb
olt
s.
1
7. Removecrank
sha
ft.
1
8. Remove main be
aringfro
m main be
ari
ng cap and c
yli
nde
r
bl
ock.
CAUTION:
• Checki ns
talla
tionposi
tion01eachpart
.Arrangeremoved
partstopreventmixingthemup.
Be10relooseningmainbearingcapbol
ts，checkcrankshaft
sideclea
rance.
'
-
' EMM0463
(Re1erto EM s ec
tion，" I
nspe
ctio
n0 1 crankshaft side
cleara
nce"
.)

S
ele
cti
ve-
FitServiceP
art
s
SELECTIONMETHOD
P
osi
tio
n S
ele
cti
ve-
fits
erv
icep
art
s I
temt
obes
ele
cte
d S
ele
cti
onmethod

C
yli
nde
rbl
ockt
opi
sto
n Pis
tonandpisto
npinassembly P
isto
ngrade Pi
ston grade Cylinder bo陀 抑de (Bore
NOTE:P i
stonandpist
onpinarea (
Pis
tonou
terdi
ame
ter
) i
nnerdiamete
r)
matchedse!
. Theymake upone
pa同 asanassem
bly.

• Id
enti
fic
ati
ongr adestampedoneachp artshowst hedimension
measuredwhent iwasnewasag rade
.Itisnotapplic
ablewhen
t
ihasbeenr eu
s ed.
• When partis usedo rc o
rr e
cted，measurei tsdimensionand
deci
dea ppr
opriateg rade byr e
fer
ringtoS el
ect
ive
-fitS e
rvice
Par
tsT a
bleinthi
ss ec
tion.
• Refe
rt ot hed irec
tions pecif
iedi nt h
et e
xtf o
rd etai
lso f
measurement methodf oreach p at，r
r eus
ables tanda
rd，and
se
lecti
onmethodf orsel
ect
ive-f
itservicepa
rts.

I
nsp
ect
ionA
fte
rDisassembly
CRANKSHAFTSIDECLEARANCE
Move c ranksh
aftt of ro
nto rr ear and measure clea
rance
betweent hru
stb ear
ingG ou
rnal6)andc rankarmu singad ia
l
ind
i c
atororaf e
elergauge.
Standard:
0.05・0.17m m( 0.0020・0.0067in
)
Repairlimi
t:
0.30m m( 0.011
8i n
)
• Replacemainb e
aring(inte
grate
dw i
ththr
ustbeari
ng)ofjourn
al
6，andt henmeasurec learanc
ea ga
inifout
sidethere
pairlim
i.
t
• Replacec ran
kshaftf
itis
ti
llexceedstheli
mit 関

EM33圃
 CYL
lNDERBLOCK

InspectionA
fte
rDisassembly(
Con
t'd
)
CONNECTINGRODSIDECLEARANCE
• Measurec onnectin
gr od-
to-cr
ankarms i
dec l
earan
ceusin
ga
fe
elerg au
ge .
Standard:
0.20・0.3 5m m( 0
.0020・0.0138i
n)
Repairlimit
:
0.40m m( 0
.0157in)
Replacec onnectingrOd，andt he
nmeasurec lea
rancea
gainf
i
outsid
et herepairli
mi.
t
• Replacec ranks
haftifi
tst
il
lexceedstheli
mi.
t

PISTON-TO-PISTONPINCLEARANCE
I
nsi
dem
icr
oπl
ete
r
1. Pistonpinholedi
ameter
• Measure i nn
erdiamet
erofpis
tonpi
nh ol
eu s
ing an i
nsi
de
micrometer
Standard:
22.993・23.
005m m(
0.905
2・0.9
057in
)d i
a.

2. Pistonpinouterdiameter
• Measurep istonpinoute
rd i
ameteru s
ingam icr
ometer.
Standard:
22.989・2 3.001m m( 0.9
051・0 .9055in
)d i
a.
3. Howt oc a
lculatepis
ton-
to・p
istonpinclear
ance
(Pist
onp i
nc leara
nce)
=(Pistonpinholediameteけ・( Pis
tonp i
nouterdiame
ter)
Standardclearancea troomtemperature[ 2
0・C(
0

68F
)]:
-0.001to0 .00
9m m( 0to0.0004i n)
• Replacep isto
nandp ist
onp i
nassemblyi fclearan
ceexceeds
EMM0467
thestandard.

PISTONRINGSIDECLEARANCE
Measure p is
tonr in
g-t
o-pi
sto
nr i
ng groovecle
aran
ceusi
nga
fe
elerg au
ge.
Standard:
Topr ing 0.040・0.073m m( 0
.00
16・0.00
29in)
Secondr ing0 .030・0.063m m( 0
.00
12・0.00
25in)
Oi
lr ing 0.065・0.135m m( 0
.00
26・0.00
53in)
Repairlimit
:
Topr ing 0.1m m(0.004in)
Secondr ing0 .1m m(0.004in)
Oi
lr ing
• Replacep is
tona nd
/orpist
onrin
gassemblyfiout
sid
ether
epair
li
mi.
t

EM・34
 CYL
lNDERBLOCK

I
nsp
ect
ionA
fte
rDisassembly(
Con
t'd
)
PISTONRINGENDGAP
• Makes urecylin
derbor
ei n
nerdiam
eteriswith
inthestandard
.
(Re
f ertoEMs ecti
on，"
Pist
onandC yl
inderBoreClearanceへ)
Pr
ess-fi
tp is
tonr in
gsincyli
nde
rh alfw
ayu singa piston，and
measureendg a
p.
Standard:
Topring 0.30・0.4
5m m( O.012・0.018in)
Secondr ing0.30・0.4
5m m( O.012・0.018in)
Oi
lr i
ng 0.20・0.60m m( O
.008・0.024in)
Repairlim
it:
Topring 1.5m m(O.059in
)
Secondr ing1.5m m(O.059in
)
Oi
lr i
ng

CONNECTINGRODBENDANDTORSION
F
eel
ergauge
• Checkconnect
ingr o
dbendandtor
sio
nusi
ngaconn
ecti
ngr
od
ali
gnmentto.
ol
Bendl im
it:
0.1
5m m( O.
0059i
n)[
per100m m(3.
937
0in
)]
Torsionlim
it:
0.3
0m m( O
.011
8in)[
per100m m(3.
937
0in
)]

EMM0470

CONNECTINGRODLARGEENDDIAMETER
In
st
a l
lc o
nnectingr o
d cap w
ithoutc o
nnecti
ngr odb
earin
g.
Tightenconnecti
ngr o
dnutst
ot h
es pe
cifi
edtorqu
e.
• Measure c onn
ectingrodlar
geendd iamet
eru singan i
nsid
e
micrometer
.
Standard:
59.987・60.000m m(2.361
7・2.3622i n
)d i
a.

EMM0471

CONNECTINGRODBUSHINGOILCLEARANCE(AT
SMALLEND)
1
. Connectingr o
dsmallendinn
erdiame
ter
Measurei nnerdiamete
rofconnec
tingrodsma
llendus
ingan
ins
idem icro
meter
.
Standard:
23.000・23.012m m(O.
9055・0.9060i
n)d
ia.

EM-35
 CVL
lNDERBLOCK

InspectionA
fte
rDisassembly(
Con
t1d
)
2. Pis
t o
np i
nouterd
iameter
• Measurep i
sto
npinout
erd i
ame
terus
ingamic
rome
ter.
Standa附:
2
2.989・23.
001m m( 0
.90
51・0.90
55in)di
a.

EMM0473

3
. Howt
oca
lcu
lat
eco
nne
cti
ngr
odb
ush
ingo
i
lcl
ear
anc
e
• (
Con
nec
tin
gro
dsm
allendo
i
lcl
ear
anc
e)
=(Connectingrodsmallendinnerdiameter)・ (Pistonpinouter
d
iamete
r)
Standard:
0.
005・0.01
7m m( 0.
0002・0.000
7i n
)
• Re
fertostand
ardsfo
reachparti
fcl
earancewasn o
twi
thi
nth
e
s
tand
ard.Replaceconn
ect
ingr o
dand/
orp i
stonandpi
sto
npi
n
a
ssembl
y.
• Refert o EM sec
tin，"
o Pisto
nSelec
tiv
e-fi
tS ervi
ceP a
rts"if
reusi
ngc onn
ect
ingr od and rep
laci
ngp i
ston and pis
ton
assemblywithnewone.Se
lectpi
stonfi
tte
dtot h
eboregradeof
cyl
inderblo
ck.
NOTE:
・ Pistonandpistonpinareamatchedse.
tTheymakeuponep
art
asana
sse
mbl
y.
Smallendgrade
(0OrNostamp)

EMM0474

CYL
lNDERBLOCKUPPERSURFACEDISTORTION
Com
plete
lyremoveol
dg a
sketoncyli
nderbl
ocksur
匂ceusin
ga
s
crape
r.Als
oremoveol，
i wat
ersta
ins，andcarbond
epo
sit
s.
CAUTION:
・ 00 not allow gas~et fragments t
oe n
teroi
l or engine
coolantpassages.
• Checkf l
atnes
so fcylinde
rblockuppers u
rface
.Measure
distor
tionin4d irectio
nsshown i nthefi
gue，
r atse
veral
pointsineachd irec
tion.
Repairli
mit
:
0
.1m m( 0.004in)

EMM0475

EM-36
 CYL
lNDERBLOCK

I
nsp
ect
ionA
fte
rDisassembly(
Con
t'd
)
PISTON-TO-CYL
lNDERBORECLEARANCE
1. Cyl
i nde
rbored iameter
• Measurec ylind
erborea t2p oi
nts(AandB )in2d i
rec
tio
ns(
X
andY)u s
ingaboregauge.
Cylinderborei n
nerdiameterstandard:
99.500・99.550m m( 3.91
73・3.9 19
3in)d
ia.
Wearl imi
t:
0.2m m( 0
.008i n
)
Out-of-roundlim
it
(i行erencebetweenmeasurementsXandY
d )
:
EMM
似苅 0.015m m( 0.000
6i n
)
Taperl i
mit(di
fferencebetweenmeasurementsAandB )
:
0.01m m( 0.000
4i n
)
⑦
• Honeo rborecylin
derf
iout s
idet herepa
irlimi
to rcy
linde
ri n
ner
wa
llisfoundwithdamageands eizur
e.
・ 0.
5( 0.0
20)08[ 0.5m m( 0.02
0i n
)o v
ersiz]and1
e .
0( 0
.039)08
[1
.0m m( 0.0
39in)ove陪 i
ze]piston
sa reavail
ablefo
rs e
rvic
e.Be
suretouset hesameo versizepisto
nr ing
sw it
hp is
toncylin
der
clear
ancesizepist
onwhenu sin
go vers
izep i
ston
.

2
. P
ist
ono
ute
rdi
ame
ter
• Measurep ist
onski
rtoute
rdia
meterusi
n gamic
rom
eter.
Measuringp o
int:
20m m( 0.7
9in)upfrompistonbo悦om
Standard:
99.460・99.51
0m m(3.91
5 7・3.917
7in)d
ia.

HOWTOCALCULATEPISTON-TO-CYLINDERBORECLEARANCE
• (Cleara
nce)=
Micrometer (Cyli
nderboreinne
rd iam
ete
r)・( P
istons
kir
to ut
erdiam
et e
r)
EMM0478 Standardclearanceatroomtemperature[ 20・
C( 68・F
)]
:
0.030・0
.050m m( 0.001
2・0 .002
0i n
)
Replacep i
stonandp is
tonpinassemblyf
ic l
earancei
so uts
ide
thestandar
d.
3
. Pis
tonse
lect
ive
-fitser
vicepar
ts

Cコ 1
Whenus
) Checkc
i
y
n
l
gnewc
i
nde
y
linde
rblock
rboregradenumber(1to5)stampedoncyli
nde
r
blo
ckuppers ur
faceands e
lectpi
stonfromse
lec
tiv
e-f
its
ervic
e
par
tsta
ble.
NOTE:
• Pi
sto
nandp
asanas
sem
b
i
l
s
t
y
o
.
np
ina
r .
tTheymakeuponep
eamatchedse art

O
ρ コF
〈 4
1 コ
C
/アヘ r
--¥ー/六 ペUMω79

EM-37
 CYLINDERBLOCK

I
nsp
ect
ionA
fte
rDisassembly(
Con
t'd
)
・ Whenreusingcylinderblock
1
) Measurecylin
derboreinnerdia
meter.
2
) Findgradenumbero fthemeasuredc ylind
erborein"Cyl
inde
r
Bore Inn
er Diameter S
ele
cti
ve-fi
t Service P
artsTab
le"，and
sel
ectpisto
n (grades 1to5) from sele
cti
ve-
fitse
rvicepar
ts
ta
ble.

S
ele
cti
ve-
fits
erv
icep
art
sta
ble U
ni:
tmm(
in
)

Grad
e
nu
mber 2 3 4 5
EMM0480
(
sta
mpi
ng)
99.
510 99.
520 99.
530 99.
540 99.
550
C
yli
nde
rbore (
3.9
117
) (
3.9
181
) (
3.9
185
) (
3.9
189
) (
3.9
193
)
mner
dia
mete
r 99.
500 99.
510 99.
520 99.
530 99.
540
(
3.9
173
) (
3.9
177
) (
3.9
181
) (
3.9
185
) (
3.9
189
)
99.
470 99.
480 99.
490 99.
500 99.
510
P
ist
onout
er (
3.9
161
) (
3.9
165
) (
3.9
169
) (
3.9
173
) (
3.9
177
)
di
ame
ter 99.
460 99.
470 99.
480 99.
490 99.
500
(
3.9
157
) (
3.9
161
) (
3.9
165
) (
3.9
169
) (
3.9
173
)

CRANKSHAFTJOURNALDIAMETER
• Measurethejou
rnalout
erdiameterusi
ngamic
rom
eter.
Standa同:
70
.9 0
7・7 0
. 9
20m m( 2.7916・2.7
921i
n)dia
.

CRANKSHAFTPINDIAMETER
• Measuret hepino
uterdiameterusingamic
ro m
eter.
Standard:
56.91
3・56 .
926m m( 2
.2407・2.
241 2in)d
ia.

OUT-OF-ROUNDANDTAPEROFCRANKSHAFT
Measureeachj ourna
landp inat4p osi
tion
sshownint hefig
ure
A usingamicrometer.
• Out-of-roun
di sindic
atedbyt hedif
feren
cebetweendimensions
A andBmeasureda tpOin
ts1and2 .
B • Taperisi ndicatedbydiffere
ncebetweendimensions 1and2
measuredi nd ir
ectio
nsAandB .
Repairl i
mit:
Ta
per: 1-2 0.06m m( 0
.0024in)dia.
O
ut-
of-
rou
nd:A-B (bothout-of-roundandt aper)
EMM0482

CRANKSHAFTBEND
Setap airofV -blo
cksonal ev
elsurfac
eandsupportjou
rna
ls1
and7o fc ra
nkshaft.
Setad i
ali ndi
catorver
tica
llyontojou
rnal4
.
Rotatecrankshaftandreadi ndic
ati
ononthein
dicat
or.
Halfofthereadingi sthebend.
Repairl i
mit:
0.2m m( 0
.008in)

EMM0483

EM-38
 CYL
lNDERBLOCK

InspectionA
fte
rDisassembly(
Con
t'd
)
CONNECTINGRODBEARINGOILCLEARANCE
1. Measuringmethod
• In
stal
lc onnec
tingr odbeari
ngt oconne
c t
ingr o
dandc onnec
tin g
rodc ap
.T ightenc onn
ectingr odnutstot hes p
ecif
iedtorqu
e .
Measure c onnectingr odi nnerd iameteru sing an insi
d e
micro什le
ter
.
(O
ilc le
arance)
=(Connectingrodbearinginnerdiameter)
-( Cr
ankshaftpinouterdiam
eter)
Standard:
EMM例 制 0.027・0.061m m( 0
.0011・0 .0024in)
Repairlimit
:
0.09m m( 0.0035in
)
• Replacec onnecti
ngr odbearingand/orcranks
haftaccor
dingt o
judgementf romvaluesmeasureda tp rev
ioussteps11and1 5・
1)ficonnectingr o
db eari
ngo i
lc l
earancei sout
sidethe陪 pair
li
mi.
t
2. Usingplastig
age
Completelyc le
an 0行 oil and dust on cran
ksh
aftp i
ns and
beari
ngs u
rfaces
.
• Cutap ie
ceo fp l
astig
ages l
igh
tlyshorterthanbea
ringwidh，
t
andp la
cetiinaxia
ldirec
tionavoid
ingoilhol
e.
In
sta
llc onn
ectingr o
db earingtoc o
nne c
tingrodcap.Tig
hten
connect
ingr odnutstothespec
ifiedtorqu
e.
CAUTION:
・ 00notrotatecrankshaftwhileplastigageisinplace.
• Removeco
nnect
ingrodcapandb
ear
ing
.Measurew
idt
hoft
he
pl
ast
iga
geusi
ngs c
alepr
int
edoni
tsb
ag.
CAUTION:
・ Followthemethodo utl
inedin"Bymeasuring"i fclearance
isstandardandrepai
rlimi
t，andifclearanceexceedsr e
pair
lim
it，butremeasurei
fclearanceislessthanstanda
rd.

MAINBEARINGOILCLEARANCE
1. Measuringmethod
• In
stal
lmainb ear
ingt ocyl
inderblockandb eari
ngc a
p.T i
ghten
bearingcap boltstot hespecif
iedt o
rqueand measure main
bearinginnerdiam
eter.
(O
ilc le
arance)
=( Mainb earingi nn
erd iam
eter)・ (Crankshaf
tj ou
rnalo u
ter
diamete
r)
Standard:
0.030・0.087m m( 0.0012・0.0034in)
Repairlimi
t:
0.09m m( 0.003
5i n
)
• Replace u nde
rsizedb earin
g upper and l ower as a setfi
standards ize main b ea
ringo i
lc le
arancei so uts
idet he
standar
d.
(RefertoEMs e
ction，"U
singU nders
izedB e
aring
".)

EM-39
 CYL
lNDERBLOCK

InspectionA
fte
rDisassembly(
Con
t1d
)
2. Usingplastigage
• Completelyc
bearingsur
fa
l
c
e
e
s
a
.
noffoil and duston cr
ankshaf
tj ou
rna
l and

• Cuta p
andp la
i
c
ec
eo
ei
ti
fpl
n制 a
as
ld
t
i
i
g
r
a
e
g
c
t
es
io
l
i
na
g
v
h
t
o
l
i
ys
d
in
ho
r
go
i
te
lh
rt
ole
.
ha
nb ea
ringwidh，
t

• Tightenmainbearin
gt othespeci
fiedto
rque.
CAUTION:
・ 00notrotatecrankshaftwhileplastigageisinplace.
• Remove b
pl
ast
iga
g
e
eu
a
s
r
i
n
in
g cap and b
gs c
alep
rint
e
ear
i
doni
n
t
g. Measure w
sbag.
idho
t ft
he

CAUTION:
・ Followthemethodoutlinedin"Bymeasuring"ifclearance
i
sstandardandrepai
rlim
it，andifclearanceexceedsr ep
air
l
imi
t，butre、e
町 asurei
fclearanceislessthanstandard.

3. Usingundersizedbearing
Use undersi
zedb ear
i n
gf i standard s
ize main b
earingo i
l
cl
earan
cei sout
sidet hestand
a r
d.
• Whenu
diam
ete
s
r
i
n
，
gun
andg
d
r
e
i
r
s
n
i
z
dj
eb
our
e
n
a
a
r
lt
ig，
n
oo b
i
t
n
s
a
t
i
a
l
ns
t，
li
p
ec
measureb
ifi
edoi
lcl
e
e
a
a
r
r
a
i
n
n
gi
ce
.
n
ner

R
3.O~4(O. 00118~01') (川 1p ins) M
ainb
ear
ingu
nde
rsi
zet
abl
e U
ni:
tmm(
in
)
R2.5~4(O. 098~01') (
AI
Ijo
urn
aIs
)
S
ize T
hic
kne
ss
STD 2.000(
0.0
787
)
(

)
9-9-9-au
5一

au
nu-nu-nu-4

nu--nu-nu-nu
nu-nu-nu-nu
nu--司，一円4 一
cu--MU cu CM

。
川
u

4 一民叫一マ'一
- - - - -n

-
-(-(-(

2.125(
0.0
837
)
一HU一

-)
-E
o-5一

'- ヲ
・ ・--

2.250(
0.0
886
)
一一

3
=)
U U
一

E
一

2.375(
0.0
935
)
-T
O
，

-
円

)
。
u

2.500(
0.0
984
)
斗

U
ni
t:nm i
n
EMM0547
NOTE:
・ Eachtoleranceis+0.008to+0.012(+0.0003to+0.0005).
CAUTION:
・ Becareful notto damage fillet-roll areawhen grinding
crankshaftj
our
nali
nordert
ouseundersizeb
ear
ing
.

MAINBEARINGCRUSHHEIGHT
• T
i
i
n
g
s
h
t
t
a
l
e
l
nb
e
d
earin
gcapt
. Removeb e
ot
a
ri
h
n
esp
eci
fie
dtorqu
ew
gcapand makes
i
u
r
thmainb
ethatth
ea
ring
emain
bea
ringedgesp r
otr
ude打heremustbec
rushheig
ht.
).

i
:
J
f EMM0489

EM-40
 CYL
lNDERBLOCK

InspectionA
fte
rDisassembly(Confd)
VALVEL
lFTEROILCLEARANCE
• Checksli
din
gsurface
swithcamshaftandl
if
te
rboref
oruneven
wearanddamage.
• Replacev
alvel
if
te
rifnec
essar
y.
1. Valvelif
te
ro ute
rdiameter
Measuret hev a
lvel i
ft
erouterdiameterusingam icromete
r.(Ain
thefigu
re)
Standard:
24.960・2 4.970m m( 0.98
27・0 .9844i n
)d i
a.
2. Valvelif
te
rborei nnerdiameter
Measurev alvelif
terboreinnerdiameteru s
in gaboregauge.( 8
inthefigur
e)
Standard:
25.000・2 5.003m m( 0.98
43・0 .9844i n
)d i
a.
EMM0490
3. Howt oc al
culatevalveli
fte
roilclearanc
e
(Clearance
)= ( V
alvel i
ft
erbore i nn
erd i
amet e
r)・ ( Val
velif
te
r
outerdiameter)
Standard:
0.030・0 .073m m( 0.0012・0 .0029in)
Repairl i
mit
:
0.
1m m( 0.004in)
• Refertostandardsf oreachp artandr eplacev al
vel i
ft
erand/
or
cylin
derblockifclearanceexceedst herepairlim
i.
t

VISUALINSPECTIONOFCAMSHAFT
• Checkcamshaftnoseorj
ourna
lfordamageandunevenw
ear
.
Replacecamshaftasn
ecess
ary.

CHECKINGFORCAMSHAFTBEND
• Setap airofV-bl
ocksonal e
velsur
faceandsupportjour
nals(1
and7 )ofcamsha
ft.
• Setad ia
lindic
atorver
tica
llyontocente
ro fjou
rnl4
a .
Rotate the camshaft in one dire
ction by hand and read
ind
icati
onont hedia
li n
dica
tor.(H
alfofther e
adingi
sthebend.)
Repairlim
it:
0.0
3m m( 0.0
012i n
)

EMM0491

CAMNOSEHEIGHT
Measurewit
ham i
crom
e t
er.
Standard( i
ntakesid
e):
42.126・42.376m m(1.
658
5・1.
668
3in
)
Standard(exhaustside
):
42.
12 6・42.376m m(1.
658
5・1
.668
3in
)

EM-41
 CYL
lNDERBLOCK

I
nsp
ect
ionA
fte ・
rDisassembly(Contd)
CAMSHAFTOILCLEARANCE
1
_ Camshaftj o
urn
alouterdia
met
er
Measurew it
ham i
cromet
er_
Standard:
Journal1 5 0.7
21・50.740m m(
1.996
9・1.9976i
n)
Journal2 5 0.5
21・50.540m m(
1.989
0・1.9898i
n)
Journal3 5 0.31・50.340m m(
2 1.9
811-1.9819i
n)
Journal4 5 0.12
1・50.140m m(
1.973
3・1.9740i
n)
Journal5 4 9.91・49.940m m(
2 1.965
4・1.9661i
n)
Journal6 4 9.7
21・49.740m m(
1.95
75・1.9583i
n)
EMM0493 Journal7 4 9.5
21・49.540m m(
1.949
6・1.9504i
n)

2. Camshaftb ushin
gi nnerdiameter
Measureu singab oreg a
uge.
Standard:
Journal1 5 0.76・5 0.
83m m( 1.9984・2.00
12in)
Journal2 5 0.56・5 0.
63m m( 1.9905・1.993
3in)
Journal3 5 0.36・5 0.
43m m( 1.9827・1.9854i
n)
Journal4 5 0.16・5 0.
23m m( 1.9748・1.9776i
n)
Journal5 4 9.96・5 0.
03m m( 1.9669・1.969
7in)
Journal6 4 9.76・4 9.
83m m( 1.9591・1.9618i
n)
Journal7 4 9.56・4 9.
63m m( 1.9512・1.9539i
n)
3. Howt oc al
cula
tec amshaftoi
lc l
earance
• Oi
lc learance=Camshaftb ush
ingi nn
erd i
amet
er-Camshaft
jou
rnalo u
terdiameter
Standard:
0.020・0.109m m( 0.
0008・0 .
0043in)
Repairlimi
t:
0.15m m( 0.0059in)
• Refert othes tand
ar d
sf iclearanc
eexceedst herepa
irli
mi.
t
Replacecamshafta nd/orcamshaftbushin
g.

Camshaftbushing
REPLACEMENTOFCAMSHAFTBUSHING
replacements
et 1
. Removewelchp
lug
.
N-KV111・
O45S0
dhmw
⑬/

EMM0495

EM-42
 CVL
lNDERBLOCK

I
nsp
ect
ionA
fte ・
rDisassembly(Contd)
2
. P
ulloutcamshaft b
ush
ing
sfr
omc
yli
nde
rbl
ocku
sin
ga b
ar
(
SST)
.

ミぉ

加 梅 里i
EMM0496

3. I
nst
allcamshaftbushin
gsU o
urnals7to2)
.
Cutout
• I
nst
alljourna
ls7t o2intheo r
derfromcyl
inde
rbl
ockfr
ontsi
de

む •
h
o
I
n
l
s
e
t
a
s
l
.
l camshaft bu
shingsw i
thc u
toutfaci
ngfron
twa
rd and
u
pwar d
.( I
tissameasj ou
rnal1.
)

EMM0497

• Al
igncamshaftbu
shi
ngn
otc
hesw
ithknockp
ino
fab
ar(SST)
whenins
tal
lin
g.

Camshaftbushing
EMM0498

• Securejou
rna
ls4t
o2wrappedi
nta
pesoasn
ott
odi
slo
cat
e
bushi
ngs
.

⑮ EMM0499

EM-43
 CYL
lNDERBLOCK

I
nsp
ect
ionA
fte
rDisassembly(
Con
t'd
)
I
nser
tb arwithbus hin g sintoc y
lin
derblok，andt
c he
ni ns
tal
la
gu
ideplate(SSη.
• T
ightenbolt
swith11丁目 11 markstampedong uidepl
atefaci
ngu p
.
• P
ress
-fi
tu n
tilbarm at c hing mark(stamp l
ine
)isint h
esame
p
osit
ionasg ui
dep l a
teedges urfac
eA.

F ¥ ¥

N.KV111・
04510 N-KV111-04520
A
li
gns
tam
pli
n
ewi
thA

〈
コ C帥

EMM0501

• S
lideba
rmatching mark(stampl
ine
)ino
rde
rdependingon
j
our
nalpo
sit
ion
.

EM-44
 CYL
lNDERBLOCK

I
nsp
ect
ionA
fte ・
rDisassembly(Contd)

Camshaftbushing
A
lig
nstampl
inew
ithA
Example

Wheni
nst
all
ingN
o.6j
our
nal

。
Crankshaftp
ull
eyi
nst
all
ati
ons
ide
Stampl
ine

A
lig
nstampl
inew
ithA

Wheni
nst
all
ingN
o.2j
our
nal

Stampl
ine

EMM0
502

• Makesur
et ha
toilhole
si neachjou
rna
landc y
lin
derb
loc
koi
l
.
ho
lesa
rea l
ignedaf
terin
sta
lli
ngeachjo
urn
a.l
4. In
st
allcamshaftb u
shingj(ourn
al1 )
.
• Al
ignjour
naloilholewithcylind
erb lo
ckoi
lhole
.
• Pr
ess-
fitunt
ilj o
urnalfron
tendi s0.5m mi ns
idefromc
ylin
der
blo
ckfron
tends ur
faceus i
ngad ri
ft(SST
).
• Makes urethatjourna
lo i
lh oleandc yli
nde
rb lo
ckoi
lholeare
ali
gnedaft
erinsta
llin
gj o
u rn
a.
l

Camshaft Cyl
inderb
lock
bushing f
rontendsur
face
(No.1jour
nal
)

• F
ron
t

O.5mm

EMM0504

EM-45
 CYL
lNDERBLOCK

I
nsp
ect
ionA
fte
rDisassembly(
Con
t'd
)
5
. Checkcamshaftbushingi
nne
rdiameterandmakesuret
hatt
ii
s
wi
thi
nthes t
andar
d.

6. In
sta
llwelchp l
ug.
• Applyliq
uidgasket(Th
reeBondTB1303)towelchp
lug
.
Pre
ss-f
itusingad r
if
t(commercials
erv
icet
ool
)
.

CAMSHAFTENDPLAY
• Ins
tallloca
tingplateandcamshaftgeartocamshaft，andti
ght
en
bo
ltt othespecifi
edt or
que.
• Measurec lear
ancebetweenl oc
ati
ngplateandcamshaftfro
nt
ends urfaceusingaf ee
lergauge.
Standard:
0.08・0.28m m( 0.00
31・0.0110in)
Repairl i
mit
:
0.5m m( 0.020in)
• Replacel ocat
ingp la
teandmeasurea g
ainfioutsid
et h
erepa
ir
J
型工
EMM li
mi.
t
Replacecamshafti ft
isti
llexceedsthel
imt
.
i

Assembly
1. Thoroughlycleanenginec
oolantandoi
lpassagesincyl
inder
block，aswel
lasi nsi
deofcrankcaseandc
ylind
erboresusi
ng
compressedair
.

EM-46
 CYLINDERBLOCK

Assembly(
Con
t'd
)
2. I n
sta
llmainb ea
ring.
1 ) Cleanb earingmountings ur
facesonc ylind
erb lockandmain
Mainbear
ingcap b earingcapt oremoveanyf or
eignmaterial，dust，andoi.l
(No.6)
2 ) I n
sta
llmainb earin
gi nthecorre
ctd i
rect
ion.
Mainbea円ngcap • In
sta
ll main b eari
ngh al
fw ithoil grooveand o ilh ol
et o
(No
.1-5and7 )
cyli
nderblock，andt hehal
fw it
houtoi
lgrooveando ilholeto
mainb earingcap.
• In
sta
lli nte
gratedthrus
tb ea
ringtoj ou
r n
al6 .
• Apply engineo i
lt ob earings urfac
e( i
nside) and thru
st
outsid
ewheni nsta
llin
gb ear
ing.Don ota pplyengineoilto
reversesideofb ear
ing，butthoroughlycleani.
t
• In
sta
llbya lignin
gmainb e
aringd e
tentw iththeno t
ch.
• Makes u
ret heoilholesincylinde
rb lockandmainb earing
arealigned
.
Wit
hoi
lho
leandgroove 3. I n
sta
llc r
ankshafttoc yl
inderblo
ck.
• Makes uret h
attiturnssmoothlybyh and.

in
民
主
s
t
主
Crankshaftp
alla
tions
i
u
d
l
l
e
ey q
EMM0508

4. In
sta
llmainbear in
gc a
ps.
~Cran帥aft pulleyi
nst
蜘 t
ions
ide
• In
sta
lltiby alignin
g main bea
ringi de
nti
fic
atio
n numberwit
h
jo
urnalpo
sit
ion.
• In
sta
ll sothat upperiden
tif
ica
tion numberf a
cesthef r
onto
f
engme.
・ Tapwithaplas
tichammerandi ns
tal
li.
t

EMM0509

5. T igh
tenmainb ea
ringcapb ol
ts.
〈
コ Crankshaftpulleyinst蜘 t
ion帥 • L ubr
icatethreadsands eatsurfac
eo fbo
ltw i
thnewengineo .
il
• T igh
tenb olt
se venl
yi nseve
rals tepsi
nt heo r
dershowni nthe
figur
e.
・ R otatecranksh
aftbyhandandmakes uretiturn
ssmoothlyaft
er
t i
ghteni
ng.
6. I n
sta
llpistontoconnectingrod
.
1 ) I n
sta
llsnapr inginsnapr ingins
tall
ati
ongrooveonr earsideof
p i
stonu si
ngsnapr ingpli
ers
.
• Makes uresnapr in
giss e
curelyseatedint h
egroove
.
EMM0510

EM-47
 CVL
lNDERBLOCK

・
Assembly(Contd)
2
) I n
st
al
lp is
tontoconnectingrod
.
• Heatp ist
on[ obetween 60and70・
t C( 140and 178 下)]
usingad ryersot ha
tp i
stonpincanbee as
ilyinse吋edby
hand.Insertpisto
np ininpist
onandc on
nectin
gr o
df rom
fro
ntsideofpisto
n.
• Assemblesot ha
tf r
ontmarkonp o
siti
onhead，oilh ol
ei n
d
connect
ingr od，andc yli
nderNo.stampedonc onnecting
rodarep o
sitione
dasshowni nt h
ef i
gur
e.
cvy 3
) I n
st
al
lsnapr ingontopistonf
rontsi
de.
e

r
a

e
r

O
a
n

M川
Au
n
M
n
vy

Au
v
hH
-
ι
e

ea
n

H
併H

v
u

Make s uret h
att hec o
nnectingr o
d swings fr
eelya ft
er
a
H

•
n

EMM0511
complet
ingw or
k.
7
. I
nst
al
lp i
stonr
ing
swi
thp
ist
onr
ing expander (
com
mer
cia
l
s
ervic
eto
ol)
.
Stamp
CAUTION:
・ Becarefulnottodamagepiston.
• I
nst
al
lt opandsecondr
ing
swi
thstampmarksonendgaps
f
acingu
p.

EMM0512

• I
ns
ta
llo
i
lri
ngw
ithr
ingendgapasshowni
nth
efi
gur
e.

mmFN
EMM0513

• P
osi
tio
nendgapso
feachp
ist
onr
ingasshowni
nth
efi
gur
e.
O
ilr
ingspacer

F
ron
tmark
戸
〉

Secondr
ingendgap

EMM0514

EM-48
 CYL
lNDERBLOCK

Assembly(
Con
t'd
)
8. In
sta
llcon ne
ctingrodb ear
ingtoconnect
ingr o
dandc on
necting
rodcap.
・ Applyengine oilt ob e
arings ur
face( i
nsi
de) when i
nst
all
ing
connect
in grodbearin
g.Don otappl
yengineoiltore
verseside
ofbearing，buttho
roughlyclea .
t
ni
• In
sta
llc onnecti
ngr odb eari
ngbya l
ign
ingt h
ep r叫e
ctionwith
deten
tn otchonc onn
ectingrod.

9. Ins
tal
lp is
tonandc onnect
ingrodassemblytocranksha
ft.
• Set crankshaftpina tt heinst
all
ati
onp osit
iont o BDC on
compressions t
rok
e.
• Applyengineo iltoc yl
indrbore，p
e i
ston，andc ranksh
aftpin
su
ffic
ien
tly.
• Ins
tal
lc onnectingr o
dt oc yl
ind
erp osi
tionc orre
spondin
gt o
cyli
nderstampedoni .
t
• Ins
tal
lp isto
nsot h
atf r
ontmarkonp istonheadf a
cestoward
cranksh
aftp u
lleymountingsideusi
ngap ist
onr i
ngcompressor
(commercialservi
cetool
).
CAUTION:
・ Becarefulnottodamagecrankshaftpinwithconnecting
rodl
areendbycon祖 ct
g .
1 0
. Inst
allconnec
tingrodc a
p.
• Bes uretha
tc yl
ind
eronc onne
c t
ingrodandc on
nectin
gr odcap
match.
1 1.Tightenconne
ctingrodnu .
t
• Angl
e-tight
enasd escri
bedbelow.
1 ) Applynewengineo i
ltot h
readsandseatsurf
acesofconn
e ctin
g
rod
.
2 ) Tightent ・
o38・40N m ( 3.9・41kg-m，
. 28・30ft-I
b)
.
3 ) Tighten40to45・u si
ngana nglewrench(SST)orap r
ot阻 ct
o仁
CAUTION:
• 00notju
stestimatet
igh
ten
inga
ngl
e.
NOTE:
・ Tightento67to71 N・
m(6
.8t
o72 kg-m，49t
. o52f
tIb
)if ・
c
heckingtig
hten
ingang
lei
sdi
fficu
l.
t
4
) Rot
atec r
anksh
aftand make sure t
itu
rnssmoothly a
fte
ral
l
c
ylind
ersaretigh
ten
ed.
1 2
.I n
sta
llcamshaft
.
• Applyengineoi
ltocamshaftmachiningsurf
ace
.
• In
sta
llcamshaftstrai
ghtlysoasn o
ttodamageb u
shing
.
1 3
.I nst
all
locat
ingplat
e.
• Inst
all
locat
ingplatewithit
smark(concavemar同f a
cingu
p.
1 4
.I n
sta
llvalveli
ft
er
.
• Applyengineoi
ltov alv
el i
ft
er
.
• In
sta
llthemi nth
eirorig
inalposi
tio
ns.

EMM0518

EM-49
 CVL
lNDERBLOCK

・
Assembly(Contd)
1 5
.I ns
tal
lrearo
ils e
alandr et
aine
rassembly.
• Applyac ontinuousbeadofThreeBond1207C(N-KP51
0・00
150
)
tothepo
sitionsshowni nthef
igu
re.

EMM0519

1 6
.I n
sta
llfly
wheelhousing
.
1 7
.I n
sta
llflywhe.
el
• Securecranks
haftusingari
nggearstopper(SST)
.
• Tigh
tenboltsevenl
yi nse
ver
alstepsintheo rd
ershowni
nth
e
fi
gur
e.
1 8
. Assembleotherpart
sinreve
rseorde
rofd isa
ssembly
.

T f1
ighteningordero fywheelb
olt
s
EMM0520

EM-50
 CONTENTS
OILPUMP… ・
..
.
.・ ・
H .
.
..
.・
.
..
..
..
..
.
..
・ ・
H .
.
・ ・
.
.
・ ・..
.
.
.
H・ ・ ・
..LU2
H H DisassemblyandAssembly…
.
..
・ ・.
.
.
.・ ・
H .
..
.
.
・ ・ .LU・
H 2H

ComponentPa
rtsLoca
tion・. ・・・
H..
.
.
.・ ・
H .
.…
.LU-2
H H Insp
ection…… ・・
H ..
・ ・
H .
..
.
.
・ ・
H .
.…
…
H.
..
・ ・.
.…..
H.
...
..U・
L 3
 OILPUMP

ComponentP
art
sLocation

~Outer 剛or

O
ilpump∞I
ver O
ilpumph
ous
ing(
fro
n∞
t v
er)

~: Engineoil
~ :Notreusable
悶:N-m{kgf-m}
LUMOOO1

CAUTION:
• Applynewengineo
iltothep
art
smarkedi
nthef
igu
rep
rio
r
toins
tal
lat
ion
.

DisassemblyandAssembly
PREPARATION
F
ron
tco
ver(
Ref
ert
o"TIMINGCHAIN"i
nEMs
ect
ion
.)
NOTE:
Oi
lpumpi
sin
teg
rat
edi
nfr
ontc
ove
r.

INSTALLATIONOFINNERROTORANDOUTER
O
ilpumph
ous
ing ROTOR
I
nst
alli
nne
rroto
rwi
thi
t
smarkfaci
ngr
earwa
rd(cov
ersid
e).
I
nst
allo
uterr
oto
rwi
thi
tsmarkf
aci
ngf
ron
tward(
housi
ngs i
de)
.

LUMOO02

LU-2
 OILPUMP

I
nsp
ect
ion
OILPUMPCOMPONENTSINSPECTION
F
eel
ergauge Measureeachc lear
anceusi
n gafeel
ergauge.
Outerr otortohousingclearance(1inthefigur
e)
Standard:
0.114・0.260m m( 0
.0 0
45・0 .01
02in)
Outerr otortoinnerroto
rtipclearance(2inthefi
gur
e)
Standard:
0.180m m( 0.0
071in)orless

∞
LUM 03

Measureeachc l
earanc
eusingaf e
elergaugeandstrai
ghte
dge
.
Innerrotortohousingsideclearance( 3inthef
igure)
Standard:
0.030・0.070m m(0.0012・0.0028in)
Outerr otortohousingsideclearance(4inthefig
ure)
Standard:
0.030・0.190m m(0.0012・0.0075in)

LUMOO04

INNERROTORTOHOUSINGSOCKETCLEARANCE
Measuretheinn
erdiameterofo
ilpumphousingsocketu
sin
gan
in
sidemic
rome
ter.(5int hef
igu
re)

LUM0005

Measuringp
oin
t6
• Measure t heouter diameter o
fi nne
rr ot
or socket u
sin
ga
micromet
er.( 6i
nthef i
gure)
(Clearan
ce)=( Inn
erdiameteroffron
tcoversocke
t)一
(ou
t e
rdiameterofinnerrotorso
cket)
Standard:
0.045・0.09
1m m( 0.0018・0.091
4i n
)

LUMOO06

LU-3
 OILPUMP

I
nsp
ect
ion(
Con
t'd
)
REGULATORVALVECLEARANCE
• Measure i nn
erd iam
eterofreg
ulato
rv al
vec y
linde
ru singan
in
si d
em icrom
eter.
• Measurer egula
torvalv
eou
terdiamet
eru s
ingam i
cromete
r.
(Clea旧 nc) =(
e Cyli
nderb
orei nn
erd i
amete
r)ー ( Val
veo ut
er
dia
m ete
r)
Standard:
0.040・0.097m m(0.
0016・0.0965in)
CAUTION:
• Applyengineoilt oregu
lat
orv
alv
e. Makesuret
hatthe
LUMOO07
valvemovessmoothly.

REGULATORVALVESPRING
• Checks p
ringfo
rsa
ggi
ng.
Freelen
gth:
Approx.63m m(2.
48i
n)

LU-4
 ENGINECOOLINGSVSTEM

CONTENTS
CHANGINGENGINECOOLANT ..…・一一一一一・ .CO 2
・ RemovalandIns
talla
tion.・ ・ .
.…
..
.
H・ ・ .
.…
..
.・ ・ .CO
H ・3 H

Drai
ningEngineCoolant …..
.・ ・.
.…'
"・ ・
H .
.
.・.
.
. ..CO・
2 H WaterPumpInspection..
・ ・H.
..
.
・ ・ -….
H..
.・ ・ ..CO・3
H

Re
fill
ingEngineCoolant…..
.・ ・
H ..
.
.
.・ ・・・ .
.…
H… CO-2 H H THERMOSTAT. 日
…
..
…
.
.…
.
.
….
.
…
..
…
.
.…
.
.
….
目
.
….
…
.
一.
…
…
..
刷
.
.…
.
.
.川
.
.
.…
.
…
..
.
…
.一
.
目
.…
.
…
..
WATERPUMP. ..
.
..
..
・ ・
H -…一一
...・ ・-…
H….
...
..・ ・...CO3
・ H ComponentPa
rtsL ocation.日…
.
日
.
.…
.
日
.
.…
.
.
…
..
…
.
日
….
日
…
.
.…
.
日
…
.日
…
.
.
….
日
…
.
日…
.
.
…
.日
…
.
.
….
日
…
..
…
.
日
….
日
…
.
.….
…
.
日 .CO-4
ComponentP artsLoca
tion. ・ ・
..
.
.
・ ・ .
.
.
・ ・
H .
...
..C
HO-
3 H RemovalandIns
talla
tion.・ ・ .
.
..
.
・ ・
H .
..
..
..
.
..
.・ ・
H .CO・4 H
CHANGINGENGINECOOLANT

D
rai
nin
gEngineCoolant
WARNING:
• 00notdraincoolantwhenenginei
sst
il
lho
t.I
tmaycause
burns.

• Removeexhaustman
ifoldsi
dedra
inp
lugo
fcy
lin
derb
loc
kand
dr
ainth
ecoolanti
ncyli
nderb
loc
k.

R
efi
lli
ngEngineCoolant
• Refert
othef
oll
owi
ngf
orLLCd
ens
ity
.

En
gin
ec ool
antl
eve
l[i
ncl
udi
ngt
her
ese
rvo
irt
ank(MAXl
eve
l)v
olu
me]
U
ni:
tI(Impqt
)
E
ngi
net
ype TB45E

W
ith
outr
earh
eat
er App
rox.11.2(9・7/8)
W
ithr
earh
eat
er A
ppro
x.12.3(10・7/8)

LLCdensity(%):
50(Standardandcoldarea)
• In
sta
llcyli
nderb l
ockdr
ainplu
g.
• Applysealan
t(ThreeBond1215Bo requiv
a l
ent)tothethreads
ofcyli
nde
rb lockdra
inplu
g.
ロ:34・44N.m(3.5・4.5kgf-m， 26・32f t-
Ib)
• Makesuret hateachclampanddr
ainplugissecurel
ytig
htened.

CQ-2
 WATERPUMP

ComponentP
art
sLo
cat
ion

③:Not削 sable
悶 :Nm{kgf刊}
凶 F
ans
pac
er
COM0012

RemovalandI
nst
all
ati
on
PREPARATION
WARNING:
• 00notdr
ainc
ool
antwhenenginei
sst
il t
.I
lho tmaycause
bu
rns.

• E
ngi
ned
riv
ebe
lts
CAUTION:
• Handlewaterpumpvanesot
hati
tdoesnotc
ont
actw
ith
othe
rparts
.

WaterPumpI
nsp
ect
ion
• Checkwaterpumpbodyandvanesfo
rseve
rec o
rro
sio
nand
d
ir
t.
・ Make sur
et ha
twater pump s
haf
tturn
ss mo
othlywith
out
roug
hne
ss.

CQ-3
 THERMOSTAT

ComponentP
art
sLocation

B
olt(
3)
目 15.7-23.7
{
1.8-2.
4)
T
her
mos
tath
ous
ing
Watero
utl
et

匂
国Liquidgasket Crankshaftp
ull
eys
ide
~ :Notreusable
悶 N-m{
kgf
-m}
COM0013

RemovalandI
nst
all
ati
on
WARNING:
• 00nottouchthermostatorc
ontai
nerandhotwateru
nti
l
theyg
etco
ld.Theymaycauseb u
rns.

INSTALLATIONOFTHERMOSTAT
In
st
allt
herm
ostatwi
thji
ggl
eval
vefa
cin
gupwa
r d
.
Makesuretha
tt h
ermo
statfl
angei
ssecu
relyins
ert
edt
ose
al
nng
.

COMOO14

CQ-4
 THERMOSTAT

RemovalandI
nst
all
ati
o ・
n(Contd)
THERMOSTATI
NSP
ECT
ION
Thread WARNING:
00nottouchthermostatorcontainerandhotwateru
nti
l
theygetc
old
.Theymaycauseburns.

• Puta t hrea
dt hroughthermost
atvalv
eandsubmergei tina
Thermostat
wa
ter-fi
lledcon
tainer，t
henh e
attiupwh
ilesti
rri
ngthewa
ter.
• Readt hewatertemperaturewhenthermos
tatdrop
s.Thisisth
e
val
v eopeningtemper
ature.
Valveopeningtemperaturestandard:
82・C(180・町 (Standardandcoldarea)
Maximumvalvel i
ftstanda同:
8m mormore/95C( 0.3 normore/203・
1i F)
0

(Standa同 andcolda陪 a)

CQ-5
 ENGINEFUELSYSTEM

間 O
NFL
CONTENTS
DESCRIPTION… ・ ・・
H -
H…
・・
..
..
・ ・.
.・ ・-…
H…
・ ・・
H..
...
...F
L-
H2 H REMOVALANDINSTALLATIONOFFUEL
GasolineSpe
cifica
tion.・ ・.
.…
.
H.
.・ ・.
.
..
.
・ ・
.
..
.
・ ・H.FL・
2 H H INJECTOR(GASOLINEANDCOMBINEDUSE)・ … FL・4
LPGS p
eci
ficati
on・.
.・ .
..
.
H.
..
..
..
..
..
..
..
..
… ・・-…. .FL・
3
H H Prepa
ratin・
o .
. ・
H..
.
..
..
..
.
..
・ ・..
.
.
.・ ・.
.…
..
.
H・ ・.
.
..
.
・ ・H.FL・4 H H

Spe
cific
ati
onforCombinedGasol
ineandLPG …. FL-3 RemovalandI n
stal
lati
onofFulHose.
e ・ ・ .
.
… FL ・4 H

RemovalandI n
stal
lati
onofFue
lTubeand
FuelInj
ect
or…・ ・・ .
.
.
.
H・ ・.
.
・ ・
H -
圃 ・・
H .
.
.
..
・ ・H.
...
...
..F
L・
H4 H H

CheckforFue
lLeakageA fterI
nst
allat
ion・
. ・ .FL・6 H
 DESCRIPTION

• Threefu
elsystemsp
eci
fic
atio
ns("G
asoli
ne"，"LPG"，"Combined
gasol
ineandLPG")havebeenap
plied
.

GasolineS
pec
ifi
cat
ion
Fuelpumpt yp
ei nteg
rate
dwithfu
eltankhasbeena dopted.
Completepumpiscomposedo ff
uelpump，fu
elfi
lt
er，pressure
reg
ulato
r，and fu
elg auge.AI
Iof them t
ogeth
era rec a
lled
ret
urnle
ssfu
elsuppl
ys ys
tem.

日
F
uelpump

F
uelt
ank F
uelf
il
te
r
ENGINE
Fuelp
陪ssu陪 r
egu
lat
or
F
uel
lev
巴Igauge

G
aso
lin
ein
jec
tor
FLM0001

ENGINECOMPONENTPARTSLOCATION

I
'
J:Engineo
il

~:Not 剛 sable
∞
FLMO 2

CAUTION:
• Apply newengineoi
ltothe p
art
s marked i
nthef
igu
re
beforein
sta
lla
tio
n.

FL-2
 DESCRIPTION

LPGS
pec
ifi
cat
ion
• LPGgasi 吋ectio
nsystemhasbeena dopted
.
• LPG i nj
ect
orh olderis equipped w
ithi nj
ect
or，assista
nce
in
jec
tor，fue
lp ress
uresensor，and re
lie
fv al
ve，andt he
ya re
composed as an a ssem
bly.A IIof them arei n
sta
lled on
el
ectr
onicthr
ott
lecont
rolact
uato
r.

一
一一一
-Normalflow
ーーー.. R
eli
eff
low

LPGa s
sis
tan
ce
in
jec
tor

LPGint
erc
ept
ion LPGi
nje
cto
r
LPGt
ank va
lve

:---fReliefvalv

ー-ー￨
Fuelpres
sur
e
sensor
F
LMO
OO3

Sp
eci
fic
ati
onf
orCombinedGasolineand
LPG
T
hisspec
ific
ati
oni
sfo
rcombinedga
sol
ines
pec
ifi
cat
ionandLPG
s
pec
ifi
cati
ontha
tar
ebothd
escr
ibeda
bove
.

FL-3
REMOVALANDINSTALLATIONOFFUELINJECTOR(GASOL
lNEANDCOMBINEDUSE)

Preparation
• Ai
rhose
• Movingengineharnessc
onn
ect
or

RemovalandI
nst
all
ati
ono
fFuelHose
REMOVAL
• Releaseth
efu
elp
res
sur
e.R
efe
rtoECs
ect
ion，
"Releaseo
ffu
el
pre
ssure
".
CAUTION:
・ Plugthefu
elhoset
opreventthef
uelfromd
rai
nin
gaf
ter
remova.
l

I
NSTALLATION
• I
nser
thoseu n
ti
li t
sendreaches25m m( 0
.98i
n)ormorefr
om
f
ueltubeend.Inst
allaclampands ecu
relyti
ght
eni.
t00not
i
nst
al
lt h
eclampont opo
ft h
eb u
lge.
• S
tartengie，i
n n
creaset
heenginespeed，andmakes ur
ethat
t
hereisnofuelleaka
geaf
terrep
air
ing.

RemovalandIn
sta
lla
tio
nofFuelTubeand
Fue
lI n
jec
tor
REMOVAL
CAUTION:
• Fuel remaining i
nthetube l
eaks during o
per
ation
.This
opera
t ionshouldbedoneinaplacefreefromfi
re.

• Removefuelgal
lerybo
lts
.
• Removef u
elgal
ler
y.Removefu
elin
jec
torandf
uelg
all
eryasa
se.
t
・ Remove clip
s( 6)u sin
glon
g-no
sep li
ers
.Oisco
nnectfue
l
in
jec
torandfue
lg a
lle
r手

CAUTION:
• 00notreusec
lip
s.

INSTALLATIONOFFUELINJECTOR
I
ns
ta
llf
ue 吋e
li c
tort
ofu
elt
ubeasshowni
nfi
gur
e1.

FL-4
REMOVALANDINSTALLATIONOFFUELINJECTOR(GASOL
lNEANDCOMBINEDUSE)

RemovalandIns
tal
lat
iono
fFu
elTubeand
Fuel
lnje
ctor(
Cont'
d)
1
. P recautionsforinsta
llat
ionoff u
elinject
or
1
) Therei snoc on
ta mi
nationn ordamagei nO-ringcontactarea
F
uelt
ub巴
tha
tiscausedbyd i
r.
t00notcleanO-ringwithsolven. t
) 00n
2 otreuseremovedO -
ring.
3
) HandleO -ringwithb arehands.
4
) Applyengineo i
li nt
oO -ringandh olderforassembly.( 00not
(
c)
applyengineo i
li n
tofuelpassageso ffue
li n
jec
tor.
)
) 00n
5 otusedamagedO -ring.
) 00n
6 ota pplyexcessiveforcethatcou l
ddamageO -ring.
7
) P ressc li
psi n
tofuelinjec
torwhena ssembling.Securelyfi
tclip
s
tofue
li njec
torlocatin
ggrooves( a)and( b).(00n otreusecli
ps.
)
民 8
) Alwaysr
9
) Assemblef
epla
u
c
e
eO
li
-
n
r
j
i
e
c
n
t
gwhenc
ortof ue
l
lt
i
psc
ub
o
ea
nt
f
a
c
t
e
tO
ri
-
r
n
s
i
t
n
a
g
l
l
.
in
gc lipstofue
l
inj
ecto仁
10
)F ueli nje
ctorispressedbyaf orceo f196N ( 20k gf，44Ib)or
les
s.Stopo pe
rationfiaf orceof147N( 15k g
f，33I b
)o rmoreis
necessary.)
11
)I ns
ertf ue
li nje
ctortof u
elt ubew h
ilea lig
ningfueltub estopp
er
(c
)w i
t hcli
pc uto
ut( d
)b eforeinst
all
ing.Securelyfi
t(c)to(d)and
holderrib(e)tocliphole(f
)a ft
eri n
serti
ng.
F
igu
re1 12
) Makes urethatfuelinje
ctorissecurelyinsta
lledwithoutrot
atio
n
andd isconnectionafte
ri n
stall
ingtofueltube.
∞
FLM 04

FUELTUBEINSTALLATION
1
. In
sta
llfueltubetoi n
takem a
nifoldasshowni nfigu
re2.
2
. Sat
isfyp r
ecaution
s1 )to6)forinst
all
ati
onoffuelinj
ect
or.
F
uelt
ube
3
. Inse
rtionoffue
li n
ject
orisperformedbyaf orc
eo f196N( 20kg，
f

f
44Ib)orl es
sp erfue
li n
ject
or.Stopoperat
ionfiaforceof147N
(15kgf，33Ib)ormorei snecessa叩.
. 00 n
4 o
tc ontactO -
ringw iththe edge thatis made by each
processofi n
takemanifoldforasse
mbly.

0・r
ing，lo
wer
(
1吋ecto
rcomponent)

I
nta
kem
ani
fol
d

F
igu
re2

∞
FLM 05

FL・
.
5
REMOVALANDINSTALLATIONOFFUELINJECTOR(GASOL
lNEANDCOMBINEDUSE)

RemovalandIns
tal
lat
iono
fFu
elTubeand
Fuel
lnje
ctor(
Cont'
d)
5
. Fir
sttighte
nf u
elt ubebol
ti npos
iti
o
四na "infig
ure3，andt
hen
tig
hteniti
np o
sitio
n" b
"int h
esamef ig
ure
.
Repeatabovet ight
eningproce
dure2t i
mes.

正 t
Tighteningto閃 ue
Fi
rsttighten
ing:
ロ:9・20N-m(0.9・2.1kgf-m， 7・15ft
-Ib
)
Secondt ighte
ning:
・
ロ:21・26N m (2.1・2.7kgf・m， 16・19ft
-Ib
)

o
C
ran
ksh
aftp
ull
eys
ide

F
igu
re3
FLMOO06

Checkf
orF
uelLeakageA
fte
rIn
sta
lla
tio
n
Checkforf
uelleakagebyr
aci
ngs
eve
ralt
ime
saf
teri
dli
ngf
or5t
o10
min
utes
.

FL-6
 ENGINECONTROL

CONTENTS
PRECAUTIONS・ .
.・ -…
H…
・………・
....
..…..
..・ ・..
・ ・ ..
EC・3 M H SSTD a
taM onit
orD i
splay・
..・ -
…..
.・ ・..
.
.
.・. .
.EC・6
7 H H

Gene
ralP r
ecautionsforServic
eO perations..EC・3 ECMI np
utlOutp
utS i
gnalSpeci
ficat
ions・..
. .
.EC・6
7
ENGINECONTROLSYSTEM. .
.
.
.・ ・ .
....
…・・・
一一・.EC-4 H Ci
rcu
itDiagram...
.
..
..
..
.
..
..
・ ・ .
.…… ・・ .
.
..
.
.・ ・.E
. C -6
7 H H H H

Des
cri
ption...
.
..
..
.
..
.・ ・..
.
..
・ ・..
….
...
..
..
..
..
・ ・・ ..
H..
.E
C-4 H S H ComponentP a
rtsInspec
tion….
..
・ ・ ….
.
. ...
..
...
EC・6
7 H

SystemDiagram・. ・ ..…
… ・・ .
.・ ・・ .
.…
.
口…
.
口
H.
.
口…
.
..
.…
.
日.EC-5 H H H H ENGINECOOLANTTEMPERATURESENSOR
Sens
orsa ndActu
加ator
陪sContro
lI tems.日
…
.
日.
.
…
.
日.
.
.
….
日
.
.
日日.
…
. .
EC-8 SYSTEM・.
.・H.
..
..
.
..
.
・ ・ .
.
.
.
・ ・
H .
.
..
.
・・ ・・..
.
..
・ ・.
..
.
.・ ・
H ..EC・6
8 H H H H

BASICIN SPECTION. 日…
.
….
.…
"
….
…司
"
….
.
“…
..
.
….
.
.…
..
…
..
….
.
山.
“…
.
.日
…
..
.…
.
.….
周
" ..E
C-9 SSTdatamo n
itordispl
ay・. ・ .
.
….
..
・ ・ .
.
..
.
・ ・ .EC・6
8 H H H

Ins
pec
tionofIdl
eS peed，Ign
iti
onT imin
g，a nd ECMI np
utlOutp
utS i
gnalSpeci
ficat
ions…… EC・6 8
Ai
r-F
uelRatio・. ・ .
.
.
..
・ ・・・
H ..
…….
..
・ ・ .
.
..
.
・ ・ ...E
C・9 H H H H H Ci
rcu
itDiagram・. ・・・ ..
..
.
..
.
..
・ ・
H ..
・ ・
H .
..
.
.・ ・..
HEC・6
8 H H H

Th
rot
tleValveClo sedPosit
ionL ear
ninga nd ComponentP a
rtsInspec
tion..
..
...
..
..
.…
..
.・ ・.E
. C -6
8 H

Id
leAi
rV olumeL earni
ng・. ・ ..
…….
..
・ ・ ..…E
… C-1
1 H H HEATEDOXYGENSENSORSYSTEM. .
..
・. .
.EC・6
9
Fue
lP re
ssureI n
spection・
. ・ .
.
.
.・ ・ …
…..
...
....EC-13 H H SSTD a
taM onit
orD i
splay・. ・・・ ..
….
..
・ ・. EC ・6
9 H H H H

TROUBLEDIAGNOSIS・ .
. ・・・ ..
.
..
..
・ ・..
.
..
.
.・ ・ ..E
C・15 H H H H H ECMI np
utlOutp
utS i
gnalSpeci
ficat
ions…… EC ・6
9
HowtoP rocee
dw ithTroubleD iag
nosis…… EC・1 5 Cir
cu
itDiagram・. ・..
… ・・ .
.
・ ・
H .
.……
..
.・ ・ … EC
.
. ・6
9
H H H H

Diag
nosisChartbyS y mptom… .
.
.・ ・ ..…….
… .E
C・19 H VEHICLESPEEDSENSORSYSTEM…… ・・. .EC・7
0 H H

ComponentPartsL oca
tion…..
.・ ・.….
. .
...
...
...
.E
C・29 H SSTD a
taM onit
orD is
play・
.. ・・・..
・ ・.
..
.
・ ・ .EC・70 H H H H H

Ci
rcu
itDiagram・. ・ .
.… ・・ .
.
..
.
.・ ・
H .
..
.
.
・ ・ .
.
.・.
. ..E
C3 4 H H H H 圃 ECMI np
utlOutp
utS i
gnalSpeci
ficati
ons. .
・
..E
. C -7
0
ECMT ermi
nalL ayout・.
.・.
.
・ ・ -….
..
・ ・ .
.
..
.
・ . ・EC-37 a H H H THROTTLEP O SITIONSENSORSYSTEM. .
..
.EC ・7
1
ECMI nput
lOutpu
tS ignalSpeci
ficati
ons・..
. ..E
C・40 SSTD a
taM onit
orD i
splay・. ・・・ .
.
..
・ ・ -…. EC・7
1 H H H H

SST...
.
.
・ ・.
H.
・ ・.
H.
…..
.
・ ・ ..…
….
..
・ ・ -冒
….
..
・ ・ ….
.
. .E
C・4
H6 H H ECMI np
utlOutp
utS i
gnalSpeci
ficat
ions・..
. .
.EC・7
1
Sel
f-d
iagno
sisF unct
ion( wi
thoutSST)・・ ・・ .EC・55 H H Cir
cu
itDiagram・.
.・ .
.
・ ・・H.
.…
..
.・ ・.
..
.
.
・ ・・・ ..
HEC・7
1 H H H H H

SSTR ef
e r
enceV alueinD at
aM onitor.・ 圃・E
- C・6
1 H ComponentP a
rtsInspec
tion・. ・.
.… ・・ -…E C・7
1 H H H

Fai
l-S
afeFunction… …
...
・ ・ .
.
..
.
・ ・ .
.…
・ ・・ .….
. EC・63 H H H H ACCELERATORPEDALP OSITIONSENSOR
POWERSUPPL YANDGROUNDSYSTEM…E C-64 SYSTEM....一一… ・・
H .
.
..
.
.
H.
・ ・..
.
.
.・ ・.
.
・ ・ .
.
..
..
.
..
・ ・ .EC・7
2
H H H H

ECMI nput
lOutputSignalSpeci
ficati
ons. .
..
.
.EC ・64 SSTD a
taM onit
orD is
play・. ・・・ ..
….
..
・ ・ ..
.EC・72 H H H H

Ci
rcu
itDiagram・. ・ ..
…
..
.・ ・..
.
.
.・ ・
H .
.…
…..
.・ ・ ..E
C・64 H H H ECMI np
utlOutp
utS i
gnalSpeci
ficati
ons…… E C-7
2
CRANKSHAFTP O SITIO NSENSOR1 ・( POS)EC ・65 Cir
cu
itDiagram・. ・..
.
.
.・ ・..
…
..
.・ ・
H ..
….
..
..
・ ・ .E
.
. C-72 H H H

ECMI nput
lOutputSignalSpeci
ficati
ons・..
. ..E
C・65 ComponentP a
rtsInspec
tion…… ・・ .
.
..
.
・ ・ ..
.EC・73 H H H

Ci
rcu
itDiagram・. ・ .
.…
..
.・ ・.
..
.
・ ・・・
H .
.
..
.
.・ ・ ..E
C・65 H H H H H PNPSWITCHSYSTEM. ・ ・-… ・・・・ -……. ...
EC・74 H H H H H

ComponentPartsI nsp
ection….
..
・ ・ -
冒
..
.
・ ・ … EC
.
. ・65 H H SSTD a
taM onit
orD is
play・. ・.
.
..
.
・ ・ .
.
.
.・ ・....
EC・74 H H H

CRANKSHAFTP O SITIO NSENSOR1 20・( REF) ECMI np

utlOutp
utS ig
nalSpeci
ficati
ons…… EC ・7
4
SIGNALC IRCUIT..・ ・ .
.
..
..
..
..
.
..
..
..
・ ・ -
山
H.
..
.・ ・....E
C・66 H H Cir
cu
itDiagram・. ・..
.
.
.・ ・.
.
..
.
・ ・
H ..
…… ・・ -… EC ・74 H H H H

ECMI nput
lOutputSignalSpeci
ficati
ons…… EC ・66 ComponentP a
rtsInspec
tion・. ・.
..
.
.
・ ・・・ ..EC・74 H H H H

Ci
rcu
itDiagram ・・ .
.
岡H… ・・ .
.
..
.
.・ ・・・
H .
...
...
...
.E
C・66 H H H H H STOPLAMPSWITCHSYSTEM. 山一目
...
.・ ・ … EC
.
. ・75 H

ComponentPartsI nsp
ection……..
..
..・ ・..…… EC・66 H SSTD a
taM onit
orD is
play・
..・ -
…..
.・ ・・・ ..
.EC・75 H H H H

MASSA IRFLOWSENSORSYSTEM. ..
….
..
.・. .E
C・67 ECMI np
utlOutp
utS ig
nalSpeci
ficati
ons・..
. .
.EC・75
 Ci
rcu
itDiagr a
m・.
. ・ ..
.
.・ ・ .
H.
….
..
.・ ・..
.
.
・ ・ .
.
.
・ ・ ..EC・75 H H H H PCVGASRESTORATIONDEVICE. .
..
・ ・ ..
...E
C・8
5 H

ComponentP a
rtsI ns pecti on.・ ・..
.
.
・ ・ .
.
.
・ ・ ..EC・75 H H H SystemDiagram… ..
.・ ・.
..
.
・ ・ .
.
・ ・ .
.
..
.
・ ・ ..……E C・8
5 H H H H

ELECTRICLOADSWITCHSYSTEM・ .・ .
.
.
・ ・ ..EC・76 a H RemovalandI ns
tall
ationofPCVV alve…… .EC・8 5
SSTD a
taM onit
orD ispl ay… .
..
・ ・ .
..
.
.
・ ・ ..
..
.・
'"E C-76 H H PCVV al
veI nspe
ction・.
. ・..
・ ・ .
.
… ・・ .
.
・ ・ .
..EC・8
5 H H H H H

ECMI np
utJOutp
utS ignalS pecific
ations…… EC・7 6 FUELCUTFUNCTION. ..
.一一
...
・ ・ ....
.・..
一一・…. .
EC・8
6 H

Ci
rcu
itDiagr a
m… .
..・ ・ .
.… ・・ ..
.…
..
.・ ・..
.
..
・ ・.E
H C-76 H H H H Ins
pec
tionProcedure…… ・・ ..
.
..
・ ・..
.
..
・ ・ .
..E
.
. C・86 H H H H

IGNI
TIONSYSTEM・ .. ・ .
.
.・ ・ ..
.
・ ・
H ..
..
..
.…
・ ・・ ..
....
EC・77 H H H H REMOVALANDI NSTA LLAT IONOFECM
SSTD a
taM onit
orD i spl ay. ・ ・ ..……… ・・ ...
.EC・77 H H H COMPONENTS・ . ・..
.
.
・ ・ .
..
..
.
.・ ・・・H .
.
.
.・ ・ .
....
...
.E
C・8
7 H H H H H

ECMI np
utJOutp
utS ignalS pecifi
cations…… EC・7 7 RemovalandI ns
tall
atio
no fECM. ・ ・・・ ..E
.
. C・8
7 H H H

Ci
rcu
itDiagr a
m… ..
.・ ・ .
.…..
..
..
.・
・ ・・・・ -…. EC・
H77 H H H H RemovalandI ns
tall
atio
no fC ranks
haftP ositi
on
ComponentP a
rtsI ns pecti on.・ ・・・ .
.
..
.
・ ・ .E
. C-77 H H H H Senso
r( In
tegr
atedI n
tot heDistr
ibut
or)..・ ・E
.
. C・8
7 H

FUELINJECTORSYSTEM. .
..
..
..
.
..
..
・ ・ .
.… ・・ ..EC・79 H H H RemovalandI ns
tall
atio
no fM assA i
rF low
SSTD a
taM onit
orD i spl ay. ・ ・..
….
..
・ ・ ..
..
..
..EC
. ・79 H H Senso
r… '
"・ ・.
..
.
.・ ・..
.
..
.
.・ ・
H .
.
..
.
.・ ・..
….
..
・ ・ ..
…・EHC・87 H H H

ECMI npuνOutp
utS ignalS pecifi
cations…… EC・7 9 RemovalandI ns
tall
atio
no fE ngineC oolant
Ci
rcu
itDiagr a
m. .
・ ・ ..…
...
・ ・ -
・・ ・・
H .
..
.
..
.
・ ・ ..EC・79 H H H H Temp
eratureS ensor.・ ・ .
..
..
..
..
.
.・ ・ .
.…
..
.・ ・ ..
EC・8
7 H H H

ComponentP a
rtsI ns pecti on.・ ・・・ .
.
..
.
・ ・ ..EC・79 H H H H RemovalandI ns
tall
atio
no fH eatedO xyge n
FUELPUMPSYSTEM. ..
.
..
・ ・ ..
.
..
.
・ ・ .
.
.
・ ・・・ .....
EC・80 H H H H H Senso
r( W
ithH eatedO xyg enS ensor
SSTD a
taM onit
orD i spl ay… .
..
・ ・ .
.
..
・ ・..
.
..
・ ・.E C-80 H H H Hea
ter)..
・ ・..
..
..
.
.・ ・
H ..
..
.
..
.・ ・.
..
.
・ ・ .
..
..
..
.
..
..
・ ・ .EC・8
8H H H H

ECMI np
utJOutp
utS ignalS pecifi
cations…… EC・8 0 RemovalandI ns
tall
atio
no fThrottl
eP ositio
n
Ci
rcu
itDiagr a
m.・ ・ ..
.
..
・ ・ ..
….
..
・ ・
H . ・・ .….
. .EC・80 H H H H Senso
r( E
lec
tricThrot
tleC ont
rolA ctuator
ComponentP a
rtsI ns pecti on・.
. ・・・ ..
.
..
.
・ ・ ..EC・80 H H H H Asse
mbly)… .
..
・ ・ ..
.
..
..
.
.・ ・..
.
.
・ ・ .
..
..
.
..
・ ・
H .
.
・ ・ .EC・8
8 H H H H

THROTTLECONTROLMOTORSYSTEM. ..
..
.EC ・8
1 RemovalandI ns
tall
atio
no fA c
celeratorP edal
ECMI np
utJOutp
utS ignalS pecific
ations…… E C
- 8
1 Pos
iti
onS en
so r
Ci
rcu
itDiagr a
m… ・・ .
..
.
.・ ・
H ..
.
..
・ ・ -… ・・
H .....
EC・8
1 H H H H (Ac
cel
erato
rP edalA ssembly). .
・ ・..
.
.
・ ・ -….E
. C・8
9 H H

ComponentP a
rtsI ns pecti on.・ ・..
.
.
・ ・ .
.
・ ・ ..EC・8
1 H H H RemovalandI ns
tall
ationofI n
takeAir
MILSYSTEM・ . ・・・
H .
.
H.
..
・ ・
H .
..
・・
・・ ・・ -一一…
・・・・
・・. .EC・82 H H H
Temp
eratureS ensor
ECMI np
utJOutp
utS ignalS pecifi
cations…… EC・8 2 (Wi
thM assAi
rF lowS ensor)..・ ・.
.・ ・.
..
.
・ ・ .EC・8
9 H H H

Ci
rcu
itDiagr a
m. .
..
..
...
.・ ・ .
...
.
..
..
..
・ ・ -… ・・ ...
.EC・82 H H H H RemovalandI ns
tall
atio
no fIgnit
ionC o
il
HEATEDOXYGENSENSORHEATER (In
teg
rate
dinD is
tribu
tor).・ ・・・ ..
…..
.・ ・..
..EC・8
9 H H H H

SYSTEM…一一....・ ・-一一一........・ ・・・

H ..
..
...
...
...
..
EC・83 H H M RemovalandI ns
tall
atio
n0 1F u
elI nje
ctor…. .
EC89 圃

SSTD a
taM onit
orD i spl ay・.. ・.
.
..
.
.・ ・..
.
.
.・ ・ .
..EC・83 H H H RemovalandI ns
tall
ationofF u
elPump. ..
・.EC
.
. ・8
9
ECMI np
utJOutp
utS ignalS pecific
ations・..
. ..EC・83 RemovalandI ns
tall
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ttleC o
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LPGASSISTANCEINJECTORSYSTEM…… . .EC・84 RemovalandI ns

tall
ationofLPGI njec
tor
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utJOutp
utS ignalS pecific
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1 H H H
 PRECAUTIONS

GeneralPrecautionsf
orServiceOperations
• Evenwheni gni
tio
nswit
chisOFF ，batteryvoltagemaydamage
thecont
rolun
i.
tTurnign
iti
onswit
chOFFandd isco
nnectbat
tery
ground cab
leb e
for
e removing and i n
stal
lingc o
ntro
lu n
it
harnes
s.

ECM0215

• Bec are
fulnottodamagec onnecto
rterminalswhenconnect
ing
andd isco
nnecting
.Checkt hetermin
alsf o
rbendo rbreakage
befo
r econne
cting.
• Check t hei np
utlout
putsig
nalo ft er
minalb e
forer e
placin
g
co
ntroluni.
tConfirmt h
att
ioper
atesnormal
ly.
RefertoECs e
ction，"ECMInput
lOutp
utS i
gnalSpec
ifi
cati
ons"
.

ECM0216

• Ensure th
ea pprop
riated is
tance between t
est probes when
usingac irc
uittest
er.A l ongerd ist
anceis recommended，
becausef
it h
ed i
stanceistooshort，t
imaycausec ontactofte
st
probes，r
esul
tin
ginas h
ortcirc
ui.
tAshortc i
rcu
ita l
lowsbatte
ry
volt
ageto bea ppl
iedd ir
ect
lytot hec o
ntr
olu nt，r
i es
ult
ingin
damaget oit
sinte
rnalpowertrans
isto
rs.

EC-3
 ENGINECONTROLSVSTEM

D
esc
rip
tio
n
• Adopts E le
ctroni
c C oncentrat
ed Engine C ontro
l System
(ECCS).F u
eli n
ject
ioncont
rol，ig
nit
ionti
mingcont
rol，id
lespeed
con
trol，andelect
roni
call
yc o
ntrol
ledgoverno
rcontro
le t
c.areal
l
performedbyas ingl
ec o
ntro
lu n.
t
i
• Adopts elec
trict h
rot
tlec o
ntrola c
tuato
r system t ocontr
ol
ele
ctron
ical
lycontro
lledgovern
or.
• Adopts Hal
lI Ct y
pec ranksh
aftp os
iti
on sensor (POS) and
camshaftposit
ionsensor(PHASE).

Item D
esc
rip
tio
n
E
le
ct
ri
cth
roW
eco
nt
ro
l • Adoptsele
ctro
nicthr
ott
lecontr
ola c
tuato
rw i
thintegra
tedthr
ott
lec
ontr
olmotort
oadjus
tthro
ttl
ev al
veopening
opt
imall
yaccordingtodri
vin
gc on
ditio
nso rtoimprovesaf
etyandope
rabi
lit
ybyele
ctr
onic
allycon
troll
edgover
nor
.
F
υeli
n挿c
ti
onc
on
tr
ol • WithSOFISc ont
rol，amountsofinj
ectedf
uelareoptimizedtoimproveexhaustperformanceandresponse.
• Usingfeedbackcontr
olthroughl
earni
ngofair
-fu
elratiocompensation，thesystemcorre
ctst h
er a
tiod
uring
tr
ansi
tio
nalconditi
ons，suchassuddensharpchangesi ntherato，i
i nordertoimprovedri
vab
ili
ty.
I
gn
it
io
nti
mi
ngc
on
tr
ol • UsesHallICc rank
shaftpositi
onsensor(POS)andcamshaftp osit
ionsensor(PHASE)t opeげ'or
mc on
trolssotha
t
optimumignit
iontimingi
sobtainedforeveryop e
ratin
gcond
iti
on.Optimumi gn
iti
ont i
min
gsetupaccordingtoeach
fu
elisalsoenableda tthetimeofacombinedusef ormu
la.
• Adoptselec
tronicdis
trib
utionsystem(NDIS)i nwhicheachcyli
nderi
sequippedw i
thani g
nit
ioncoi
li nc
orpo
rat
ing
apowert r
ansist
orforbette
ri gn
iti
onperformance.
I
dl
esp
ee 酒n
dc t
ro
l • Adoptse
lec
tro
nict
hro
ttl
eco
ntr
ola
ctu
ato
rth
atc
ont
inu
ous
lyr
egu
lat
esi
nta
kea
iramountr
equ
ire
dfo
rid
lin
g.
G
ove
rno
rs田e
dco
nt
ro
l • Performsmaximumr
egu
lat
iono
fenginespeedf
oro
ilpressurepumpp
rot
ect
io .
nbyenginespeedsignal
Max
imums
pee
dre
gul
ati
on • Performsmaximumspeedreg
ula
tio
nbyv eh
icl .
espeedsensorsignalAlso，pe同brmsvariablec
ont
rolo
fmaximum
c
on
tro
l
speedbychangeovers
witc
hasano pt
ion
.
I
dl
in
gar
eat
o悶u
eupc
on
tr
ol • PerformstorqueUpc
ont
roli
nid
lin
gareabyenginespeeds
ign
ali
nordert
oal
soenablecargoworka
tid
lin
g.
O
ver
hea
tpr
eve
nti
onc
on
tr
ol • Reducesengineheatg enera
tionbyreducingmaximumenginespeedandr eg
ula
tin
gmaximumthr
ott
leopening
whenenginec oolattemperaturereachesapproximately110・
n C(230・
F)
目

• Preventsresult
inginenginebreakagebyoverheatbyperformingf
uelcu
tat1，
000rpmormorewhenengine
coolanttemperaturereachesapproximately135・
C(275・ F)
.
S
low叩@剛旧 nmodec
on
tr
ol • Changest
hro
ttleopeningc
har
acter
ist
ico
fth
rot
tlep
osi
tio
nbyslowo
per
ati
onmodes
wit
ch，andthenminute
ope
rati
onofenginespeedisena
bled.
F
uelpumpco
nt
ro
l • Turnsf
uelpumpr
ela .
yON/OFFdependingonenginespeedsignal
(
gas
oli
ne)
LPGi
nt
er
ce
pt
io
nva
lvec
on
tr
ol • Turnsi
nte
rce
pti
onv
alv
ere
layON/OFFdependingonenginespeeds
ign
alandf
ue .
lpressuresensorsignal
F
ai
l.
sa
fef
unc
tio
n • Ensuresveh
icl
e'ssa
feopera
tionandenablesv e
hicletobed rive
ninanemergencywhenanyofthemajorsystem
components(massairf
lo ，enginecoolanttemperaturesensor，e
wsensor tc.
)havem
alf
unct
ion
e d
.
D
iag
nos
tics
yst
em • Adoptss
elf
-di
agn
osi
ssystemf
ore
asi
ert
rou
bled
iag
nos
is.

EC-4
 CANcommunication

ECM

E
lec
tri
cthro
ttl
econtr
olactua
tor
(
Thr
ott
leposit
ionsensor2systems)
(
wit
hthro
tll
econtr
olmotor
)
mZOEZmOOZ4

問。目印
Enginec ool
ant
temperaturesensor
F
uelpumpr
ela
y
ヨO ﹁ω︿

ω可一切件。ヨロ一白白﹃曲ヨ
↓ ω m冨

Pressurer
egu
lat
or

F
uel
Fu
elt
ank(
Gas
oli
ne)
肝l
Mu e
r Threewayc
ata
lys
t F
uelpump
(
gasol
ine)
non
-retu
rnty
pe

問。豆白旧 4白
 pedalp
ositi
on
sensor
(2systems)
Acceler
ator
workunit

M
ωdBS

Elect
ricth
rottl
econtr
ol
actuat
or

mOEO
(Th
rottlepos
it旧 nsensor2
systems)
(wi
ththrot
tlecontr
olmotor
)
ヨ OEe
mzo-zmOOZ420﹁ω︿

﹃曲﹃
ω↓m言
4d(00
コ神田a
)

mOZOM4 由
 w
ωm
可一g

m
ヨ

O
ロ
一

E吋
白

A
irc
lea
ner
mzo-zmooZ430﹁ω︿

F
uelpumpr
ela
y
ω↓同室

Pressurer
egu
lat
or
血 33(002白色)

M
uff
ler Threewayc
ata
lys
t

Fu
elt
ank(
Gas
oli
ne)
Fue
lpump
(
gasolin
e)
non-r
eturnt
ype

問。豆 DN
向。
 ENGINECONTROLSVSTEM

SensorsandA
ctu
ato
rsC
ont
rolI
tem
s
Mainsensorsanda
ctu
ato
rsr
ela
tedt
oth
eECMa
rel
ist
edb
elo
w.

Gasoline s
td s
td s
td s
td s
td s
td s
td o
pt C
omb
ine
d s
td s
td
F
uel
LPG s
td s
td s
td s
td s
td s
td o
pt C
omb
ine
d s
td s
td

C
ont
rolI
tem F
ueli
nje
cti
onc
ont
rol
8
ち
A
EC 8
ち
E 8
C
O 8
b
ち
Z 8
C
O 。
」
L
E
-
l
G
E
L
L
国B

E 。
U
O
E 8 a
. C
。 3
司
o
U H
』 Z
O E
E3
3 国
E 邑 邑
由
a
コ E 2 ω
。
Q)

= =
?
司
吉
U
3
c
c
U
0
由『
コ
L
L
由 =
2
0C コ
て
由
4
E
qn
z
Z
3
2 Z
U
由
〉
g
帽
z
c)
コ
志
L
t
コ
u
由. E
i
EL
コ
E
E
コ
話 ε
話
芸
き
喜
三
E
D:S
ign
ifi
can
timpactt
oco
ntr
ol コ
比
由

• :Impactt
oco
ntr
ol

••
Crankshaftp
osi
tinsensor(POS，
o REF) @ @ @ @ @ @ @ @

Massa
I
nta
k
i
ea
i
rf
lowsensor
rtemperaturesensor
@

••
@

• @

•• •
Enginec
ool
anttemperaturesensor
Heatedoxygensensor
@

@
• • •• ••
V
ehi
clespeedsensor
•• •• •• •• ••• •• ••
@

•••
••
T
hro
ttl
epo
sit
ionsensor

品
A
c
I
g
c
n
e
l
i
t
e
i
r
a
o
t
ns
o
rpedalp
w
itc
hIGN
osi
tio
nsensor
• • •
@ @ @ @ @ @ @ @

PNPs
wit
ch
Stoplamps
wit
ch • • • • • •
• •• • •
Headlamp(
ele
ctr
ica
llo
ad)s
wit
ch
Ba
抗er
yv
LPGf
u
LPGi
n
e
j
o
l

e
c
t

t
a
g

o
e
lpressuresensor
rdr
iveu
nitchecks
ign
al
•• @

• •
F
uelchangings
wit
ch @ @ @ @ @

Gasolinei
nje
cto
r @ @ @

I
gni
tio
nsystem Powert
I
gni
t
r
i
a
o
n
s
nc
i
o
i
s
t
l
or @

@ •
•• •
T
hro
ttl
eco
ntr
olmotorr
ela
y @

T
hro
ttl
eco
ntr
olmotor @

Gasolinef
uelpumpr
ela
y @ @

Gasolinef
I
gni
ti
ECMr
e
o
nr
la
y
e
la
u
y
elpump

@ @ @
@

@ @ @ @ @
•
@

LPGi
nje
cto
rdr
iveu
nit @ @ @

LPGi
n
LPGa
s
j
s
e
c
i
s
t
t
o
r
a
ncei
nje
cto
r
@

@
@

@
@

@ • •
LPGi
n
LPGi
n
t
t
e
r
e
r
c
c
e
p
e
p
t
t
i
o
i
o
nv
a
nv
a
l
l
v
er
v
e
e
lay @

@
@

• •

EC-8
BASICINSPECTION

Ins
pec
tionofI
dleSpeed，
Ign
iti
onTiming，
andAi
r-F
uelRati
o

STANDARDATIDLE
I
dlespeed[Np
osi
tio
n](rpm) 650:
t50

I
gni
tio
nti
min
g(BTDC/rpm) 10:
t2650
l

COden
sity(%) 00
.1orle
ss
HCd
ensit
y (
p恒m) 50orl
ess

CAUTION:
・ Perform"IdleAirVolumeLearning"(ECsection)whenidle
speedo
rig
nit
iontimingi
soutsidethes
tan
dar
d.

• Turnign
itio
ns wi
tchON， andthe nmakesurethatnomalf
unctio
n
i
sd etec
tedbys elf
-di
agnos
is.
• Makes uret h
atengineisf r
eeo foi
lpres
su r
epumpl oadsand
anyelec
tric
alloads.Per
f o
rmt h
ei ns
pec
tio
nw iththes
hif
tl e
veri
n
theNp os
itio
n.
• Warm Up engine and t rans似 l
et othe normal o pe
ratin
g
tempe
rature.

IDLESPEED

⑥ WITHSST
1. ConnectSSTtoveh
icl
es ided
atali
nkc
onn
ect
or.
2
. S ele
ct"ENGSPEED“i n"DATAMONITOR"mode.Makes
ure
th
attheid
lespeedi
s650:t50rpm
.
CAUTION:
• Perform"I
dleA i
rVolumeLearning"(ECs
ect
ion
)wheni
dle
speedisoutsidethes
tand
ard.

⑮ WITHOUTSST
1
. Connectana dapterharnessformoldedcoil
s(SST)between
thedi
str
ibu
torharnessconnecto
rs，andin
sta
llatac
home
ter.
2
. Makes u
rethatid
lespeedi s650:
t50rpm.
CAUTION:
・ Perform"IdleAirVolumeLearning"(ECsection)whenidle
speedi
soutsidethes
tan
dar
d.

CO/HCDENSITYINSPECTION
The vehicl
e uses an ai
r-f
uelratio feedback system wit
has el
f-
l e
arn
ingfunct
ion
.Becauseawidecompensationr angeisavail
able，
noa d
diti
onalCO/HCd ensit
ya dj
u s
tme ntisnecessar子
• Warmupenginet onormaloperatingtemperatur
e.Confirmi dl
e
speedandi gn
iti
ontimin
ga r
ew it
h inthestandard
s.Then，check
CO/HCd ensit
ywithaCO/HCmeasuringd evice.
• Checkc ond
itionofa i
r-f
uelrati
o feedbackw i
tht hef o
llowi
ng
step
swhenmeasuredv aluesareo utsid
et hestand
ard:

EC-9
 BASICINSPECTION

Ins
pectionofId
leSpeed，
Ign
iti
onTiming，
and
A
ir-FuelRati
o(Cont・
d)
⑥ WITHSST
*
ENGSPEED ∞
2 0 巾m 1
. Sele
ct"H02S1MNTR( B
1)"in"DATAMONITOR"mode.
HO但S1(B1
) O76V
第

*
REALTIMEDTC
目

NONE 2
. Keepenginespeeda
tapprox
imate
ly2，000rpm，andmakes
ure
E31:1・凶絹・品 I~回 ;n掴ーーーーーーーーーーーーーーー圃:r，1~_
th
at"RICH"and"LEAN"arealt
ern
ate
lydisp
lay
ed.

S
ave H
old

⑮ WITHOUTSST
1
. Insp
ectusingheatedoxygensensorm o
nitormode. (
Refe
rto
EC s e
ction， "DIAGNOSTIC TEST MODE 1 ? HEATED
OXYGENSENSORMONITOR f o
ro
目 p
er a
tio
np ro
cedu
re.)
2
. Keepenginespeedatappro
ximatey2，
l 000rpm，andmakes ur
e
th
atMILblink
sa tle
ast5timesw
ithin10seconds.
NOTE:
• Increase engine speed when i
nsp
ectin
gwh
ilea
ir-
fue
lra
tio
feedbackcontroli
sa c
tiv
ateddu
ringi
dle
.

INSPECTIONANDADJUSTMENTOFIGNITIONTIMING
Connectat im
inglig
ht(su
pertun
er，et
c.)tor
eceiv
eas ig
nalfrom
thei g
nit
ionp rima
ry system us
ing an adap
ter harness f
or
moldedcoil
s( SS
T).
(At
tachp ic
kupt othe1h igh
-tens
ionc a
bleforgene
ralt i
ming
li
ght
s.)

⑥・ P
erf
orm"AACV
alv
eAd
jus
tme
nt"i
nWORKSUPPORTmode.

⑧・ Remov
陥 四l
eh陥arn
鰯e
s
路s∞
c
馴
。町
∞n附
n
1
鴎e
即ct
o
。
町rr
fm
附m
加 r
n
川
打

(Theoper'
，
悶at
ionabove針
stopsi
d
同l
陥espeedandi
gni
tio
nt i
mingfeedback
c
。n
∞ 削
川t
r1
o.)
)
• Makes uretha
tign
iti
ontimi
ngandbasei
dlespeedisBTDC100
:
t2/650rpm.
0

EC-10
BASICINSPECTION

Ins
pecti
ono fI
dleSpeed，
Ign
iti
onTiming，
and
A
ir-Fu
elR a
tio(Cont
'd)
• Perfor
madjustme
ntf o
llow
ingth
ep ro
ceduresdescri
bedbelowf
i
ig
nit
ionti
mingisout
sidethest
andar
d.
• Loosendist
rib
uto
rb ol
ts，androta
tet hedi
str
ibut
orsot h
att h
e
ig
nit
ionti
mingmeetsBTDC10・ z2・/650rp
m.
• Clockw
iser ot
ati
ono ft hedis
tri
buto
r advances theigni
tio
n
ti
ming
.
⑥・ C
anc
el"AACV
alv
eAd
jus
tme
nt"i
nWORKSUPPORTmode.
⑮・ Connectt
h訓 l
epo
sit
ions
ens
orharnessc
onn
ect
or.

• Makesu
reth
atign
iti
ont
imi
ngadvancess
ync
hro
nou
slywhen
ra
cin
gth
een
gine
.

T
hrot
tleValveClosedP o
sit
ionLearningand
I
dleAirVolumeLearning
DESCRIPTION
Whene le
ctri
cthrot
tlecon
trolactuatororECMc onn
ectorisremoved，
t
iisnecessaryforECMt ol ea
rnt h
rot
tlevalveclos
edp os
itio
n( t
hro杭l
e
po
sitio
ns ensoro utputw itht hro
ttlev alv
ef ull
yc lo
sed)a fter
re
inst
all
ati
on. Thus，t h
rot
tlev alvec l
osedp osit
ionl e
arnin
gi s
pe斤or
' med.
When e l
ect
rict hr
ott
lec on
trola ctuat
oro r ECM i sr epl
aced，t h
e
minimumr eq
uiredidleai
rvolumeneedst obel ea
rned.Thus，thr
ottl
e
va
lvec losedp o
sitionl e
arning and idl
ea irvolume l e
arnin
ga r
e
perfo
rmed.
Id
lea i
rvolume l earni
ngi s necessary even when idl
e speed o r
ig
niti
ont i
mingiso utsid
et hes tandar
d. Notet ha
ti dl
ea i
rvolume
lea
rningise q
uivalentt ot he base i d
le speed a dju
stment by
conv
ention
alt h
rott
leadjust
ingscrewo fcarbure
tororLPGm ix
er.

OPERATIONPROCEDUREFORTHROTTLEVALVE
CLOSEDPOSITIONLEARNING
1
. Turnign
iti
onswithON→ OFF
c .(Andho
ldt
iforapp
roxi
mat
ely5
secondsafte
rturn
in iOFF
gt .)
2
. Makes uret ha
tthro
ttl
ev a
lveo p
era
tes
. (Checkfo
roper
ati
ng
sound
.)
3
. Uponc omp
letionofabove，l
earn
ingi
scomp
lete.
CAUTION:
• Thro
ttle valv
e closed p
osi
tio
n l
ear
nin
g cannot be
performedw
ithSST.

EC-11
 BASICINSPECTION

T
hrot
tleValveClosedP o
sit
ionLearningand
I
dleAirVolumeLearning(Con
t'd
)
OPERATIONPROCEDUREFORIDLEAIRVOLUME
LEARNING
1
. Perf
ormthrot
tlevalv
ec l
osedpositionlea
rnin
g.
2
. Fu
lly warm up e ng
ine and t r
ansa
xle. [Engin
e co
ola
nt
te
mperatu
re:70・990C( 158・ 194F
0
)
]
3
. Makes uret h
ate ngin
ei sfreeo fo i
lp re
ssurel o
adandany
el
ectri
calloa
dsw i
ththeshi
ftleverintheNp os
itio
n.
4
. Execut
et hefoll
owin
gcontent
sw hileidli
ngusingSST.
1
) Touch"START"on" I
DLEAIRVOLLEARN(NORMAL)"i n
WORKSUPPORT.
￨
IDL
EARVOLLEARNCLRI
I
IDL
EA IRVOLLEARNWIL
LBE CAUTION:
CLEAREDBYPRESSING'YE
S'
• "IOLEAIRVOLLEARN(PLANη"i
stheo
rig
ina
lse
tti
ngon
7
13r
pm theve
hicl
e.00n
o t
.
tusei

P
ri
nt F
2 言 [F4

2
) Whenl
ear
nin
giscompleted，
"CMPL
T"i
sdi
spl
aye
d.
￨
IDL
EARVOLLEARNCLRI
I CAUTION:
I
DLEA
IRVOLLEARNC 孔EAR • I
twilltakeapproximately20secondst
ocompleteth
ei dl
e
COMPLETED
P問 s ・
s YES'・ ai
rvolumel e
arning.00nott urnOFFtheigni
tio
ns wi
tch
mg
ME

R屯
nuM川

unt
ilcom
pl e
tion.
M刊n
﹁tilll111Illli---

n
FE
u
u

7
03巾m

3
) Make s uret ha
tt hel ear
ning has been c
omplete
d by
checkingthe" I
DLA NLEARN"s creeninDATAMONITOR
mode.
P
ri
nt F
2 3._~
F F
4 Learningcompleted :CMPLT
Learningnoty etcompleted:YET
4
) Makes uret h
atidl
espeedandi gnit
iont
imi
ngarewi
thint
he
sta
n d
ard.
5
) Perform" ld
leAirVolume L ear
ning"againf
iv a
luesare
out
s i
det hestan
dard.

ACCELERATORPEDALRELEASEDPOSITION
LEARNING

OESCRIPTION
Whent h
ea cc
eler
atorp e
dalassemblyhas been re
place
do rth e
ac
cele
rat
orpedalpos
itio
ns enso
rc on
necto
rhasbeendiscon
nected，
th
ea c
cel
erat
orp e
dalr elea
sedp o
siti
onneedstobel e
arnedaft
e r
bei
ngrepa
ire
d，solearnaccel
erato
rp ed
alinf
ull
y-r
ele
ase
dp o
sit
ion
.

OPERATIONPROCEOURE
1
) T urni
gni
tio
ns w
itchONandwa
itatle
ast2s e
conds.
2) Turni
gni
tio
ns w
itchOFFandw
aitatl
east10s e
conds.
3) Thenturnig
nit
ionswit
chONaga
inandw a
itatl e
ast2seconds
(Ie
arn
ingcomp
leted)
.

EC-12
BASICINSPECTION

F
uelPressureI
nsp
ect
ion
QUICKINSPECTION
⑧ WITHSST
1
. Tur
ni gn
iti
onswit
chON( engi
nestopp
ed)
.
2
. Press "ON" o
r "ON/OFF" o
f "FUEL PUMP RELAY" on t
he
ACTIVETESTs cre
en.
3
. Pinchthefu
elfeedhosewi
thfin
ger
s.Hosesh
ouldfee
lhardand
pu
lsati
ng.

⑮ WITHOUTSST
• When thef u
elf eed hose i
s squeezed whi
lef u
el pump i
s
op
erati
ng(immedi
atelya f
tert
hei g
nit
ionswi
tchisturnedONor
wh
ilecrank
ing)，thehoses houl
dbes we
lli
ngw i
thp r
essu
reor
pu
lsa
ting
.

FUELPRESSURERELEASE
CAUTION:
• Relie
vefu
elpressureb
efo
reremovingf
uelp
ipi
ngt
osecure
saf
ety.

⑥ WITHSST
1. St
arteng
ine.
2
. S el
ect"FUELPRESSURERELEASE，andtouc
h"START"in
WORKSUPPORT.
3
. Cranke ngine2or3ti
mest
oconsumet
hef
ueli
nth
efuelli
ne
a
ftert
ist
all
s.
4
. T ur
nigni
tionsw
ithOFF
c .

⑮ WITHOUTSST
1. Dis
connec
tf u
elpumpf us
e.
2
. Starten
gine.
3
. Cranke ngine2o r3timestoconsumethef
ueli
nthef
uelli
ne
a
fte
rtis
tal
ls.
4
. TurnOFFt hei g
nit
ions
witch，
andins
ta
llt
hefu
elpumpfu
se.

FUELPRESSUREINSPECTION
CAUTION:
• Safe
lyands ecurelyremoveandi ns
tal
lf u
elhoser eferr
ing
to(?
?)
， "RemovalandI nstal
lati
on"
.
• Uset hef
uelpressuregaugef orfu
elpressurei ns
pecti
on.
• 00 not inspect f
uel pressure w
hileo ther systems are
oper
ating
.Malfunctionsmayoccuri nf u
elpressurevalue.

EC-13
BASICINSPECTION

F
uelPressureI
nsp
ect
ion(
Con
t'd
)
1
. Releasethefu
elpre
ssu
re.
2
. In
sta
llfuelpress
uregaugeusi
ngf u
elhosefo
rfuelp
res
sur
e
ins
pecti
on.
3
. Removef ulhose，
e andtheni
ns
tal
lfuelhosef
orf
uelp
res
sure
ins
pecti
on.
CAUTION:
・ Usableperiodoffuelhoseforfuelpressureinspectionis
30timesorl es
s.(Fue
lhosest hataredamagedanda
llo
w
fu
elleakagearenotcontaineda
bove.)

4
. Tu
rnignit
ionswit
chON， andthenmakes u
retha
tther
eisnof
uel
le
akag
e.
5
. St
artengine，andcheckfo
rfue
ll e
akage
.
6
. Makesuret h
atfue
lpressurei
swith
inthesta
ndard
.
Atid
l e:
353kPa( 3.5
3bar，3.6kglcm2，51ps
i)

• I
fthevehic
leshowsp oorstar
tig，checkf
n ue
lp res
surewit
hf u
el
pumpo pe
ratingf
orapprox
imately1secondafterig
nit
ionswi
tch
i
sturnedON，andd uri
ngc r
ankin
g.
For1seconda f
terignit
ionswitchisturnedONand
duringc r
anking
:
353kPa( 3.
53bar，3.6kglcm2，51psi)

• Checkt
hef
oll
owi
ngi
tem
sfiam
alf
unc
tio
nisd
ete
cte
d.
CAUTION:
• Alsocheckf uelpressureatincreasedenginesp鵠 d
.
• Malf
unctio
ningp ress
urer egu
lator(inte
gra
tedwithf
uel
pump)
・ Cloggedfue
lpiping
• Cloggedfue
lfil
te
r
• Poorfue
lpumpd i
scharg
e

EC-14
 TROUBLEDIAGNOSIS

Howt
oProceedwithTroubleDiagnosis
1
. The most i m
portantpointinp erf
ormingtroublediagnosisof
Sensor C
/U malfun
ctionsistot horo
ughlyu nderst
andt hevehic
lesystems
(bot
hc on
trolandm ech
anical).
AnECM-basede n
ginec o
ntrol
sa ctu
atorssuchasi nje
ctor
sand
theignit
ioncoilaccordin
gt oi nf
ormati
onf romsensors.Then
througha c
tuatoroperat
ion，t hee n
gine( mechani
cals ystem)
run
s. Sensorst rans
miti nf
ormat
ion ont her u
nningc on
ditin，
o
whichchangesc onst
antl，
ytoECM.I tisimpo
rtanttou n
derstand
thesecycle
s.

ECM0233

2
. I
tisalsoimp
ortan
tt oc
lar
ifycustomerconcernsb efo
r esta
rtin
g
thei n
spe
cti
on.F ir
sto fall，r ep
roducet he symptom，and
unders
tandi
tful
ly
.Askt hecustomera bouth i
s/hercomplain
ts
ca
ref
ull
y.In some cases，t
iw il
l be necessaryt o checkthe
symptomsbydriv
ingtheve
hi c
lewiththecustomer
.
CAUTION:
• Customersarenotprofes
sio
nal
s.00notassume"maybe
the customer means "or "maybe the customer
mentionedth
issymptom".

ECM0234

3
. t
Iise s
se n
tialtoc onfirmsymptomsr igh
tf romt hebeginningin
ordert
oensurea l
lm al
f unc
tionsarec omplete
l yrepai
red.
Forani ntermi
tten
tm alfunctin，
o t
iisi m
portanttor eproducethe
symptom basedonan i nter
vieww i
tht hecustomerandp ast
examples. Don otp erformani nsp
ectiononanadhocb as
is.
Mosti n
t e
rmitte
ntm alf
u n
c t
ionsa recausedbypoorc on
tacts.In
th
iscase，tiw i
llbee ffec
tivetoshaket hesuspectedharnesso r
connectorbyh and.When r epa
irsa repe斤 ormedw
' it
houtany
symptom check，no one can j udgeift hem alfunctio
n has
act
uall
ybeene limin
ated.
ECM0235
4
. Then exti mportantthingist of i
ndwhichsystemamongt he
fo
llowi
ngi sc ausingt hem a
lfuncti
on: ECCS c ontro
ls ig
nal
system， o
ram ech
an i
ca lsystem( suchast hee n
gi n
emainbody
anda u
xiliarycomponent).Itisi mportanttoinspectthesystem
usingSSTo rbyc heckingtheECMi nputlou
tputsignal
s.
Whenc heckingtheECMi nputl
outputsigna
ls，connectacheck
adapte
r(SST)t oECMi no rd
ertop reventmisdiagn
osis.
Spec
i alServiceTools( SST):
CheckadapterV(N-EG175・ 30000)
(fo
rSMJ150 p
・ inconnector)
Harnessadapter(N-EG175 ・50200)
(150・pin→ 1 21・pinconversionada 同er)

EC-15
 TROUBLEDIAGNOSIS

Howt
oProceedw
ithTroubleDiagnosis(
Con
t1d
)
5
. Uset
her
e1e
ren
cev
alu
e01i
npu
Vou
tpu
tda
ta(
gui
del
ine
)int
his
manualino rd
ertojudgetheECMi np
uV ou
tpu
tsigna
ls.Measure
thedata01a not
hervehic
le0 1thesamemodelundert hesame
cond
itionswhentiisdif
fic
ulttojud
ge， andcomparethedata
.It
i
sa dvisa
b l
et ocol
lectsuff
icie
ntdata0 1a norm
allyopera
ting
ve
hicle
.

TROUBLEDIAGNOSISFLOWCHART
There are many di
ffer
entm al1u
nction symptoms. 50t he
rei s no
per
fectt r
oubledi
agnosist echniqueapplica
bletoallm a
l1unc
tions.
Experienceisa ls
oi mport
antt oa chi
e vin
g an accuratet ro
uble
diag
nosis.
Nonetheless，anaccuratet ro
ubled i
agnosiscan beperformedby
apply
ings i
milrprocedures，
a regar
dless01t h
em al
1unct
ionsymptom.
Performtroub
lediagno
sis10l1
0wingt h
e11 0wcha
rtshownb elow.

Useth
ediag
nosissheet
Noma
lfun
ctionsymptoms
M
alf
unc
tio
nsymptoms
Symptomcheck

T
CONFIRMAlONOFDRIVINGCONDITION
BYFREEZEFRAMEDATA
-EEd
R-

RT
nr-

nr-
町一

凶一
角-

FE-
Z﹂ -

E﹂ -
FUE

N
ote
:Repairmal
func
tio
ningp
art
s
foundd
urin
ginsp
ec旧n
t

SELF-DIAGNOSIS
• BASICINSPECTION :
(Er
aset
heself
-di
agn
osti
cres
ult
s.)
:
・・・ーーーーー-~ -・ーーーーーーー」
• Ins
pec
tionofi d
lespeed，ig
nit
iont
iming，andai
r.
同 fu
elra
tio ーーーーーーーーー _c_ーーーーーーーー-
• CheckinpuUoutputs
igna
l(Datamonitororcheckthevol
tag
e.) EXPLAINCUSTOMER
: REPAIR
- lREPLACEPROCESS.
-----------ー・司ーー・ー--"

ECM0237

EC-16
 TROUBLEDIAGNOSIS

Howt
oProceedw
ithTroubleDiagnosis(
Con
t'd
)
DIAGNOSTICWORKSHEET
DESCRIPTION
• Inordertocla
rif
yt hemal
functinsymptom，
o i
tisim
p or
tanttoask
Questionp
oin
t
thecustomerandc oll
ectinfo
rmati
onaboutthei
rconcerns.
• WHAT.
....
....
..V
ehi
cle&e
ngi
nemodel Askt h
ecustomeraboutwhatsymptomsa representunderwhat
.WHEN. ・・
・・・
・ ・
・・・ D
・ ate，F陪 q
uen
cle
s
cond
ition
s.Uset h
ei n
forma
tiontocla
rif
ythesymptom.
Uset het r
oublediagnos
issheett obec e
rtai
nn ottomissany
.WHERE.・・・・・・・・・・・ ・
・・ Roadc
・ ond
iti
ons
vi
ta
li nfo
rmati
on.
E

• HOW.
...O
per
ati
ngc
on
di
ti
on
s，W
eat
herc
on
di
ti
on
s
• WHATBECAME...
....
.. ..
.. ・ Symptom

ECM0238

EC-17
 TROUBLEDIAGNOSIS

Howt
oProceedw
ithTroubleDiagnosis(
Con
t1d
)
T
rou
bleDiagnosisI
nfo
rma
tio
nMemo

T
rou
bleD
iag
nos
isI
nfo
rma
tio
nMemo
Memos
eri
alNo
I Date 陶 i

I
ssu
eofmemo

L
oca
tio
n:
Dateo
foccurrence Weather:
JO
per
ato
r:

V
ehi
clet
ype Modelc
lass T
rav
ellim
e No.stamped
Enginet
ype F
uel T
ran
smi
ssI
on Heater 国I
OBp
pa
uc
mH
yp(
cc) /VC
V
ehi
clemodel Type 1
1・
0岡崎ecode)VehicleIDNc Modelyear
(
hr.
) onenglne
‘・~ Gasoline :~M/T に~ Yes ~:~Yes
コ
l LPG
( geaの

ー
J‘ P
r耐r opa ne j
- :
;A
lT :::NO ::iNo
，
-
ー'Fsuupepliler
.~ Combineduse
:

TC
rD
onu
db
lt
ll
on
ed1
Iat
eg
nm
OSIS Desαription(Entera checkmark，
value，
orcommentinthedashedorsolid-lineboxlortheapplicableitem.)
「
ー
-， ー ， 句
・ー
， 咽 剛ーー
':
.ー 「
ー.
・
_)~ Poorstarting a
F-e crankingn
otpos
sib le Ea
.-
bINoin
iti
a
lcombusl Doesn
ots
tar
tsm
oot
hly
. .t
i!~ Doesnotstarta
tal
l
，
.
-
.._ I噌岨
司
ー
討 Pooridle ，
圃
a咽・~ Doesn ots
tar
tatal l.・~ lI n
con
sisle
nt r
'-
c H
unt
ing(
ste
adyspeed1
fu
ctu
atl
on)

ー 目前
主 Engines t a l l 4
sas
1yJ
1
m5p
to日官
m4e
s
t2
n
u7
9
r
nn
凶e
e ，
sF
-‘
c・
-4
J日a
ll
sbu
tre
sta出 隠 q
uic
kly
.;:
f
!
<
_ JOccurswhens
tee
rin
g ・
. r・
ee3
l
o'
1
a;
d
1t
m
rg.
s四 .‘
rγlOCCU目 a
ftr∞I
e dst副

Zpoorpoweroutput 「
，
-
-ー
a・
}Poorhill-clir耐 nga
bi
l r・・・b・・司~ Insuffic剛 tspeed
町 t C~ 噌} Loadingn
otp
oss
ibl
e C
ー~ Loading
・
‘
・
d 蜘 W，
di
ff
ic
ul
ttoope悶 t
e

・
・J
「
・
，・ Inappr叩 riateliftingspeedduringlifting∞ntrol ，
'
.ー
，
.JGovemorhunting
f

_
J5~ Poor即 時 l
era
tio
n 「

& Hesitation
ー
ラ:Surge(vibrationi
nfi
Nd
and臥Nddげ'
ect
ion
)
〉
Symptom :~ 刷 oc
制ng(問g
ln 叫
gsoun

9
08ack筒r
e(blowbackn
ois
e)

1 0A
fte凶 u
r日(
exh
aus
tde
ton
ati
on)

13 P町向陥刷
e
剖1∞
e削n
叩omy 1..
.，.
...
，
叩
…
ω…
.…
.
叩
…
.
…
.
…
.
.一
…
ω…
何
伽
..
ω
叫_
.
.4;仏仰PG h
r.1t叩
.
』
F.
'1
.ー
.
2，
.Poor
011e∞nomy ‘・・
・.
...
".
..
"
・ (hr.ん) j
13i Overheat 印
r・-・・~ J
刷 o
toverh
eat
ed，b
ute nginec
ool
anttem開 r
atu
regaugeind
ica
tesh
ig.・
h 司
酔
[TJ
司
l印 刷he副 ed

14j白 0

]~j
1酬凶l

N
oi
e

s
e
ak
age L
o

L
o
c

c
a
t

a
t
i

i
o
n

o
n
・f::~-“a・"・"・・・・・・"""・""m “ .一 “ ・
・駒
田・
・・
..
..
..
・"
・・mN
・ .
.
.
. ・・州・a
・m・
“
-
・・"
則
胸"
“・
.・“
・ .
..
..
.m ・
.
“
山 間 閉
山
田

r-'
J.
!
i!
山畑rninglampi
Iumination '
自， No i ‘
a"bJY目

ー r・
ー
， 「
i目
圃a。
Firstoccurrence 1，
削thnewvehicle i 2.Re
叩 n
tl x
yAppro.date Aterbroughtbackf
ors
efV
1Cl
ngApprox.date

O
Fcr
ecq
uur
ree
nnc
ce
yof ・
圃
]JAta
l
lti
mes 圃
，-z
-
4，
aUnderc
e「t
ain
eon
dit
lDf
1S・
r
E--
-3
-， Sometimes
-
a

ー
J;J
JT
(a
em
由p
9e
Cr
a)
tu
re
;i f
L.
.f
呂J
!(
H
弘u)
mαt
y1

「
ー
， Cold ー司¥
N h
en r-~
Temperature
condition
再_~! Co
∞
01an
陥 川t
t旬emp '
:.
._ e
J 叩問 酔
一
.
し
」
自JJt
e
sW
町 g
lJ
a
J
陪門e
「m
円1
1し
L
n
m-Jト
H
均1
喧引
g
引 印∞
刷hc
耐 00
1a
訓n
旧川ttem
叫

.
-22
J!
Ete
nmg
MpecompaHmeni
z
i 、
i
a--am"""""i-
un ngup

-
， r-，
_]l
lrr
e'e
van
t ~ー 2
・ 1A
tid
le 「
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EC-18
 TROUBLEDIAGNOSIS

DiagnosisChartbySymptom
TB45ENGINERELATIONSHIPBETWEENMALFUNCTIONING
SYMPTOMSANDTHESENSORCIRCUIT

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EC-19
 TROUBLEDIAGNOSIS

1m・ ・
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EC-20
 TROUBLEDIAGNOSIS

DiagnosisChartbySymptom(
Con
t'd
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TB45ENGINE RELATIONSHIPSBETWEENMALFUNCTIONING
SYMPTOMSANDACTUATORCIRCUITS
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EC-21
 TROUBLEDIAGNOSIS

Ir
rト 1m・
Symptoms
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LPGi
nje
cto
r H
Is id
e OPEN
c
irc
uit
SHORT

C
oil OPEN

LOside OPEN
ci
rcu
it
SHORT

LPGa
ssi
sta
n i
n四
je
cto
r OPEN

C
ontr
oluni
t
s
idesho
同

LPGi
nte四
， 四
r p
tio
n I
ve聞 l
ay OPEN

C
ontr
oluni
t
s
idesho
rt

LPGi
nte
rce
pti
on咽 I
ve OPEN

MIL OPEN

ImproperTASl
ear
nin
g
• -
・
・

EC-22
 TROUBLEDIAGNOSIS

DiagnosisChartbySymptom(
Con
t'd
)
TB45ENGINE RELATIONSHIPBETWEENMALFUNCTIONING
SYMPTOMANDTHEENGINEMAINBODY/AUXILIARY
COMPONENT
Whent het h
reeelementso fcombustion，compressionp ressure， f
uel
mixt
ure，ands parkingareallnormal，nom alfu
nctionsa recausedi n
thegas
oline-typeengine.
TheECMc ontro
lst hefue
lm ixtu
reands parking(ig
nitio
nt imi
ng).But
wi
thm alf
unctions ont hep ar
to fenginemainbOdy ，malfunctioning
symptomsr esu
l.
t
The tab
le below shows t hep os
sible symptoms caused by t he
malf
unctiono f engine main body s ystem.Itw i
ll be h elpfuli n
malf
unctiontrou
bled ia
gnosis
.(Thet ableli
st
sg en
eralsymptomsand
somemayn otbea ppli
cable
.)

1m・ 1m.
pOS
SI. possト
Symptoms Poori
dle Poord
riv
ingc
ont
rol Engines
ta
ll Ot
her
bleto bleto
s回目 s
tart

E，B
g
. EE コ
ZL
E @
壱
。
E 。 豆
E 宮
ロ
』

3
@
壬
@ 壱Q) E 司

ε
き E
@ ‘
E 〈
詰
aB
U
E
j
盟 壱 盟 EB E
〈 d

E
l 。~
E
E
旨 旦
・
τ
ω
U3
E E急
宝 きE
F
@
3
3

e ω 壱ω P"
'
盟 D
esc
rip
tio
n/n
otab
lech
ara
cte
ris
tic
s01
ec
g 有 =
EE E
宕

。
s
E
o
z e
g
E
志
ロ
コ
EC
2
B th
esymptom
E
』

B
c E
さ 主 E
Z
C
書 z
百 L
E
ω
コ
ω
百
t L
コ
τ
-3

主 8
S ロ
c
c
コm 』 E
全
E &
言

，a
Mainun
itsymptom
e:Highlypossible U
E
@
ロ
ZJ
.:Possibl
e
V:Notveryp ossib
le

F
uel A
irsuckedIromo
ill
ev副 gauge .
.
，
• 1V v v v Ai
r-Iue
lrati ∞
obe mesLEAN.
m
ixt
ure
A
irsuckedIromo
ilI
il
le
rcap .IV.
.
， v 守 v
Higha
Lows
inta
k
i
u
em
r
c
-
I
t
a
n
u
i
i
e
o
l
lc

ol
o

d
r

.
re
c
npower(
tin旭c
o to
仁
咽cuumpres剖 陪 )0
1

Ai
rsuckedIromPCVhose
(downstream0
1PCV
) .IV .
，
.・- • 1• .1V 1V .
，
. • v
Useapressuregauget
Gene
in
t ak
悶
es
lI
y
ya
st
e
pp
昨1
li
cablet
ocheckI
oairs
ucti
h
o
es
ni
u
c
na
i
t
r
io
n

AirsuckedIromi
gasket
nta
kem
ani
lol
dand
.IV
・-.
.IV .
， .IVIV .
，
. • v

PCVk
eptopen
• .1V.
.
，..
， ..
，Noise(highhissingtone)
Cloggedl
uels
tra
ine
r .1V .
.
，.
.IV .
， • 1. 1. VI.
• • Symptomdependsonc l
oggin
gs tatu
s

Cloggeda
irc
lea
nerelement .
，
.-・
・ •
Thistendst
highloado
ohappend
p
era
tion
uringhigh-speedo
r

M
a
r
e
l
g
l
u
l
u
n
a
c
t
t
o
r
io
nin
gga
sol
inep珂 s
sur
e
VI. .
，
. .
，
..，
.-・
・ .
，
...
， • Symptomv
P惜 s
sur
e.
a
rie
sdependingoncombustion

Poorq
ual
ityg
aso
lin
e VI. .
.
， .
，
..，
..，
. .IV .
.
，..
， v • Symptomv
ari
esdependingono
ilq
ual
ity
.

ImproperLPGl
propane阻 l
io
)
u
el(
col
dareaand
@ • 1• .
，
..，
..，
. • 1V .
.
，..
， • Sta
rtinga

• UseLPGw
b
il

i
i
t

l
ya

hp
tc

ro
o

p
l

e
dareai
dependingonpropane問 t
lO
.
schanged

rpropane阻む 0

Malfunct
ion
ingLPGvap
ori
zer • Illhepre田 urei
slow ，i
tiscause司bypoor
pressuread
jus
tin
gva
lve
v • I• I• .
.
，.，
.-・
・ -.
・ .
， o
o
• 1
u
p
It
t
e
r
h
p
a
u
t
td
io
u
n
r
.
inghigh-speedorh

epressureise xcessi
vel
i

yh
g

i
hl

g
o

h，
a

r
e
d

li
el
valveoperatesandengines t
all
sa trl
ch

.
.
， .
CloggedLPGv
apo
riz
erh
otwater • Symptomdependsonl uelte
mperature
.
.
，.， .
，
...
，
•
ci
rcu
it Thistendstohappendur
ingenginesta
ll
• 1. andisi mp
ossi
bletore
star
tduringengine
warmlngup

CloggedLPGi
nte
rce
pti
onv
al四 l
il
te
r
.IV .
.
，・-.
.
，.，
..
， • V 1.
• Symptomdependsonc
T
h
h
i
i
stendst
g
hloado
ohappend
p
erat
ion.
u
r
l
i
o
g
n
gin
gs ta
tus.
ghigh-speedo
r

Valved
epo
sit
.
.
， 守
・-.
.
，..
，
v.
，..
，..
， v
• Them al

vacuum)
lun
ct
high-speedo
io
ntends1
rhig
hloa
0happendu
dope国lin(
o
同ng
ow
l

EC-23
 TROUBLEDIAGNOSIS

Im
- 1f
T
ト

Symptoms
p
ossi・possト Pooridle 向
。 rdrivingcontrol E
ngi
nes
tal
l Other
ble
to bleto
s回同 s
tart

S
号 室 iE 号
言 t
g
3
害
i
豊E
m O
EE

言3
E
i
i
E
町
盟 旦
豆 豆
虫 盟
回
何

を
<
e 2
E Ez
雪 ・
E芸 伺R

4
zp き
園

22 3 ，. D
esc
rip
tio
川、ote
blecha阻 c
ter
ist
ics0
1
，盟盟
E
豊 E
雲 ~
宮
a
Ea
E t
hesymptom

2 τョ
旦 c
芭 島
君
EE
重 豊 E
S
EωE
2L

E
M副 nu
E
9: H
i
n
g
i
h
tsymptom
lypos
sib
le cm
L@
C
EU
E
E
P
+ :Pos
sibl
e
V :Notveryp
oss
ibl
e

Spark- Improperhigh
-te
nsi
oncord @
・ Checkt
hei
gni
tin
gs岡 田n
ce.
ing connection E
91E
9 6)16) E
916
l 6)16
) @ )16
6 l 6
l16
l @

+ +，
， ， +，
Improperi
gni
tio
nti
min
gadjustment
・
- + + + + + + 1+ +IV +
，+ 一
.
，
MaKunctioningsparkp
lug

∞
同
+ + +1+ + 1• + 1•
• v VIV
• Checkt
fo
rsoi
l(
h
a
s
tt
mo
k
h
i
egapi
ng)
spr
ope
r.Checkp
lug

Leakagelromh
igh
-te
nsi
on
V 1+ + + ， .
，+ +，
+ +，
+
• + ，
.
• • • • Symptomv
leakage
a
rie
sdependingont
he胤 刷 0
1

Leakagelromd
i

Looseoropen0
connection
st
rib
uto
rcap

1primary刷 r
e
VI+ +
，+ +
，+ +，
+ + ，
.
• + ，
+
• • •
・ Improperbulbcontact
•
Com • Symptomvar
iesdependingoncon
t a
c t
pre・
s l1E
V 1+ 6 9 E
916
l l 6)1E
6)16 9 @ + 1• + 1+ co
ndit
ionandthenumber01cyl
inde問
si
on
pr
es- Wornp
sure
ist
onring
VI+ 6) I
ED E
916
l 6
l16) 6)1E
9 @
-
・
・ • • Symptom咽 r
wearandt
i
esdependingondegree0
enumbero
h fcyli
nde
悶
1

O
ther Cloggedt
c
onv
ert
e

Lowi
d
h
rl

l
e
r
x
e
e
h
a
-
u
w
a
s
yc
ata
lyt
i
tsystem

ebasespeed
c
VI+I. .
，+・
- +1.
• + 1+ + 1•
• • I
nsomecases，a
陪st
art
ingi

• Engines
s凹 s

ta
l
f
s
i
t
b
e
rengines
l
e.

lmay cu∞
rb
ta
ll，

ypowersteering
VIV VIV
・
- • 1• l
a
oa
ti
dandca l
dl
ing
。
旬
oa
dduri
n gd
ecel
erationor

1b阻 kes
Dragging0
-•
・ .
・ T
ire
sんv
hee
lsa
r .
t
eho

.
，.
•
B
eltten
sio
nto
ohi
gh(
ex伺 s
si四
t
ensi
on) +1+

HighA
fTload • Ins
ufli
cientATFamount，impropero
il
v 守 + 1V
• S問 c
esp
i
li
田 i
，t
国
al
l
ion(Thi
ssymptommay
yoccurint
he I∞d
.)

HighHYDPUMPl
oad(PS，Cargo) -
Ma l
func
umi
nsgpe
oeill
f
p田r
a
e1
s1
s
0uve用 l
ielv剖時，
VIV V 1+
• 甲 Impro
田 ro
mayesp
i
lsDecilicationσhissymptom
回 剖I yoccurinthecol
d.)

。
∞ur，
For
e
asd
i
u
g
s
t
nsubstancei
)
nlu
eltank(
suc
h
VI. + + ， ..，
.， .-・
・ .，
+ • 1.
• Withlowl
uel，t
hismaye
asi
ly

Damaged勉 n，m
all
unc
tio
nin
gwater • Noise
pu

司
。
、
町p

CI g ed
lre
str
ict
edr
ad t
orl
•
•
旧，
condenser

Alsocheckt h
efol
low
ingtt
emsothe
rthantheabove:
• Checkharnesst
ensio
n Checkeachconnectorconn
田 t
ion
. • Checkgroundw
iref
orI s
ene
ss. • Checkb
at∞
t
ery n
nec
tio
nfo
r10
国@冊目o ∞
r W曲 i
on ∞
・ n ・
目 ・ 目

Checkwaterando
il∞n
dit
io Check勉 nb
elt
slo
rlooseness 目

EC-24
 TROUBLEDIAGNOSIS

DiagnosisChartbySymptom(
Con
t'd
)
TB45ENGINE RELATIONSHIPBETWEENMALFUNCTIONING
SYMPTOMANDTHEENGINEMAINBODY/AUXIL lARY
COMPONENT
Whent hethreeelementsofcombustion，compressionp r
essure，fu
el
mixt
ure，ands pa
rkinga r
ea lnormal，nom
l alfu
nctionsarecausedi n
theeng
ine.
TheECMc on
trolsthefuelmixtu
reands parking(ig
niti
ontim
ing).But
wi
thm al
function
s ont hep artofenginemainbody ，mal
funct
i o
ning
symptomsr e
sul.
t
The tab
le below shows t hep os
sible symptoms caused by t he
malf
unctio
no f engine main body s ystem.Itw i
ll be help
fuli n
malf
unctio
nt r
oublediagno
sis.Thet ab
lelis
tsgeneralsymptomsand
somemayn o
tbea p
plica
ble.

1m. 1
m.
po時ト po倒・
S抑羽 ploms P
oor
idl
e Poord
riv
ingc
沼nl
rol Engines
la
ll OIher
blelo 回elo
s
lal 副a同
r

き
号
g
2
sE2EZ きE i
又
;g E;
Es E
i
i 5主
E
4:
( 宮 古
@

E ヨ
去
ω ー

5
3
盟
C
E
E
3
0E E
a ~
蚕 .
.
E
D
esc
rip
lio
nln
olab
lecha阻ct
eri
sli
cs0
1
e
=官芯
c
百事
，
。
宅 三
鋼
、 ~
~I~ E
伺 E ロ
0
c
コ
』3ロ
c
z
コm』
Ih
esymplom
差 言旦
~
豆
L 百届
E E
z
e
3
s
宅 担
邑
巴
コ
@

。
EEE
=
Mainun
ilsymplom
ED
:Highlypossible ロ
c
ロ3
コ
』

.:Possibl
e U
U
E3
』

V:Nolveryp ossib
le

F
uel A
irsuckedlromo
il町 e
l lgauge .
，
. • Ai
r.lu
elr al
iobecomesLEAN

.
，
.
.IV T v v
m
ixt
ure • Highair.l
uelcorr
ect
ion幅clor
.
A
irsuckedIrom0
11li
ll
ercap .IV v v v • Lows uc
lion power(vacuump r
essu
re)01

Ai
rsuckedIromPCVhose
(downslream0
1PCV) .IV ，..
.IV.，
. .
，
.• .IV v v
Ge
i

n
n

e
l
a

r
k
CheckI
a
emanHold

l
h
l
es
yap
u
c
p
l
l
io
田a
nu
bl
si
n
e1
gap
0airs
r
u
e
田 u
ct
io
regauge
nina
ir

，..
.，
. ・ in祖国 s yslem

. - • •
Ai
rsuckedfromi
nta
kem
ani
fol
d
andgaskel .IV .IV .IV v マ
PCVk
eplopen
• .
，
..， • Noise(
hig
hhi
ssi
ngl
one
)

.
，
.-，.
，
.. •
.IV

.・
Cloggedf
uels
lra
ine
r • Symplomdependsonclo
ggings l
alu
s.This

.
，
.1V .IV

.1
.
1.
V 1.
lends10happend
uri
nghigh.speedorhi
gh
Cloggeda
irc
lea
nerelemenl

.
，
. .
，
..，
.- .
，
..，
. • loadope陪:t
io
n.

・
・
M
alfu
nclio
nin
gga
sol
inepressure • Symplomv
ari
esdependingon0
11q
ual
ity
.
r
egu
lalo
r VI.

Poorqu
剖it
yga
sol
ine
V ・.
，
. .
，
..，
..，
. ..
.
， ，
. .IV v • Symplomv
ari
esdependingono
ilq
ual
ity
.

ImproperLPGf
propane阻 l
io
)
u
el(
∞Idareaand

@
・
・ .
，
..，
..，
. .
.
，.，
. .1V
• Slar
tinga

• UseLPGw
b
il

i
i
t

l
yi

hp
nc

ro
o

p
l

e
dareai
dependingonpropaneral
io
schanged

rpropane問 I
t
io

Malfuncl
ion
ingLPGvap
ori
zer • al
fI hepressu陪 islow.i
liscausedbypoor
pressuread
jus
lin
gva
lve
・
守・- .
，
..，
..，
.
，
. ・ -.，
. oul
ope
• Ifl
pu
問.
h
ld
I
i
u
o
n
目
ringhigh.speedo

epr<謁surei sexcessi
ve
rh

l
i

yh
g

i
g
hl

h
o
a

.r
d

el
ief
valveope悶l esandengines l
all
salrich

.
，
..，
.- -.，
.
CloggedLPGv
叩 剖z
erh
olwaler • Symplomdependsonf uellempe国Ilu
re
ci
rcu
it

• ・・ ・
Thislends1
andisi mp
o
warmlngup
s
0happend
si
ble10re
s
u
l
r
i
a
n
r
gengines
tdurin
la
ll
gengine

CloggedLPGi
f
lll
er
nle
rce
pHo
nva
l四
.1V .
，
..，
. •.1
.
1 VI. 令
• Symplomdependsonc
lends1
loado
0happend
p
era
tion
uri
n
l
oggingslalu
s
ghigh.speedo
.T
rh
i
h
g
i
s
h

-。.
- ・
ー 目

V
alv
ede
pos
il
.
，
. .，
.・
.IV .
，・-..
， v
• Them alf

vacuum).
un
clio
nl
high.speedorhig
e
hl
n
ds1
o
0happend
dope国 l
a ion
(
u
l
r
i
o
n
w
g

EC-25
 TROUBLEDIAGNOSIS

1m・ 1m・
問翻ー po割ー
Symptoms Po
ori
dle Po
ord
riv
ingc
酒nt
rol Engines
ta
ll Ot
her
凶eto bl
eto
S祖 r
t S祖 r
t

書E豆旦E5
告
2 告 5 i E
i
i
iz量
ω
ー ミ;

z
i
E 盟 E ミ
コ 雪
'
"
E 崎
D
esc
rip
tio
n/no祖b
lechar冨c
ter
is甘csol
m
豆
E 豆
E
玄
E E
@豊
C E
，
三
mE 』
E
側 5
E
冒 E ロ
E E
z
c
コn th
esympto打3

三
3 さ
旦
宝
E 島
"E

号
EE ω δ
E
Mainunitsymptom
E
I
l:Highlypossible E
F
E
.
目 Possible u
c
c
Em
』

V :Notverypos副凶 e

Spark- Improperhigh
-te
nsi
oncord • Checkt
hei
gni
tin
g詞 quence.
ing connection E
I
lIE
l
l E
I
lIE
l
lEI
lIE
l
lEI
lIE
l
l@ E
I
lIE
l
lEI
lIE
l
l@ @

，. . ，. . -，. .，. .，. . ・

Improperig
adjustment
nr
tio
nti
min
g

，. .
・
，. .，. .，. .
- .1 V
•
M
all
unc
tio
nin
gsparkp
lug

，. .
v
• VI V
• Checkt
lo
rsoi
l(
h
a
s
tt
mo
k
h
i
egapi
ng
).
spr
ope
r 味 p
.Che lug

・-，. .，. . ，.，. . • • •

Leakagelromh
igh
-te
nsi
oncord • Symptom咽 r
iesdependingont
hel
eve
l01
VI • le
akag
e.

・
- ，. .，. .・- ，.，. .
Leakagelromd
i

Looseoropen0
connection
st
rib
uto
rca
p

1primaryw
i
.

re
VI •
• • •
Com-
pr
es-
Improperb
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ont
act VI. E
I
lIE
l
l E
I
lIE
l
lEI
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I
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mal
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t g9阻 deandth
enumber0
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tlromheadgasket
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• • ma
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，. . ，. .，. .，. . ，.，. . ，. .
•
mal
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ctio
ning9悶 deandthenumber0 1
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mal
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ter
ior
ati
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，. . ，.，. . • Thesymplomoccursdependingon
spri
ng VI.
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m
a
l
a
l
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f
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n
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c
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vestem
，.，. . • Thesymplomoccursdependingon

PressureleakageIromsparkp
lug
VI. E
I
lle E
I
lIE
l
lEI
lIE
l
lEI
lle

@
@
• m
m
a
l
a
l
f
l
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u
n
c
c
l
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i
i
o
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i
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n

• Checkgaskelandl
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g
e
r

h
l
s

en
in
h
enumber0

g n
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il
ion
1

O
the
r Lowi
dlebasespeed
VIV VIV ，. .，. . • Engines
l
a
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e
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ionor

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旨
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ro

、
n
lorr
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ra

町pistonor
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ksh
aft

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s
l
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a
o
r
anoe
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hit
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目
hexhaustgas Wo

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clearance

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o
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i
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g
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pr.
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E
旨 • connecting end and assemble i
down.
t upside

量
Ex
cl
e
自 由i
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c
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e
i
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ng

• • W
h
g
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i
o
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v
hexhaustgaS.Womp
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ng.
isl
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ing

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erp
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l

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nder
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出
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主
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n
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alv
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hlt
ish副 祖 国tgas

l
ip
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Dele r
ali
on0
1va
lveo
ils
eal

•
EC-26
 TROUBLEDIAGNOSIS

1m
・ 1m・
P
OSS
I- P曲 Sト
Symploms P
oor
idl
e P
oord
riv
ingc
ont
rol E
ngi
nes
ta
ll O
the
r
凶eto blet
o
st
art s
ta
rt

iiZ E
EE E
。
E
盟

ii 雪き Z i
4
E
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c
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hesymptom
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@
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s
yp
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E
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c
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。
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sib
le

Oth
ers Exc
essiveo
rcl
ogg
edv
al四 • Excessi
vec lea
rance:
.
，
.+，
+，
+
~ I

百
〉
Clea
ran
ce
• C
hatte
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Engin
ri
l
e
el
n
gn
a
e
r
a
a
k
o
n
a
i
s
c
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e
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ea
ti

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d
l
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i
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n

n
g
g

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a
k
c
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m
e

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rg
a

gc
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k
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n
to
i
l
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si
on
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r
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n
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l
i
n

l
g

e
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lo
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lo
• Looseo
i
m
c
a
rb
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t
r
o
n
gmarkr
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e

e
t
la
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oti
min
gch
ain

I
mpr
ope
ren
gin
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l • I
nsuf
lici
en lamount i
to
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pro
p，
er9悶 de ，
• • d
e
• R
e
t
f
e
i
l
ri
o
ll
r
u
l
at
ion
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l
M
alf
unc
tio
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goi
lpump
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.
，•• WOpoerrnatoirobnrmoaklefnunrcottioronoroillea。
唱eol
l
r
egu
lat
or

E
2
6
O
ill
eak
agea
rou
ndo
i
lpan

善 Cloggedlrestrictedo
• • Looseo
rb
• Looseo
i
ro
ke
lpand
no
r
ai
i
lpang
npl
ug
a
ske
t

s
t
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ra
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ll
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n
a
e
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k
age0
10/1
fi
lt
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l
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ir
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ore
ignm
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line
ngi
neo
i
l

@
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• Applyo
i
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lt
ro
og
k
a
s
e
ng
ke
asket
twhenre
pla
cin
goi
lfi
lt
er ，
C
log
ged
lr

Looseo
P陪 s
sur
e
st

rm
es
a
w
r
i

l
i
c

l
u
t
c
t
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n
h
do

c
t
i
lf

io
n
i
l

i
t
e

n
r

goi
l
.
，
+
• • D
irto
ren
try0
1fo
rei
gnm
ate
ria
line
ngi
neo
i
l

，. + ，
-+
・ ，
. +
，
.+1+
F
ore
ignm
ate
ria
linf
uelt
ank • W
ithl
owl
uelt
hismaye
asi
lyo
ccu
r.
VI. .1.1.
2 (
L
2
L suc
hasdus
t)
O
ill
ea回g
elroml
uelsystem

聞， • • CheckLPGl
eak
agebya
ppl
yin
gsn
oop
.
R
o
o
t
rw
a
t
a
i
t
o
e
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alf
u
rpump
nc
tio
n011
• • S
lipo
rwornb
eltcausedb
ybe
杜lo
ose
ne田

M
a

M
a
l

l
f
u

f
u
n

n
c
t

c
t
i

i
o
n

o
n
i

i
n
gw

n
gt
a
t

h
e
e

r
rpump

m
ost
at
•+，. .-Wfroor
m
na
ox
rl
e
bs
ro
e
ka
elnb
ear
i
目ng
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ola
ntl
eak
age

M
c
o
a
l
o
f
l
u
a
n
n
cti
onin
ge n
ttempe団 t
gi
ne
u陪 gauge
.
，
.
C
o
c
o
R
a
o
o
d
l
l
a
i
a
a
n
n
t
tl
t
o
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rr
e

e
l
a
k
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a
a
p
e
t
e
g
r
eI
a
t
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a
u
l
r
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me
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n
n
e
c
t
g
n
i
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o
o
n
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r
e
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erio悶tio
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ato
rcappre
ssure and ，
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a
l
t
o
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e
g
andw
rl
ed
a
t
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l
e
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r
e
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s
rl
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t
e
e
r
a
i
c
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t
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d阻 d
e
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e
i
ato
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C
o
i
n
n
s
t
u
f
a
l
m
i
c
i
i
n
a
e
n
tionand
tamount01c
ool
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lng
e
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romc
ool
ant

.
，
..，
.
•
E
(
e
n
x
g
i
c
n
e
ed
s
si
r
i
v
v
et
eb
e
e
n
s
l
i
tt
on
)
en
sio
nto
ohi
gh
• ， ，
• -.
・ ，
.+1.1. .
，
..，
.
•
Cloggedthre
e-wayc
ata
lyt
ic • I
nsomecasesa
fte
ren
gin
est
al
lre
sta
rti
ng
conv
erterl
exhau
stsystem VI.
i
spo
ssi
ble

.
，.，
.
D
rag
gin
g01b惜 k
es
• • T
ire
s/wheelsa
reh
ot

EC-27
 TROUBLEDIAGNOSIS

1
m- 1
m-
同副ー 問 時，-
Symptoms
凶eto 凶eto
Po
ori
dle Poord
riv
ingc
ont
rol Engines
ta
ll O
ther
st
art s回rt

~I~ 号 E
z EE
E
告Z 2室
書 盟 S号E
Z
E書盟 ZE
E 盟 雪5
E盟 E 5
2Ei
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2豆
・
豆 ~
豆
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コ
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E
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D
esc
rip
tio
nlnot
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thesymptom
te
ris
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皇
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C
Z
z
島草
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且 c
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a
p
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o
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Malnun
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E
E
9:Highlypossible E
3
0 F
.:Possibl
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EP
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マ:Notverypossible
O
the
rs HighA
fTload • In
suffic
ientATFamount，impropero
il

HighHYDPUMPl
oad(PS，
Cargo)
v マ .IV
• s

• M
p

a
e
国 c

l
c

l
u
i

n
l

c
i

t
c
urint

i
o
a
t
h

n
i

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o
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go
h
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i
ssymptommayes
.
)

lpressure陪 l
ie
lva
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l
ve，
i
all
y

VIV VI.I. v Im
prl
叩e roilspe
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cat
ion打hissymptom
maye s
pecial
ly0∞urinthe∞ I d
.)

Alsocheckt hef
ollo
wig~ems α
n the
rthantheabove
• Checkharnessten
sio
n. • Checkgroundfo
r10田 e間 関 ・ Checkeachconn
町 t
orc
onn
ect
ion ・Ch
田 kba y∞n
陶 r nec
tio
nfo
r1∞時間話 or∞問510n
• Checkenginedr
i糟 bel
tfo
rloosene田 . .Checkwaterando
ilc
ondi
tion

EC-28
 TROUBLEDIAGNOSIS

ComponentP
art
sLocation
S
pec
ifi
cat
ion
s
Maincomponentp
art Type L
oca
tio
n
Gasoline LPG Combined

吋ector
Gasolinei Highr
esi
sta
nce I
nta
kem
ani
fol
d O O
LPGi
nje
cto
r Gasi
nje
cti
on I
nteg
rat
edininj
ect
orh
old
er(
on O O
i
nta
kemani
fol
d)
F
uelpump E
lec
tri
cmo
tor
/tu
rbi
ne I
nte
gra
tedi
nfu
eltank O O
F
uelpressurer
egu
lat
or Diaphragm O O
T
hro
ttl
eco
ntr
olmotor E
lec
tri
cDCmotor(DCm
oto
r) Int
egrat
edinele
ctr
oni
cth
rot
tle O O O
c
ontro
la ct
uat
or
I
gni
tio
nco
il Molded I
nte
gra
tedi
ndi
str
ibu
tor O O O
Powert
ran
sis
tor 1-channel
Crankshaftp
osi
tio
nsensor P
hot
oel
ect
ric I
nte
gra
tedi
ndi
str
ibu
tor O O O
Massa
irf
lowsensor Hotw
ire A
irhorn O O O
Acceler
ato
rpedalp
osi
tio
n V
ari
abl
ere
sis
tan
ce I
nteg
ratedi
nacce
lerato
rwork O O O
sensors1and2 u
nit(ac
cele
rat
orpedalassembly)
Thr
ottl
eposi
tionsensors1and I
ntegr
ate
dinelec
tro
nict
hro
ttl
e O O O
‘
G
n
E
0
E
回
的・
3
2 c
ont
rolactu
ato
r
Engineco
olanttemperature Thermistor Thermostathousing O O O
sensor
I
nta
kea
irtemperaturesensor Witha
irf
lowmeter O O O
Heatedoxygensensor Z
irc
oni
a(w
ithh
eat
er) O O O
V
ehi
clespeedsensor Ele
ctrom
agne
ticpower O O O
g
enera
tion
ECM 121・p
ind
igi
talc
ont
rol O O O
ECMr
ela
y Compact r
ela
y O O O

EC-29
 TROUBLEDIAGNOSIS

ComponentP
art ・
sLocation(Contd)
ECMCOMPONENTPARTSL
OCA
TIO
N:T
B45ENG
Specifications Reference
Component Location
Gasoline LPG Combined Actuator Sensor Other

G
aso
lin
ein
同ct
or I
nta
kem
ani
fol
d
O O O
LPGi
nje
cto
r I
nte
gra
tedi
nin
jec
torh
old
er(
oni
nta
ke
m
ani
fol
d) O O O
T
hro
ttl
eco
ntr
olmotor I
nte
gra
tedi
nel
ect
ro出 t
n hro
ttl
eco
ntr
ol
a
ctu
ator O O O O
T
hro
ttl
epo
sit
ionsensors1and2 I
nte
gra
tedi
nel
ect
ron
田th
ro世l
eco
ntr
ol
a
ctu
ato
r O O O O
I
gni
tio
nco
il I
nte
gra
tedi
ndi
str
ibu
tor O O O O
O
。
O O O
C
ran
ksh
aftp
osi
tio
nsensor

Pow
ert
ran
sis
tor O O O
Massa

I
nta
k
i

ea
i
rf
lowsensor

rtemperaturesensor
A
irhorn

Witha
irf
lowmeter
O
O
O
O
O
O 。
O

O
。
酒o
Enginec l
anttemperatu時 sensor Thermostathousing O O O
Accele
国to
rpe
dalp
osi
tio
nsensors1and2 I
nte
g阻 t
edina e∞
l
era
torworkun
it
(
acce
le阻to
rped
alassembly) O O O
F
uelpump I
nte
gra
tedi
nfu
elt
ank O O O
F
uelp陪 曲 u
rer
egu
lat
or O O O
Heatedoxygensensor (
Veh
icl
esi
de) O O O O
O O O O
。
V
ehi
clespeedsen
田 r (
Veh
icl
esi
de)

ECM l
ehi
cles
ide
) O O O O
ECM&IGN l
ir∞
e
lay (
Veh
icl
esi
de) O O O O
Stoplamps

T
hro
ttl
eco
nt
w

r
o
it
ch

lmotorr
ela
y
(
V

(
V
e

e
h
i

h
i
c

c
l
es

l
es
i
d

i
d
e

e
)

)
O
O 。
O O
O
O
O
F
uelpump聞 l
ay (
Veh
icl
esi
de) O O
V
apo
riz
er (
Veh
icl
esi
de) O O O
LPGi
nte
rce
pti
onv
alv
e (
Veh
icl
esi
de) O O O

EC-30
 TROUBLEDIAGNOSIS

ECMComponent(
Con
t'd
)

Enginecoolantlemperaturesensor
ECM Fueli
nje
clo
r

E
ngie∞o
n la
nt
t
emp
erat
uresen
sor

E
lec
tri
ctt
lro
lUec
onl
rolactuator
Massa
irf
lowsensor Heatedoxygensensar

E
I閃 tr
i
c11悶Ulec
1 印刷a dua
lor
r~rotne 閃割l旧ns町50r 1
，2'
"
~ThrロU
le∞ 川rai
;
;
-
l'
mロ "'J Massa
irf
icws
ens
or

A
cce
ler
ala
rpedal{
?os
ili
onsensors1
，2

EC-31
 TROUBLEDIAGNOSIS

ComponentPartsLocation(
Con
t'd
)

F
uelpump Sloplamps
wil
cti

EC-32
 TROUBLEDIAGNOSIS

ELECTRICPARTS

FLASHERUNIT /
7-
NEUTRALRELAY

RESISTOR

SPEEDSENSORUNIT

ζ〉
o /〆 LPGINJECTION
DRIVEUNIT
(FORLPG)

RELAY

叫;

-_?~~~~
./
〆
/

，
/

EC-33
 M
alf
unc
tio
nin
dic
ato
rlamp

L
EI 冊

1
01

且
Lb!
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.
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I
gni
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mOZDM争臼
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alfun
ction
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a)

，
.
. 理

AVCC 重
量

1
!
9
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πBody Engineground
i 印刷

"
'
主
 M
alf
unc
tio
nin
dic
ato
rlamp
Meter
30 12
ヨ隠

坦IlMP .
.
出盟且阜
且且一一
1

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1
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.
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O

・
ω

VSP8
-ω

oqozzose﹃白ヨ(Ooz.a)

E日弘塁盟1
臨~盟Z

LPGi
nte
rce
pti
onv
alv
ere
lay

Bodyground
.
.
INE 8
5
I
gni
tio
nci
rcu
it
i 1r-
Bodv Engineground
1121314151 111
・・
iground s1
101
1111
211
311
411
5118
Datal
inkconnector
M
4益
u1
 TROUBLEDIAGNOSIS

ECMTerminalLayout

D
atal
i
nkc
onn
ect
or
￨1 1 1 T
似 1X1 1 1 1

￨
￨
州￨
旺1 ー
ト1)
(
I 1 1 1

ECM0246

Thesymboli
n()n
extt
ote
rmi
nalnumbersi
ndi
cat
est
hed
atal
ink
con
nec
tor.

T
erm
ina
l D
esc
rip
tio
n
ECMg
rou
nd
2
3 T
hr
ot
llec
on
tr
olm
oto
rre
la
yp o
wers
upp
ly
4 T
hr
otl
lec
on
tr
olm
oto
r(C
los
e)
5 T
hr
oll
lec
on
tr
olm
oto
r(O
pen)
6
7
8 LPGi
nj
ec
to
r1
9 LPGi
nj
ec
to
r2
1
0
1
1 LPGa
ssi
sta
ncei
nj
ec
to
r
1
2
1
3 C
ran
ksh
aftp
osi
tio
nse
nso
r1・(PO
S)
1
4 C
ran
ksh
aftp
osi
tio
nse
nso
r120
.(REF
)
1
5
1
6
17
1
8
1
9
2
0
2
1 I
nj
ec
to
rNo
.5
2
2 I
nj
ec
to
rNo
.3
2
3 I
nj
ec
to
rNo
.1
2
4 H
eate
dox
yge
nse
nso
rhe
ate
r
2
5
2
6
2
7
2
8
2
9
3
0 MIL
3
1 LPGfue
lpres
sur
esens
or
3
2 Fu
elchang
ingsw
itc
h2(Gas
oli
ne)
3
3 Ve
hic
lespeed
3
4 In
tak
eai
rtempe
rat
urese
nsor

EC-37
 TROUBLEDIAGNOSIS

T
erm
ina
l D
esc
rip
tio
n
3
5 H
eat
edo
xyg
ens
ens
or
3
6
3
7
3
8
3
9 LPGin
je
ct
ord
ri
vek
eep
ing
4
0 In
je
ct
orNo
.6
4
1 In
je
ct
orNo
.4
4
2 In
je
ct
orNo
.2
4
3
4
4 LPGi
nj
ec
to
rdr
iv
ein
tak
e1
4
5
4
6
4
7 Sens
orpowersuppl
y( T
hro抗l
epos
iti
ons
ens
or)
4
8 Sens
orpowersuppl
y
4
9 Fu
elchangi
ngs w
itc
hp ow
ers u
ppl
y
5
0 Th
rot
tl
ep o
sit
ionsens
or1
5
1 Massai
rflo
ws ens
or
5
2 Id
lea
irvolum
el ea
rni
ngopera
tio
n
5
3 LPGinje
ct
orcheck2
5
4 Maximumveh
iclespeedsh
ift
in
g
5
5
5
6
5
7
5
8
5
9 I
nch
ings
wit
ch
6
0
6
2 Ig
ni
ti
onsig
nal(po
wertr
ans
mis
sio
ndr
iv
esi
gn
al
)
6
3 LPGinj
ec
tordr
iv
ei n
ta
ke2
6
4
6
5
6
6 S
ens
org
rou
nd(T
hr
ot
tl
eps耐o
o nse
nso
r)
6
7 S
ens
org
rou
nd
6
8
6
9 T
hr
ott
lepos
iti
onsen
sor2
7
0 F
uelcha
ngingsw
itc
h1(LPG
)
7
1
7
2 LPGinj
ec
to
rche
ck1
7
3 Eng
ineco
ola
ntt
emp
era
tur
ese
nso
r
7
4
7
5
7
6
7
7
7
8 S
ens
org
rou
nd(
Hea
tedo
xyg
ens
ens
or)
7
9
8
2 S
enso
rgrou
nd(Ac
cel
era
torped
alpos
it
io
nse
nso
r1)
8
3 S
enso
rgrou
nd(Ac
cel
era
torped
alpos
it
io
nse
nso
r2)
8
4 H
eadlam
pswi
tch
8
5(KL
lNE
) K
-l
in
e(ECMdatatr
ans
mit
!re
cei
ve)

EC-38
 TROUBLEDIAGNOSIS

T
erm
ina
l D
esc
rip
tio
n
8
6
8
7
8
8
8
9
9
0 A
cce
ler
ato
rpe
dalp
os
iti
onse
nso
r1p
owe
rsu
ppl
y
9
1 A
cce
ler
ato
rpe
dalp
osi
tio
nse
nso
r2p
owe
rsu
ppl
y
9
2
9
3 '
.
9
4
9
5
9
6
9
7
9
8 A
cce
ler
ato
rpe
dalp
os
it
io
nse
nso
r2
9
9
1
00
1
01 St
opl
ampsw
itc
h
1
02 PNPs
wit
ch
1
03
1
04 T
hro
ttl
eco
nt
ro
lmo
torr
el
ay
1
05
1
06 A
cce
ler
ato
rpe
dalp
os
it
io
nse
nso
r1
1
07
1
08
1
09(IG
N) I
gn
it
io
nsw
itc
h
1
10
1
11 ECM&I GNco
i
lr e
la
y
1
12 LPGin
ter
cep
tio
nvalv
ere
la
y
1
13 Fu
elpumprel
ay
1
14
1
15(ー
) ECMg
rou
nd
1
16→
( ECMg
rou
nd
1
17
1
18
1
19 P
owe
rsu
ppl
yfo
rECM
1
20 P
owe
rsu
ppl
yfo
rECM
1
21 P
owe
rsu
ppl
yfo
rECM(B
acku
p) 幽

EC-39
 TROUBLEDIAGNOSIS

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
REFERENCEVALUEL
lST
• Voltag
esi s measured wi
tha c i
rcu
itt e
ster，and the sample
waveformsob ta
inedwithano sc
illosc
opea reshownbelowf or
each ECMt ermin.
alMeasurementdatav ariesdependingon
va
riati
oninpa吋5 asw e
llasmanyo therfacto
rs.Suchf act
ors
incl
ude vehicle hist
ory，driv
ing conditi
ons， enviro
n m
ental
cond
itios，maintenances
n t
ats，measuringi
u nstru
ment
Jmethod，
et
c.Datashownbelowa rerefe
rencevalu
es.

ECM0247

D
atal
in
kco
nne
cto
r

￨1 11
RX1
TX1111

l
￨州
￨
旺 11
(
-)1
(
-)
1 111
ECM0248

Terminal S
ign
alname C
ond
iti
on Data(DCv
alu
e)

24 Heatedoxygensensorh
eat
er Ati
dlea
fte
rwarmingup Approx.O.3V
Approx.?rpmo
rmore B
att
eryv
olt
age
113 F
uelpumpr
ela
y Forapproximately1seconda
fte
r Approx.1V
ig
nit
ions w
itchON
A
fte
rth
at B
att
eryv
olt
age
Atc
ran
kig，
n enginerunning Approx.1V
111 ECM&IGNc
oilr
ela
y Forappr
oxima
tel
y10secondswhen Approx.1V
ig
niti
onswi
tchONandaft
erign
iti
on
swi
tchOFF
I
gni
tio
nsw
itc
hOFF B
att
eryv
olt
age

EC-40
 TROUBLEDIAGNOSIS

T
erm
ina
l S
ign
alname C
ond
iti
on Data(DCv
alu
e)

62 I
gni
tio
ns i
gnal(powert
ran
smi
ssi
on Atc
ran
kin
g Atc
ran
kin
g:Approx.0.5V
d
riv
es i
gnal)
(
v)
6
4
。
2

動na
II
E
CM0
249
Ati
dlea
fte
rwarmingup Ati
dli
ng:Approx.0.5V

(
V)
6
4
。
2

針r
u
II
・
E
CM0
250
Ata
ppr
ox.2，
000rpm Approx.0.9V

(
v)
e
4
。
2

動明S
II
E
CM0
251
101 Stoplamps
wit
ch Brakepedalr
ele
ase
d Approx OV
目

Brakepedaldepressed B
att
eryv
olt
age
109(IGN) I
gni
tio
nsw
itc
h I
gni
tio
nsw
itc
hOFF Approx.OV
I
gni
tio
nsw
itc
hON B
att
eryv
olt
age
102 PNPs
wit
ch Np
osi
tio
n Approx.OV
Otherthanabove Batteryv
oltag
e(AITmodels)
Approx.4.8V(M庁 models)
85(KL
lNE) K
-li
ne(ECMdatat
ran
smit
!re
cei
ve) Whenconnectedt
oSST Approx.6.6・B
att
eryv
olt
age
Whenn
otconnectedt
oSST Approx.6V
84 Headlamps
wit
ch L
ightingswitchOFF Approx.OV
L
ightingswitchON B
att
eryv
olt
age
67 Sensorground Always Approx.OV
115 ECMground Always Approx.OV
116

EC-41
 TROUBLEDIAGNOSIS

Terminal S
ign
alname C
ond
iti
on Data(DCv
alu
e)

13 Crankshaftp
osi
tinsensor1・(POS)
o Atc
ran
kin
g Atc
ran
kin
g:Approx.2.6V

(
v)
6ー
←川t-・ ー
← 司
←
4

。2 1
L-凶
I

→F ト O
￨ .5m
s

E
CM0
252
Ati
dlea
fte
rwarmingup Ati
dli
ng:Approx.2.5V

(
V16

~t1
。
~tt
1
1
UUL
1
I
L

ー
トー同 O
.5m
s

E
CM0
253
Ata
ppr
ox.2，
000rpm Approx.2.5V

(
v)~I

v
; 醐 醐冊」醐
11IL U ILU

'同 -05ms
E
CM0
254
9
1 Acc
eler
atorpedalp
osi
tio
nsensor2 I
gni
tio
nsw
ithON，
c enginer
unn
ing Approx.2.5V
powersupply
48 Sensorpowersupply I
gni
tio
nsw
ithON，
c enginer
unn
ing Approx.5V
121 Powersupplyf
orECM(
Bac
k-u
p) Always B
att
eryv
olt
age
47 Elec
tri
cth
rot
tlec
ont
rola
ctu
ato
rpower I
gni
tio
nsw
ithON，
c enginer
unn
ing Approx.5V
supply
78 Heatedoxygensensorground Always Approx.OV
82 Accel
erat
orpedalp
osi
tio
nsensor1 Always Approx.OV
ground
90 Acc
elera
torpedalp
osi
tio
nsensor1 I
gni
tio
nsw
ithON，
c enginer
unn
ing Approx.5V
powersupply

EC-42
 TROUBLEDIAGNOSIS

T
erm
ina
l S
ign
alname C
ond
iti
on Data(DCv
alu
e)

14 Crankshaftp
osi
tio ・(REF) Atcranking
nsensor120 Atc
ran
kin
g:Approx.0.5V

(
V)
6
4
。
2

一
I--I
Oms

E
CM0
255
Ati
dlea
fte
rwarmingup A
tid
lin
g:Approx.0.5V

(
v)
6
4
E
。
2

ー
.
..
.
.，
.
.伽n
， s
II
ECM0256
Ata
ppr
ox.2，
000rpm Approx.0.5V

(
v)6
4
。
2 i

t
-←ト
ー 10ms

E
CM0
257
5
1 Massa
irf
lowsensor I
gni
tio
nsw
itc
hON Approx.1V
Atc
ran
kin
g Approx.1.5V
Ati
dlea
fte
rwarmingup Approx.1.3V
Ata
ppr
ox.2，
000rpm Approx.1.5V
50 T
hro
ttl
epo
sit
ionsensor1 Ati
dlea
fte
rwarmingup Approx.0.6V
I
gni
tio
nswit
chONw it
henginestopped Approx.0.75V
A
ccele
rat
orp e
dali
sful
lydepressed
I
gni
tio
nswit
chONw ihenginestopped Approx.0.75V
t
A
ccele
rat
orp e
dali
srele
ased
Ata
ppr
ox.2，
000rpm Approx.0.7V
69 T
hro
ttl
epo
sit
ionsensor2 A
tid
lea
fte
rwarmingup Approx.4.5V
I
gni
tio
nswit
chONw it
henginestopped Approx.4.35V
A
ccele
rat
orp e
dali
sful
lydepressed
I
gni
tio
nswit
chONw it
henginestopped Approx.4.35V
A
ccele
rat
orp e
dali
srele
ased
Ata
ppr
ox.2，
000rpm Approx.4.4V
106 A
cce
ler
ato
rpedalp
osi
tio
nsensor1 A
tId
le Approx.0.6V
I
gni
tio
nswit
chONw ihenginestopped Approx.0.6V
t
A
ccele
rat
orp e
dali
sful
lydepressed
I
gni
tio
nswit
chONw it
henginestopped Approx.4.2V
A
ccele
rat
orp e
dali
srele
ased
Ata
ppr
ox.2，
000rpm Approx.0.65V
98 A
cce
ler
ato
rpe
dalp
osi
tio
nsensor2 A
tId
le Approx.0.3V
I
gni
tio
nswit
chONw ihenginestopped A
t ppr
ox.0.3V
A
ccele
rat
orp e
dali
sful
lydepressed
I
gni
tio
nswit
chONw it
henginestopped Approx.2V
A
ccele
rat
orp e
dali
srele
ased
Ata
ppr
ox.2，
000rpm Approx.0.35V

EC-43
 TROUBLEDIAGNOSIS

T
erm
ina
l S
ign
alname C
ond
iti
on Data(DCv
alu
e)

34 I
nta
kea
irtemperaturesensor I
ntak
eairtemperaturei
sap
pro
x.20
・c Approx.3.5V
(
68・F
).
Inta
keairtemperaturei
sap
pro
x.80・c Approx.1.2V
(176・F
).
83 Accel
erat
orpedalp
osi
tio
nsensor2 Always Approx.OV
ground
35 Heatedoxygensensor Ati
dlea
fte
rwarmingup Aircondi
tion
erOFF:
Clampbetween0-0 .7V
Aircondit
ion
erON:
Changesbetweena pp
ro.0・0.3V←→
x
approx.0.5・1.0V

(
V)
1
.5
1
.0
0.5v
hI
¥ [
1¥[
¥
s
VIV 1
'
1

ー1
1-ト -15
l
ECM0258

Ata
ppr
ox.2，
000rpm Changesbetweena p
pro
x.0・0.3V←→
approx.0.5・1.0V

~~~I IIIIIIII
1
.0

。
0
.5
1
"

- 1.

ECM0259

73 Enginec
ool
anttemperaturesensor Enginec
ool
anttemperaturei
sap
pro
x. Approx.5V
20'C.
Enginec
ool
anttemperaturei
sap
pro
x. Approx.1.2V
80'C.
21 I
nje
cto
rdr
ives
ign
al Atc
ran
kin
g Approx.10.5V
22
23 (
V)
40
40 30
41 20
42 1
。
0

←
jo-20ms

ECM0260

Ati
dlea
fte
rwarmingup Ba
悦eryvoltage

(
V)
40
30
20
1
。
0

と
竺トー ト 20ms

ECM0261

Ata
ppr
ox.2，
000rpm R
ela
tiv
elylowerthanb
att
eryv
olt
age

(
V)
40
30
20
10
D
f-+-
20ms

ECM0262

EC-44
 TROUBLEDIAGNOSIS

T
erm
ina
l S
ign
alname C
ond
iti
on Data(DCv
alu
e)

119 Powersupplyf
orECM I
gni
tio
nsw
ithON，
c enginer
unn
ing B
att
eryv
olt
age
120
104 T
hro
ttl
eco
ntr
olmotorr
ela
y I
gni
tio
nsw
ithON，
c enginer
unn
ing Approx.1V
3 Thro
ttlec
ont
rolmotorr
ela
ypower Always B
att
eryv
olt
age
supply
5 T
hro
ttl
eco
ntr
olmotor(Open) Ati
dlea
fte
rwarmingup Approx.0
.1t
o0.15V
Ata
ppr
ox.2000rpm
4 T
hro
ttl
eco
ntr
olmotor(
Clo
se) Ati
dlea
fte
rwarmingup Approx.2・2.5V
Ata
ppr
ox.2000rpm
32 F
uelchangings
wit
ch2(
Gas
oli
ne) Changings
wit
chON(
Atg
aso
lin
esi
de) Approx.5V
Changings
wit
chON(
AtLPGs
ideo
r Approx.OV
neu
tral
)
49 F
uelchangings
wit
chpowersupply Changings
wit
chON Approx.5V
Changings
wit
chOFF(
Atn
eut
ral
) Approx.OV
70 F
uelchangings
wit
ch1(LPG) Changings
wit
chON(
AtLPGs
ide
) Approx.5V
Changings
wit
chOFF(
AtLPGs
ideo
r Approx.OV
neut
raり
112 LPGi
nte
rce
pti
onv
alv
ere
lay Wheni gn
itions
wit
chisONandf o
r B
att
eryv
olt
age
approximately10secondsa
fte
rign
iti
on
switchisOFF
I
gni
tio
nsw
itc
hOFF Approx.OV
52 I
dlea
irvolumel
ear
nin
gop
era
tio
n Whenconnectingt
ool
sfo
rid
lea
ir Approx.1.5V
volumel
earning
Whenn o
tconnectingt
ool
sfo
rid
lea
ir Approx.OV
volumelea
rni
ng
54 Maximumspeeds
hif
tin
g I
tva
riesdependingons
ett
ing
c
ond
iti
on.
33 V
ehi
clespeedsensors
ign
al V
ehi
clestopped Approx.1
1V o
rap
pro
x.1V
59 I
nch
ings
wit
ch I
nch
ings
wit
chON B
att
eryv
olt
age
I
nch
ings
wit
chOFF Approx.OV

EC-45
 TROUBLEDIAGNOSIS

SST
DESCRIPTION
• SSTexecutesthefollowingfunctionsusingthecombinationof
datareception，
instructions，
andtransmissionfromtheECMvia
thecommunicationl ine
.

D
iag
nos
ist
estmode F
unc
tio
n
WORKSUPPORT • Reducestheprep
arationworknecessaryforin
spe
ctin
g.
•D is
playsin
putl
outpu
ts ig
naldat
ar el
atedtothework
.
•A ll
owsset
tingco
ntroltarg
etvalu
eso fidl
espeedorigni
tio
nti
min
g.
-Allowsperfo
rming"Idl
eAirVolumeL ea
rning
".
SELF-DIAGRESULTS • D
isp
lay
snameso
ffr
eez
eframed
ataandb
asi
cin
spe
cti
ons
tor
edi
nECM.
・
Di
spl
aysd
atar
eco
rde
dwhenDTCi
sde
tec
ted
.
-ErasesDTCs陪 c
ord
edi
nmemory.
DATAMONITOR • Provid
esusef
uld a
taalongwit
hs e
lf-d
iagn
osisr
esu
ltst
ode
ter
min
eth
emainc
aus
e.
• Disp
laysinp
utlou
tputdat
ao fECMi nre
altim
e.
• Recordsandstoresda
ta.
• Detec
tsmalfun
ctionsi
nr e
altim
e.
ACTIVETEST • Canbeusedtodete
rmineandid
ent
ifythep
rimar
ys ou
rce
sofm
alf
unc
tio
nsbasedons
elf
-di
agn
osi
s
re
sul
也a nddat
afromDATAMONITOR .
• Eachac
tuat
orisa
ctiva
teda
fte
rrece
ivin
gad ri
vesig
nal
ECMPARTNUMBER • ECMpa円 numbercanber
ead
.

OPERATIONPROCEDURE
1
. Turni g
nitionswitchO FF
.
2
. ConnectSSTtodatal i
nkconnector.
3
. TurnignitionswitchON.
4
. TurnmainbodypowersupplyswitchON.
5
. Displaysmainmenu2secondsa fte
rdisplayingini
tia
lscreen.
6
. Performthenecessarytroublediagnosismode.
Referto"CONSULT-IIOperationManual"f orfurtherinformation.

WORKSUPPORT
SST assists with id
le adjustment work. With SST ，it sends an
operation commandto ECM，and adjustmentcontrol i s peげ
'ormed
，inspectorperformsactualadjustmentwork.
accordingly.However

DISPLAYITEMLIST

Works
upp
orti
tem D
esc
rip
tio
n
1
.TARGETIDLETIMADJ(
*) A
llo
wsc
ont
rolt
arg
etv
alu
eforini
ti
align
iti
ont
imig・
n (15to5・
)
.
N
ote
:Tomakesur
eth
atig
nit
iontimi
ngandactu
altimi
ngaretesame，i
h nsp
ect
orsmustuset
imi
ngl
ig
h.
t
2
.FUELPRESSURERELEASE Shutsdownt
hef
uelpumpands
top
sth
een
gin
e.(
Whi
lec
ran
kig，
n p
res
sur
eint
hef
uelp
ipi
ngcanbe
rele
ase
d.)
3
.TARGETIGNRPMADJ(
*) S
etsac
ont
rolt
arg
etv
alu
efo
rth
eid
lespeed(
0to250r
pm)
.
4
."I
DLEAIRVOLLEARN"c
lea
r Lea
rnstheminimumidl
eai
rflowamountreq
uiredf
oridl
espeedco
ntr
olwhenp
red
ete
rmi
nedc
ond
iti
onsa
re
s
pecif
iedfo
llo
win
gr e
placeme
ntofelec
tri
cthr
ott
lecon
trola
ctua
torandECM
5
."SELF-LEARNINGCONT" C
lea
rsa
ir-
fue
lra
tiof
eed
bac
kco
ntr
olc
orr
ect
ionc
oef
fic
iet
.
n
c
lea
r
6
.LPGFUELPRESSURE Operatefu
elin
terc
epti
onvalv
eb e
for
ere
mov
ingf
uelp
ipi
ng，
andt
heno
per
ateandc
ont
roli
gni
tio
n.Enginei
s
RELEASE stoppedwhenthefue
lisconsumed.
7
."LPGSELF-LEARNING I
ni
ti
al
iz
e(c
lea
r)a
ir-
fue
lra
tiol
ear
nedv
alu
e.
CONT"c
lea
r

:T
* h
isf
unc
tio
nisn
otn
ece
ssa
ryi
nth
eus
uals
erv
icep
roc
edu
re.

EC-46
 TROUBLEDIAGNOSIS

SST(
Con
t'd
)
SELF-DIAGNOSTICRESULTS
Whenam al
functio
no cc
ursinECMi np
uto
/ut
puts i
gnalcir
cut，t
i he
mal
functi
onin
gc i
rcu
itisre
cor
ded.Then，th
atpar
ticu
larsystemname
and bas
ici n
specti
oni t
emsa r
ed i
spl
ayed.Also，malf
unction data
recor
dedisdisp
layed
.

OPERATIONPROCEDURE
[EXAMPLE:WHENTHEREISA MALFUNCTIONI
NMASSAIR
FLOWSENSOR]
1
. S
electcu
rsoronSELF-DIAG RESULTSscreenw
ithd
ire
cti
on
￨
SEL
F-D
IA TSMENUI
GRESUL ke，
yandthe
npush"YES
".
匝園町闘国.!¥'.:!:lI:
II・
lrl
!e園田昌司・ 1
・跡調
2
.ERASESE
LF-DIA
GRESULTS
3
.DISP
LAYFREEZEFRAMEDATA

F
l F
4

2
. B
asi
cin
spe
cti
oni
tem
sar
edi
spl
aye
d.
DTC RESULT
P01
02 MAFSE
N/C
IRC
UIT
T
IME
。 CAUTION:
POl
l0A I
RTEMPSENC
/IRC 1
st • Inspe
ctionitemsarenotdisplayedi
nsomes
elf
-di
agn
ost
ic
res
ults.

N
umb
erP
Ce
f
『sD
sl
ag
YE
CS
o
阻N
de 1
P
ri
nt F
2 F
3 F
4

3
. When" 3
.RECORDEDDATA"onSELF-DIAGRESULTSscreen
ENGINESPEED 103
8 巾m
i
ns t
ep1i stouched，"FREEZEFRAMEDATA"，whichshowsthe
FREEZECODE P01
02 op
erati
ons ta
tewhent hemal
fun
cti
oni
sdetec
ted，isdi
spla
yed
.
FUELS Y
S-Bl MODE5
COOLANTTEMP 8
5' C
L-FUELTRM・B
l 10%
0
S-FUELTRM-
Bl 10%
0
VEHICLSPEED okm/h
B/FUELSCHDL 7.
9m sec 目

INT/
ATEMPSE -45'C

P
ri
nt F
2 F
3 F
4

4
. S
elect".MEMORYERASE"andpush"YES"，andt
2 henerase
s
elf
-dia
gnos
ticr
esu
l.
t

CLEAR DIAGNOSTIC CODE?

P
res
s"Y
ES"o
rNO
" ・

F
l F
2 F
3 F
4

EC-47
 TROUBLEDIAGNOSIS

SST(
Con
t'd
)
DISPLAYITEML
lST

Diagnosisi
tem M
alf
unc
tio
nReturnC
ond
iti
on D
isp
lay MIL T
rip

NODTC • Nom
alf
unc
tio
nisd
ete
cte
dinanyo
fth
eci
rcu
its
. NODTC .
Massai
rfl
owsensor • Whenenginei sstopped( i
gni
tionswi
t c
hON) Massa i
rfl
owsensor ON
(MAFS) andmassa irflowsensoroutputvoltagehas LOWINPUTOPEN
been9Vo rmoref orpredeterminedperio
d. [P0102]
• Whenenginei sr u
nningandmassa i
rf low HIGHINPUTSHORT
sensoro ut
putv o
l t
agehasbeen5Vo rlessfo
r [P0103]
predeterminedperiod
.
Enginec ool
ant • Enginec ool
anttemperaturesensorout
put Enginecoo
lan
ttemperature ON 2
temperaturesensor voltag
ehasbeena pproximat
ely8Vo rmore sensor
(ECTS)(CIRCUIT) (open)orl e
ssthanO.06V(sho 同)fo
r LOWINPUTOPEN
predeterminedperio
d‘ [POl17]
HIGHINPUTSHORT
[POl18]
T
hro
ttl
ep o
siti
onsensor • Sensorpowersupplyv olta
gehasa Throt
tlepositi
onsensor ON合 1
s
ign
alcir
cui
t malfunc
tion. TPS2LOWINPUTOPEN
•T hro
ttleposit
ionsensorsign
alc i
rcu
itisopenor [P0122]
shorted
司 TPS2HIGHINPUT
• Am alfunct
ionoccursinrel
ationbetween SHORT[P0123]
th
rottl
ep os
itio
nsensors1and2 . TPS1LOWINPUT[P0222]
• Whent heful
ly-c
lose
dp o
sitio
nl ear
ningvalu
e TPS1HIGHINPUT[P0223]
wasu nusuall
ys m
allorwasn otl ea
rni
ng. Elec
tricthr
ottl
ec on
trol
motorpowersupplys ho
rt
[Pl124]
Elec
tricthr
ottl
ec on
trol
motorpowersupplyopen
[Pl126]
Elec
tricthr
ottl
ec on
trol
motors ho
rt[Pl128]
TSP1・2f ull
y-clos
edlearned
valuedecrease[P1225]
TSPf ully-
close
dl earned
valuemalfunctio
ning
update[P1226]
TSP1・2[P2135]
TPSFThrottlepositio
n
sensor
A
ccele
rationsensor •Accel
eratorpedalposi
tionsensors
igna
lcir
cui
t APPSENSOR ON*
s
ign
alc i
rcu
it i
sopeno rsh
orted. APS1LOWINPUT[P2122]
• Amalfu
nctio
noccursi nrel
ati
onbetween APS1HIGHINPUT
a
cce
leratorped
alp os
itio
nsensors1and2 . [P2123]
APS2LOWINPUT[P2127]
APS2HIGHINPUT
[P2128]
APS1[P2138]
APSFAcceleratorp
osi
tio
n
sensor
O2Sensors
ign
al(open • Heatedoxygensensors
ign
alc
irc
uiti
s叩 e
n. O2Sensor81 ON 2
c
irc
uit
) Fr02
lSOpen[P0134]
O2Sensors
ign
al(
sho
rt • Heatedoxygensensorout
putv
olt
agei
shi
ghe
r O2Sensor81 ON 2
c
irc
uit
) thannormal(2Vormore
). FR02/SVOLTAGE
[P0132]
O2Sensorh
eat
ers
ign
al • Heatedoxygensensors
ign
alc
irc
uiti
sopen. 02HTR_81 ON 2
c
irc
uit FrO2HEATERLOW
INPUT[P0031]
FrO2HEATERHIGH
INPUT[P0032]
OVERHEAT(STEP1
) • Whenenginec
ool
anttemperaturei
s110.C. OVERHEATSTEP#1 ON
[P1218]

EC-48
 TROUBLEDIAGNOSIS

D
iag
nos
isi
tem M
alf
unc
tio
nReturnC
ond
iti
on D
isp
lay MIL T
rip

LPGinj
ecto
r1 • LPGi
nje
cto
rsi
gna
lci
rcu
iti
sopen LPGF /INJ1 司

ma
lfu
nctio
n MALFUNCTION
(INJECTION)[P1240]
LPGinj
ecto
r1 • LPGi
nje
cto
rsi
gna
lci
rcu
iti
sopen. LPGF/INJ1malfunct
ion
ma
lfu
nctio
n (Noi
nje
ctio
n)[P1241]
LPGinj
ecto
r2 • LPGi
nje
cto
rsi
gna
lci
rcu
iti
sopen. LPGF /INJ2
ma
lfu
nctio
n MALFUNCTION
(INJECTION)[P1242]
LPGinj
ecto
r2 • LPGi
nje
cto
rsi
gna
lci
rcu
iti
sopen LPGF /I
NJ2
ma
lfu
nctio
n MALFUNCTION(NO
INJECTION)[P1243]
LPGf ue
lpressu
re • LPGfue
lpressuresensoro
utputvo
lta
gei
s LPGFUELPRESSURE
sensormal
fun
ction hi
ghe
rthannormal(?Vo rmor
e). SENSORHIGHINPUT
MALFUNCTION[P1245]
LPGvap
oriz
er • LPGf
uelpressurei
sex
ces
siv
elyh
igh
. LPGFUELPRESSURE
ma
lfu
ncti
on EXCESSIVELYHIGH
MALFUNCTION[P1249]
Thr
ottl
e/Acce
lerat
or • Powersupply0
1acce
lerato
rp o
sit
ionsensor AVCCSHORT[P1229]
posi
tionsensorpower andth
rott
lepos
iti
onsensorissho
rted
.
supply
Crankshaftpo
sit
ion • Thec rankshaf
tposit
ionsensor(POS)s ign
alis CKPSEN/CIRCUIT ON 2
sensor1&deg;(POS) notdetectedforapredeterminedtimeatthe [P0335]
sign
alc i
rcu
it enginestartordurin
genginer unni
ng( d
uring HALLPOSSENSOR
camshaftp os
itio
nsensor(REF)s igna
linpu
t). PPENDIAGNOSISAT
• Thec rankshaf
tp o
sit
ionsensor(POS)s ign
al START[P0335]
irr
egula
rwaveformi sdetectedlo
ra Hal
lPOSSENSOR
predeterminedtimedurin
genginer unni
ng INSTANTANEOUS/NOISEI
(duri
ngcamshaftp os
itio
nsensor(REF)s igna
l DAMAGEDTEETH
inp
ut). DIAGNOSIS[P0335]
Crankshaftpo
sit
ion • Atstart-u
p， nocamshaftp os
itionsensor(REF) CMPSEN/CIRCUIT ON 2
sensor120&deg;(REF) sign
alhasbeendetectedl o
rmoret hana [P0340]
sign
alc i
rcu
it predeterminedp er
iod. Hal
lPHASESENSOR
• Thecamshaftp osi
tionsensor(REF)s igna
lis OPENDIAGNOSISAT
notdetectedlorapredeterminedt imeduring START[P0340]
enginer unn
i ng(duri
ngc ran
kshaftposi
tion Hal
lPHASESENSOR
sensor(POS)s ign
ali n
put
). INSTANTANEOUS/NOISEI
• Acamshaftp osi
tionsensor(REF)s igna
l DAMAGEDTEETH
irre
gularwaveformi sdetectedlora DIAGNOSIS[P0335]
predeterminedt imeduringenginerunning
(duri
ngc ran
k s
h a
ftp o
sitio
nsensor(POS)s ig
nal
inp
ut).
V
ehi
clespeedsensor •Ve
hiclesensorsign
alhasn otbeeninptunder VEHSPEEDSEN/CIRC
u ON 2
somec o
nditi
onlorapredeterminedt
imedu
ring [P0500]
dr
ivi
nga f
terwarmingup ECMVEHSPEEDSEN/
CIRC[P0500]

EC-49
 TROUBLEDIAGNOSIS

Diagnosisi
tem M
alf
unc
tio
nReturnC
ond
iti
on D
isp
lay MIL T
rip

Enginec
ont
rolmodule • CPUsystemorc
irc
uit
sinECMhavea ECM[P0605) ON* 1or2(NOTE)
ma
lfu
nct
ion. SYNCMONITORING
PARTSDIAGNOSIS
[P0605)
PARTSSETTING
CALCULATION
EXERCISEDIAGNOSIS
[P0605]ALUFUNCTION
DIAGNOSIS[P0605]
CALCULATIONRESULT
COLLECTIONFUNCTION
DIAGNOSIS[P0605]
ADDIAGNOSIS[P0605]
CPUFUNCTION
DlAGNOSIS[P0605]
TPS4TIMEINPUT
DIAGNOSIS[P0605]
VAPOM-Sd iagno
sis
[P0605]
VAPOM-Sd iagnos
is
[P0605]
THROTTLETARGET
POSITIONDIAGNOSIS
[P0605]
Enginecool
anttemperature
sensorM-Sd ia
gnosis
[P0605]
TQHOAPMALFUNCTION
DIAGNOSIS[P0605]
TTEPTDDIAGNOSIS
[P0605]
TATEDIAGNOSIS[P0605]
TTEPDIAGNOSIS[P0605]
S/SOFFsystemd iagnosis
[P0605]
TASKEXECUTION
CYCLEDIAGNOSIS
(MAIN)[P0605]
ROMFUNCTION
DIAGNOSIS(MAIN)
[P0605]
RAMFUNCTION
DIAGNOSIS(MAIN)
[P0605]
WTDFUNCTION
DIAGNOSIS(MAIN)
[P0605]
TIMER/ CLOCK
FUNCTIONDIAGNOSIS
(MAIN)[P0605]
EEP-ROMWRITING
DIAGNOSIS(MAIN)
[P0605]
EEP-ROMREADING
DIAGNOSIS(MAIN)
[P0605]
ROMFUNCTION
DIAGNOSIS(SUB)[P0605]
RAMFUNCTION
DIAGNOSIS2(MAIN)
[P0605]
Mal
func
tio
nin
dic
alo
r • Valveorc
irc
uitm
alf
unc
tio
noccurss
eve
ral MIUCIRC[P0650] 2
lamp times
. WARNINGLAMP(VALVE
SYSTEM)[P0650]
WARNINGLAMP
(CIRCUITSYSTEM)
[P0650]

EC-50
 TROUBLEDIAGNOSIS

Diagnosisi
tem M
alf
unc
tio
nReturnC
ond
iti
on D
isp
lay MIL T
rip

ECMpowersupply • Poweri
sno
tsu
ppl
iedt
oECMf
orsomet
ime
. ECMBACKUP/CIRC ON 2
c
irc
uit [P1065)
BACKUPRAMSYSTEM
DIAGNOSIS(MAIN)
[P1065)
E
lec
trict
hro
ttl
eco
ntr
ol • Becauseofmechanicalmalfun
c t
ionofel
ect
ric ETCACTR[P1121) ON*
a
ctuat
or th
rot
tleco
ntro
la c
tuator，e
lec
tricthr
ott
lec
ontro
l RETURNSPRING
actu
atordoesnotoperatenorm剖￨弘 DIAGNOSIS[P1121)
DEFAULTMECHANISM
DIAGNOSIS[P1121)
THROTTLEOPEN
LOCKINGDIAGNOSIS
[P1121)
E
lec
tri
cthr
ott
lec
ont
rol • Whenam alfun
ctionoccurredduet oth
e ETCFUNCTION/CIRC ON*
f
unc
tion cor
relatio
nbetweenthet arge
tthrot
tlepo
siti
on [P1122)
andt heactu
althro
ttl
ep o
sitio
n. ETCFUNCTION/CIRC
• Overc ur
rentflow
si n
tothro
ttlemotorco
ntro
l CONTROLSYSTEM
ci
rcu.
it MONITORING
DIAGNOSIS[P1122)
THROTTLESERVO
MALFUNCTION
DIAGNOSIS[P1122)
T
hro
ttl
ec on
tro
lmotor • Whenth
rot
tleco
ntrolmotorr
ela
yhasbeen ETCMOTRLY/CIRC ON* LockedON:1
r
ela
ycirc
uit lo
cke
dONo rOFF. [P1123) (Loc
陶 dON) LockedOFF:
RELAYONLOCKING 2
DIAGNOSIS[P1123)
Engineovertemperature • Enginecoolan
ttemperaturesensorout
put ENGOVERTEMP[P1217) ON
(Over
heat) volt
agehasbeenapproximatelyO.35Vorlower
fo
rapredeterminedp er
iodoftime
.(wit
hthe
cool
anttemperaturesensornor
mal).
I
gni
tio
nsi
gna
lsystem • Ign
itionsi
gna
lhasno
tbeenc on
tinuo
usly IGN SIGNAL-PRIMARY ON 2
generatedwhi
let
heenginei
srunn
ing. DIAGNOSIS[P0350)
Brakesw
itc
hsi
gna
l • Brakes
wit
chs
ign
alc
irc
uiti
sopeno
rsh
ort
ed. BRAKESW/CIRCUIT ON 2
ci
rcu
it [P1805)
BRAKESW/CIRCUIT
[P1805)

N
ote
:Numbero
ftr
ipsv
ari
esdependingond
iag
nos
iscontent

EC-51
 TROUBLEDIAGNOSIS

SST(
Con
t'd
)
Tr
ip1 :Ifa malfunct
ionisd etecte
dbys elf-d
iagnosi
sbetweent he
timeigni
tio
nsw i
tchisturnedON( en
ginei
sr un
ning)andt henturned
OFF( thi
sisde fin
edas" tr
ip)，
" MILi si
l.
tThecorrespondingDTCi s
recordedimmediatel
ya f
terdete
ction
.
官ip2:Whenam alfunc
tionisdetectedbyself-d
iagnosi
sforthefir
st
timeint hefirs
tt rp，a t
i e
ntat
ive DTC isr ecord
ed.I fthe same
malfun
ctionisd e
tecteda gain by se
lf-
diagn
osisi nt henexttrip
(secondtri
p)，MILisli
tandt hecorresp
ondin
gf i
nalDTCi sreco
r d
ed.

SSTSELF-DIAGNOSTICRESUL
TSTIMING
DTC RESULT
P
P
0
0
1
0
1
1
2 MAFSEN/C
0A I
RTEMPS
IR
E
C
U
N
/
I
C
T
IR
C
T
IM
1
s
E
t
。 • F
d
e
o
t
ri
ect
t
e
i
m
o
so
no
ft
fam
rp 1，t
i
al
funct
i
i
m
o
i
n
n
.
g"0“isdispla
yedimme
diatel
ya ft
er

• Foritemso ftr
ip2，whenam a
lfunctio
nisdete
ctedforthef
irs
t
t
ime( tr
ip1)，timing"1st
"isd i
splay
ed.Whena m alf
unc
tionis
d
etecteda gainint henextt
rip(tr
ip2)，t
iisdispl
ayedas" 0
".
A
cc u
mula t
iv ecount
ingispertormedattheendofwarming-up
o
peratio
n.
N
umb
erP
or
fe
s
Ds
i・
a
gYC
目

E
S
o
d
'
e:
P
ri
nt F2 F3 F
4 CONDITIONSTOTURNOFFMIL
• TheMIL，markedw ithぺi st u
rne
d0行 wheni gn
iti
onswitchis
turnedON(enginesta同s)a
gainaf
ternormalsta
teisresumed.
• Foro th
ers
elf-d
iagn
osticites，s
m el
f-di
agnos
ticresu
ltssha
llbe
erasedbytur
ningign
i t
ions
witcht
oOFFa ft
ernormalopera
tion
i
sresumed.

FREEZEFRAMEDATA
• Dri
vingc ond
itionss tore
da tt he moment a m alf
u n
cti
oni s
detec
tedandd ispl
ayed.
• Thisdatacanbeusedt oreproducecon
diti
onsleadinguptothe
mal
functi
on.
• I
fmultip
leDTCse xi
st，onlythefir
stonedetect
edw i
llbes t
ored
and displ
ayed.Ift he same m a
lfun
ctionisd et
ecteds eve
ral
di
ffer
enttimes，t
hed atastoredfi
rs
twi
llbedispl
ayed.

DISPLAYITEMLIST

Storeddatai
tem U
nit D
esc
rip
tio
n

FUELSYS-B1 Disp
lay
sair-
fue
lr a
tiofeedbackcondit
ionsatt
hetimeam alf
unctionoccurr
ed.
FUELSYS-B2 Mode2:Nofeedbackc ontro
lperformedbecauseo fthesystemm alfu
nction
Mode3:Feedbackcontroldidnotrespondtodr
ivingcondi
tions
.
Mode4:Feedbackc ont
rolpe巾 rmedusingheatedoxygens enso
r.
Mode5:Conditio
nst osh
iftint
ot h
efeedbackcont
roln o
te st
ablishedaft
erign
iti
on
sw
itchwasturnedON.
CLV:CalculatedLoadValue % Basedonthef
uelinj
ect
ionamount，i
tca
lcu
lat
esandd
isp
lay
stheenginel
oada
t
thetimeam
alf
unct
ionisdete
cted.
COOLANTTEMP c
。 D
isp
lay
senginec
ool
anttemperaturea
tthetimeam
alf
unc
tio
nisd
ete
cte
d.
L-FUELTRIM-B1 % Dis
playsa
ir-
fue
lra
tiofeedbacklearnedvaluea
tth
etimeam
alf
unc
tio
nis
L-FUELTRIM-B2 d
etect
ed.
S-FUELTRIM-B1 Dis
playsa
ir-
fue
lra
tiofeedbackc
orr
ect
edvaluea
tth
etimeam
alf
unc
tio
nis
S-FUELTRIM-B2 d
etect
ed.
ENGINESPEED rpm D
isp
lay
senginespeeda
tth
etimeam
alf
unc
tio
nisd
ete
cte
d.
VEHICLESPEED km/h D
isp
lay
sve
hic
lespeeda
tthetimeam
alf
unc
tio
nisd
ete
cte
d.

ShowB1:N
o.1and4c
yli
nde
rs，B2:No.2and3c
yli
nde
rs.

EC-52
 TROUBLEDIAGNOSIS

SST(
Con
t'd
)
DATAMONITOR
Allowsdeterm
inatio
nandi denti
1ic
ati
on01t h
ep ossibl
esource01
am alf
uncti
onbasedons el
f-diagn
osistes
tresult
s.
• DisplaysECMi nput
loutp
uts i
gnaldatainrealtime
.
Recordsand p r
intsoutt hedatab e10
reanda ftertheengine
mal1unct
ionorst
all，ei
the
ra utom
atica
llyorm an
ually.

DISPLAYITEML
lST

M
oni
tori
tem U
nit D
esc
rip
tio
n

ENGSPEED rpm Enginespeedcomputedfromc

ran
ksh
aftanglesensors
ign
al
MASA
lFSE・B1 V Massa
irf
lowsensoro
utp
utv
olt
age
B/FUELSCト
iDL 打l
sec Valuec
alc
ula
tedbyECM
A/FALPHA % Averageo
fcy
cle
sfo
rai
r-f
uelr
ati
ofeedbackc
orr
ect
ionc
oef
fic
ien
t
COOLANTTEMP/S "C Valueconvertedin
totemperaturefromt
heo
utp
utv
olt
ageo
fth
eenginec
ool
ant
temperaturesen
sor.
H02S1 V Outputv
olt
ageo
fheatedoxygensensor
H02S1MNTR RICH/LEAN Air
-fue
lratioi
sgive
nasheatedoxygensensoroutputsig
nalduri
ngair
-fue
lrati
o
feedbackcont
rol
RICH:Heatedoxygensensorou
tputishi
gh.Cont
rollin
gt olo
werthevaluefo
r
leanerra
tio
.
LEAN:Heatedoxygensensoroutp
utislow
.C o
ntrol
lingtorais
et h
evaluefor
rich
errat
io.
VHCLSPEEDSE km/h Valuecomputedfromv
ehi
clespeedsensor
BATIERYVOLT V ECMb
att
eryv
olt
age
ACCELSEN1 A
cce
ler
ato
rpedalp
osi
tio
nsensor1o
utp
utv
olt
age
ACCELSEN2 A
cce
ler
ato
rpedalp
osi
tio
nsensor2o
utp
utv
olt
age
THRTLSEN1 T
hro
ttl
epo
sit
ionsensor1o
utp
utv
olt
age
THRTLSEN2 T
hro
ttl
epo
sit
ionsensor2o
utp
utv
olt
age
STARTSIGNAL ON/OFF ON/OFFs
tat
usasjudgedbyeachi
npu
tsi
gna
l
P/NPOSIS W
IGNITIONS W
BRAKESW
INJPULSE 町l
sec Valuec
alc
ula
tedbyECM
IGNTIMING "BTDC
I
nca
lcu
lab
le % Valuei
sca
lcu
lat
edenginel
oadbasedont
hef
ueli
nje
cti
o .
namount
FUELPUMPRLY ON/OFF S
tat
uso
feachc
ont
rolasc
alc
ula
tedbyECM.
THRTLRELAY
H02S1HTR
IDLAIVLEARN DONElYET S
tat
eof"
Idl
eAi
rVolumeL
ear
nin
g'¥
B
att
eryv
olt
age D
isp
lay
sva
lue
smeasuredbyv
olt
ageprobe 目

V
ehi
clespeedmaximuml
im
it km/h V
ehi
clespeedmaximumv
alu
e
LPGf
uelin
ject
ionwidt
h ms Valuec
alc
ula
tedbyECM
LPGba
sicfue
li n
jec
tio
n
A
ir-
fue
lra
tioc
orr
ect
ion(
Gas
oli
ne) %
A
ir-
fue
lra
tioc
orr
ect
ion(LPG) %
F
uelt
ype GASOLlNEI Fu
elchangings
wit
chconnectingc
ond
iti
on
LPG/NEUTRAL
LPGf
uelpressure g
k/cm2 Valueconvertedi
ntopressurefromt
heo
utp
utv
olt
ageo
fLPGf
uelpressure
senso
r.

EC-53
 TROUBLEDIAGNOSIS

M
oni
tori
tem U
nit D
esc
rip
tio
n

I
nch
ings
wit
ch ON/OFF ON/OFFs
tat
usasjudgedbyeachi
npu
tsi
gna
l
F
uelchangings
wit
ch1
F
uelchangings
wit
ch2
LPGi
nte
rce
pti
onv
alv
ere
lay

4CHGRAPHDISPLAY(HOLD)OUTPUT
SPECIFICATION

C
ond
iti
on C
ond
iti
on
。
m
旬

Normal (1
)Supportedbysupportdat
a.
nz-

(2
)Graphiss u
pport
ed.
回一
酔一
'-FE

Datavaluetha
tisn otapp
liedtocommunicationi
n
叫IJ

RUNmodei sdis
playe
dasに "
一同町山

p
S
問
Ad

S
ele
cti
onnarrowing (1
)Supportedbysupportd
ata
.
(2
)Graphissuppo同ed.
(3
)Selec
ted.
START
Datavaluetha
tisnotap 削
除dt ocommunicationi
n
ECM0372 RUNmodei sdis
pla
yedas"---"
.
Normal(LOAD) (
1)Saved.
S
ele
cti
onnarrowing(LOAD) (
1)Saved.
(
2)Selec
ted.

ACTIVETEST
Usethi
smodet odetermineandi den
tif
yt h
edeta
ilsofamalfu
nct
ion，
basedons e
lf-
diagn
osist estres
ultsanddatao bta
inedfromDATA
MONITORmode.SST ，insteado
ft heECMont heveh
ice，
l sendsa
dr
ivesi
gna
lt oa
ctuatorstocheckt h
eirope
rati
on.

DISPLAYITEML
lST

A
cti
vet
esti
tem De
唱cr
ipt
ion

Fu
eli
nje
cti
ontes
t • Cani n
creaseordecreasetheamountoff
ueli吋ectio
n(:t25%).
LPGf
uelin
jec
tio
nte
st • Canreproducecondi
tionsres
ult
ingfroma
ir-f
uelra
tiorelate
dm alfu
nct
ions(e.
g.he
sit
atin，
o poor
a四 e
lera
tio
n;poorr a
cing，e
t沼.
)andhelpsolvethesemalfunctionsbypin
poi
ntingt
hecauses.
I
gni
tio
nti
min
gte
st -Allowss
ett
ingac
orr
ect
ionc
oef
fic
ien
tfo
rre
tar
dig・
n (10・0・
)
POWERBALANCE(
Gas
oli
ne) ・
Stopso
per
ati
ono
fsp
eci
fie
din
jec
ぬ ιAlso，d
isp
lay
senginespeed創 t
hatt
ime
.
(LPG，
Neu
tra
l) • M
ain
lyusedt
oin
spe
ctf
orm
isf
iri
ngc
yli
nde
rs.

EC-54
 TROUBLEDIAGNOSIS

SST(
Con
t'd
)
CONTROLUNITPARTNUMBER
D
isp
lay
spa
rtnumbero
fECMmountedonv
ehi
cle
.

<ECMPARTNUMBER>

2371001234

PRESSYES.

PRINT I F2 F3 F4

ECM0373
S
elf
-di
agn
osi
sFunction(
wit
hou
tSST)
DESCRIPTION
• Inself-d
iagnosis，whenanyo ft hecri
tic
als ens
orsora c
tuat
or
andexhaustgasc on
trolsystemsnecessaryf orECMc o
ntr
ol
ret
urnam a l
functionandself
-diagn
osisdetect
ioncond
itio
nsare
sat
isfi
ed，aDTCc orre
spondin
gt othesuspectsystemisstor
ed
i
nECMf oreasiertro
ubledia
gnosis
.S el
f-diag
nosti
cresu
ltscan
bed i
splayedw i
thMILi nth
ec omb
i n
ationm e
ter.
• Diagnosistestmode

OPERATIONPROCEDURE
• Re
fert
ot h
ef ol
lowi
ngf
orhowtoa
cti
vat
ese
lf-
dia
gno
sismodeo
r
e
rasese
lf-di
agnos
ticr
esu
lts
.
CAUTION:
Whena malfunctionoccursi nacce
lerat
orpedalpos
ition
sensors， se
lf-di
agnos
is( with
outSSηcannotbea c
tiva
ted.
Thus，use SST t o perform se
lf-di
agn
oss，and r
i ep
air
malfunctioningpa凡

EC-55
 TROUBLEDIAGNOSIS

S
elf
-di
agn
osi
sFunction(
wit
hou
tSST)(
Con
t1d
)

[Diagnostict
estmode(
sel
f-d
iag
nos
ticr
esu
lts
)st
art
ingprocedure)

1Turni
gni
tio
nsw
itc
hONw
itha
cce
ler
ato
rpe
dalr
ele
ase
d

2A
fte
r3seconds，f
ul
lydepressa
cce
ler
ato
rpe
dalandthenr
ele
as .
tQuicklyrepeatt
ei hisc
ycl
e5t
ime
swi
thi
n5seconds(
endi
nre
lea
sedp
osi
tio
n)

3Fu
llydepressacce
lerat
orpedaげ secondsa
fte
rre
lea
sin
git，andkeept
hatp
osi
tio
nap
pro
xim
ate
ly10seconds(
un
ti
lMILb
lin
ks)
. D
iag
nos
tict
est
mode1s elf-
dia
gnost
icres
ult
ssta
rts

4Retuma
cce
ler
ato .
rpedalExecutes
elf
-di
agn
osi
s
• Performself-di
agnos
iswithig
niti
onswi
tchON.[Diag
nostictes
tmode1( self
-dia
gno
sticr
esul
ts)
]
•S ta
rtingengineinDiagnos
tictes
tmode1( se
lf-
diag
nosti
cr e
sults
)opensheatedoxygensensormo
nit
or.[
Dia
gno
sti
cte
stmode1(
hea
ted
oxygensensorm on
itor)
]
• Tumingi g
niti
onswitchOFFr et
urnst
omode1a uto
matic
ally.[Normalc
ond
ition
]

CAUTION:Countt
imea∞u
rate
lywit
hwatcho
re q
uiv
alent
I
fmode1doesnottur
ntomode2，tu
rnign
iti
onsw
itc
hOFFandw
aitf
ora
tle
as ∞nds
t10se

[Self-diagnosisr
esu
ltserasingprocedure)

1F
u l l
ydepressa c
cele
rat
orpeda
linDiagno
stict
estmode1(s
elf-
diagnosticr
eslぬ
u )
， andkeepthep
osi
tio
natl
eas ∞
t10se n
ds. S
elf
-di
agn
ost
ic
r
e sultsareerased
• Releaseacce
lerat
o .
rpedalMakesuresel
f-di
agn
ost
icr
esu
ltsareerased
・ T urni
ngigni
tionsw
itc
hOFFr et
urn
st omode1

112nOFF[ 斗 S
tar
tD i
agnost
ictes
tmode1 10sec
(
self
-dia
gno
sticr
esul
ts) orlon
ger Erases
elf
-di
agn
ost
icr
esu
lt

Fu
lly-o
pen~
，
ー I 1"寸/
A
ccele
rator Approx.10sec
ped
al
Ful
ly-
close
dL

D
iag
nos
ist
estmode Mode1(
nor
ma ∞
l n
dit
ion
) Mode2(
sel
f-d
iag
nos
is) Mode1

ECM0282

EC-56
 TROUBLEDIAGNOSIS

S
elf
-di
agn
osi
sFunction(
wit
hou T
tSS)(
Con
t'd
)
DIAGNOSTICTESTMODE1・SELF-DIAGNOSTIC
RESULTS
Inth
ismode，theMILbli
nks(ind
icat
ingtheDTC)t
oid
ent
ifyt
he
E
x a
mpl
eofc
odeNo
.13
20
0.
6
systemt
hatr
eturne
dam al
fun
ction.
ON I
fnoDTCi sdet
ected，DTC唱 000"isdis
play
ed.
OFF

0
.
叫町
3s
ec.X1
0
ECM0284

DISPLAYITEML
lST

DTC
(code Diagnosisi
tem M
all
unc
tio
nReturnC
ond
iti
on MIL T
rip
number)
0000 NODTC • Nom
all
unc
tio
nisd
ete
cte
dinany0
1th
eci
rcu
its
.
Massa
irI
lowsensor(MAFS) • Whenenginei sstopped(i
gni
tio
nsw
itc
hON)andmassa
ir ON
Ilowsensoro u
tputvolta
gehasbeen9Vormoref
or
predeterminedperiod
P0102 Massa
irf
lowsensor • Massa
irf
lowsensorLowI
npu
t(o
pen
)
P0103 Massa
irf
lowsensor • Massa
irf
lowsensorHighI
npu
t(s
hor
t)
Engine c o
olan
t temperature • Enginec oolanttemperaturesensoro
utputv
olt
agehasbeen ON 2
sensor(ECTS)(CIRCUIT) approximately8Vo rmore( o
pen)orles
sthan0.66V(
sho
rt)
fo
rpredeterminedp e
riod.
P0117 Engine c
ool
ant temperature
• Enginec
ool
anttemperaturesensorLowI
npu
t(o
pen
)
sensor
P0118 Engine c
ool
ant temperature
• Enginec
ool
anttemperaturesensorHighI
npu
t(s
hor
t)
sensor
T
hrott
lep
osi
tio
n sensor s
ign
al • Sensorpowers uppl
yvoltag
ehasam alf
unct
ion. ON*
c
irc
uit •T hr
ottleposit
ionsensorsigna
lc i
rcu
itisopenorsho
rted.
• Am alfu
nc t
iono cc
ursinrela
tionbetweenthr
ott
lepo
sitio
n
sensors1and2 .
• Whent heful
ly-cl
osedpos
itio
nl ea
rnin
gvaluewasu nu
suall
y
smallorwasn o
tl ea
rni
ng.
P0122 T
hro
ttl
epo
sit
ionsensor • TPS2LowI
npu
tma
llu
nct
ion
P0123 T
hro
ttl
epo
sit
ionsensor • TPS2HighI
npu
tma
llu
nct
ion
P0222 T
hro
ttl
epo
sit
ionsensor1 • TPS1LowI
npu
tma
lfu
nct
ion
P0223 T
hro
ttl
epo
sit
ionsensor1 • TPS1HighI
npu
tma
lfu
nct
ion

EC-57
 TROUBLEDIAGNOSIS

DTC
(code Diagnosisi
tem M
alf
unc
tio
nReturnC
ond
iti
on MIL T
rip
number)
A
ccelera
tio
n sensor s
ign
al•Accelera
torpedalposi
tio
nsensorsigna
lci
rcu
itisopeno r ON*
c
irc
uit s
horte
d.
• Amalfun
ctionoccursinre
lat
ionbetweena
ccele
ratorpedal
p
osi
tionsensors1and2 .
P2138 Acce
lerat
or pedal p o
sis
ion
• APS1-2c
onf
orm
itym
alf
unc
tio
n
sensornonadjustment
P2122 Acce
lera
tor pedal p
osi
tio
n
• APS1LowI
npu
tma
lfu
nct
ion
sensor1
P2123 Acce
lera
tor pedal p
osi
tio
n
• APS1HighI
npu
tma
lfu
nct
ion
sensor1
P2127 Acc
elera
tor pedal p
osi
tio
n
• APS2LowI
npu
tma
lfu
nct
ion
sensor2
P2128 Acc
elera
tor pedal p
osi
tio
n
• APS2HighI
npu
tma
lfu
nct
ion
sensor2
Heatedoxygensensor(
cir
cui
t) • Heatedoxygensensors
ign
alc
irc
ui s叩 e
ti n. ON 2
P0134 Heatedoxygensensor61 • F
r02/Sopend
iag
nos
is(bank1
)
Heated oxygen sensor s
ign
al • Heatedoxygensensoro
utp
utv
olt
agei
shi
ghe
rthannormal ON 2
(sh
ortci
rcu
it) (2Vormore)
.
P0132 Heatedoxygensensor61 • F
r02/Sm
atf
unc
tio
nin
gvo
lta
ged
iag
nos
is(bank1
)
Heatedoxygensensorh
eat
er • Heatedoxygensensors
ign
alc
irc
ui s叩 e
ti n. ON 2
P0171 FuelsystemLEAN61 •Aft
erwarmingupengine，m
ix t
urerat
ioi
sto
ol e
anand ON 2
heatedoxygensensoro
utputisst
uckandnotin
ver
ted
.
P0172 F
uelsystemRICH61 •Aft
erwarmingupengine，
mixtu
rera
tioi
stoori
chandheated ON 2
oxygensensoro
utputisst
uckandnotin
ver
ted
.
Crankshaft p
ositi
on sensor • Thec ranks
h a
ftp o
sitio
nsensor(POS)s ign
ali snotdetected ON 2
1&deg;(POS)sig
nalci
rcu
it fo
rapredeterminedt i
m ea
ttheengines ta
rto rdurin
gengine
running(duringcamshaftposit
ionsensor(REF)s ig
nal
in
put)
.
• Thec rankshaf
tp o
sitionsensor(POS)s igna
li rr
egular
waveformi sdetectedforapredeterminedt imeduring
enginer un
n in
g( du
ringcamshaftpositio
nsensor(REF)
sig
nali n
put)
.
P0335 Ringgearopenc
irc
uitPOS • H
allPOSsensoropend
iag
nos
isa
tst
art
P0335 Ringgearopenc
irc
uitPOS • H
allPOSsensoropend
iag
nos
isa
fte
rst
art
P0335 Ringgearopenc
irc
uitPOS • H
allPOSsensorinstantaneous/noise/damagedt
eet
h
d
iagn
osi
s
Crankshaft po
sit
ion sensor • Atsta・ up
は ，nocamshaftp osi
tionsensor(REF)s ign
alhas ON 2
120&deg;(REF)si
gna
lci
rcu
it beend etectedf
ormorethanapredeterminedp erio
d.
• Thecamshaftp osit
ionsensor(REF)s ign
alisn otdetected
forapredeterminedtimed u
ringenginer u
nning( d
uring
cran
kshaftp o
sit
ionsensor(POS)s i
gnalinp
ut)
.
• Acamshaftp osi
tionsensor(REF)s ign
alirreg
ularwaveform
isdete
ct edforapredeterminedtimeduringenginer unnin
g
(dur
ingc r
a n
kshaftpos
itionsensor(POS)s ign
ali n
put)
.
P0340 Crankshaftp
osi
tio
nsensor • H
allPHASEsensoropend
iag
nos
isa
tst
art
P0340 Crankshaftp
osi
tio
nsensor • H
allPHASEsensoropend
iag
nos
isa
fte
rst
art
P0340 Crankshaftp
osi
tio
nsensor • H
allPHASEsensorinstantaneous/noise/damagedt
eet
h
d
iagn
osi
s
P0350 I
gni
tio
nprimarys
ign
al • I
gni
tio
nprimarys
ign
ald
iag
nos
is
P0500 V
ehi
clespeeds
ign
alsystem •Veh
iclesensors
ignalhasn otbeeninp
utundersome ON 2
con
ditio
nforapredeterminedtimed
uringd
rivi
ngaf
ter
warmlngup.

EC-58
 TROUBLEDIAGNOSIS

DTC
(code Diagnosisi
tem M
alf
unc
tio
nReturnC
ond
iti
on MIL T
rip
number)
Enginec
ont
rolmodule • CPUsystemo
rci
rcu
itsi
nECMhaveam
alf
unc
tio
n. ON* 1or2
P0605 C
ont
rolu
nit • SYNCm
oni
tor
ingp
art
sdi
agn
osi
s (Note)

P0605 C
ont
rolu
nit • ALUf
unc
tio
ndi
agn
osi
s
P0605 C
ont
rolu
nit • P
art
sse
tti
ngc
alc
ula
tio
nex
erc
ised
iag
nos
is
P0605 C
ont
rolu
nit •C
alc
ula
tio
nre
sul
tco
lle
cti
onf
unc
tio
ndi
agn
osi
s
P0605 C
ont
rolu
nit • ADd
iag
nos
is
P0605 C
ont
rolu
nit • CPUf
unc
tio
ndi
agn
osi
s
P0605 C
ont
rolu
nit • TPS4t
imei
npu
tdi
agn
osi
s
P0605 C
ont
rolu
nit • VAPOM-Sd
iag
nos
is
P0605 C
ont
rolu
nit • APOM-Sd
iag
nos
is
P0605 C
ont
rolu
nit •T
hro
ttl
eta
rge
tpo
sit
iond
iag
nos
is
P0605 C
ont
rolu
nit • Enginec
ool
anttemperaturesensorM-Sd
iag
nos
is
P0605 C
ont
rolu
nit • TQHOAPm
alf
unc
tio
ndi
agn
osi
s
P0605 C
ont
rolu
nit • TTEPTDd
iag
nos
is
P0605 C
ont
rolu
nit • TATEd
iag
nos
is
P0605 C
ont
rolu
nit • TTEPd
iag
nos
is
P0605 C
ont
rolu
nit • S/SOFFsystemd
iag
nos
is
P0605 C
ont
rolu
nit • Taske
xec
uti
onc
ycl
edi
agn
osi
s(m
ain
)
P0605 C
ont
rolu
nit • ROMf
unc
tio
ndi
agn
osi
s(m
ain
)
P0605 C
ont
rolu
nit • RAMf
unc
tio
ndi
agn
osi
s(m
ain
)
P0605 C
ont
rolu
nit • WTDf
unc
tio
ndi
agn
osi
s(m
ain
)
P0605 C
ont
rolu
nit •T
ime
r/c
loc
kfu
nct
iond
iag
nos
is(
mai
n)
P0605 C
ont
rolu
nit • EEP-ROMw
rit
ingd
iag
nos
is(
mai
n)
P0605 C
ont
rolu
nit • EEP-ROMr
ead
ingd
iag
nos
is(
mai
n)
P0605 C
ont
rolu
nit • ROMf
unc
tio
ndi
agn
osi
s(s
ub)
P0605 C
ont
rolu
nit • RAMf
unc
tio
ndi
agn
osi
s(s
ub)
ECMpowersupplyc
irc
uit • Poweri
sno
tsu
ppl
iedt
oECMf
orsometime 司 ON 2
P1065 ECMpowersupplysystem • BackupRAMsystemd
iag
nos
is(
mai
n)
E
lec
tri
cth
rot
tlec
ont
rola
ctu
ato
r • Becauseofmechanicalmalfun
c t
ionofel
ect
ricth
rot
tle ON* 1
cont
rolactu
ator，el
ect
rict
hro
ttlecon
tro
lactuat
ordoesn o
t
operatenorm創 I
y
P1121 T
hro
ttl
eac
tua
tor • Returns
pri
ngd
iag
nos
is
P1121 T
hro
ttl
eac
tua
tor • D
efa
ultmechanismd
iag
nos
is
P1121 T
hro
ttl
eac
tua
tor •T
hro
ttl
eopenl
ock
ingd
iag
nos
is
E
lec
tri
cth
rot
tlec
ont
rolf
unc
tin • Whenam
o al
f u
nctionoccurredduetotheco
rrel
ationbetween ON* 1
theta
rge
tthrot
tlepos
itionandt heac
tualt
hro
ttlepos
iti
on.
• Overcur
rentflowsin
tothrot
tlemotorco
ntr
olcircu
it
P1122 T
hro
ttl
eF/B •T
hro
ttl
eF/Bc
ont
rolsystemm
oni
tor
ingd
iag
nos
is
P1122 T
hro
ttl
eF/B •T
hro
ttl
eservom
alf
unc
tio
ndi
agn
osi
s
T
hrott
le c
ont
rol motor r
ely • Whent
a hro
ttl
eco
ntr
olmotorr
ela
yhasbeenl
ock
edONo
r ON 合
ON
c
irc
uit OFF
. (Locked Locked:1
P1123 T
hro
ttl
eco
ntr
olmotorr
ela
y • RelayONl
ock
ingd
iag
nos
is ON)
OFF
P1123 T
hro
ttl
eco
ntr
olmotorr
ela
y • RelayOFFl
ock
ingd
iag
nos
is
Locked:
P1124 Th
rott
le c on
tro
l motor r
ela
y• T
hrot
tleco
ntro
lmotorpowersupplysystems
hor
t 2
powersupply ma
lfunc
tion
P1126 Th
rott
le c on
tro
l motor r
ela
y• T
hrott
lecon
tro
lmotorpowers
upp
lysystemopen
powersupply mal
funct
ion
P1128 T
hro
ttl
eco
ntr
olmotor •T
hro
ttl
eco
ntr
olmotorsystems
hor
tma
lfu
nct
ion

EC-59
 TROUBLEDIAGNOSIS

DTC
(code D
iag
nos
isi
tem M
alf
unc
tio
nReturnC
ond
iti
on MIL T
rip
number)
Engine o v
er temperature • Enginecoo
lanttemperaturesensoroutputvo
ltagehasbeen ON
(Over
hea
t) appro
ximatel
yO.35Vo rl ow
erforapredeterminedper
iodof
ti
me.(wi
tht h
ecoolanttemperaturesensornormal
).
P1217 Engine o v
er temperature
• Engineo
vert
emp
er創u
; r
e(O
ver
hea
t)
(Over
hea
t)
Overheat(STEP1) • Whenenginec
ool
an s110・
ttemperaturei .
P1218 Overheat(STEP1
) • Overheat(STEP1
)
LPGi
nje
cto
r1m
alf
unc
tio
n • LPGi
nje
cto
rsi
gna
lci
rcu
iti
sop
en.
P1240 LPG F /
INJ m
alf
unc
tio
n
• LPGF
/IN
J1m
alf
unc
tio
n(I
nje
cti
on)
(I
nje
cti
on)
LPGi
nje
cto
r1m
alf
unc
tio
n • LPGi
nje
cto
rsi
gna
lci
rcu
iti
sopen. .
P1241 LPG F/INJ2 m
alf
unc
tio
n (No
• LPGF
/IN
J2m
alf
unc
tio
n(Noi
nje
cti
on)
i
nje
cti
on)
P1242 LPGi
nje
cto
r2m
alf
unc
tio
n • LPGi
nje
cto
rsi
gna
lci
rcu
iti
sopen. .
P1243 LPGi
nje
cto
r2m
alf
unc
tio
n • LPGi
nje
cto
rsi
gna
lci
rcu
iti
sopen.
P1244 LPG fuel pressure sensor .
• LPGf
uelp
res
sur
esensors
ign
alc
irc
uiti
sopen
ma
lfu
nct
ion
LPG fuel pressure sensor • LPGf ue
lpre
s s
uresensoro
utp
utv
olt
agei
shi
ghe
rth
an
ma
tfu
nct
ion normal(?Vormor
e).
P1245 LPGfue
lpressu
resensorHigh
• LPGf
uelp
res
sur
esensorHighI
npu
tma
lfu
nct
ion
In
putm
alfu
nct
ion
LPGv
apo
riz
erm
alf
unc
tio
n • LPGf
uelp
res
sur
eise
xce
ssi
vel
yhi
gh.
P1249 LPG ma
lfunc
tioni
ng f
uel
• LPGm al
func
tioni
ngfue
lpressu
rei
sde
tec
tedandf
uel
pressure i
sd et
ected and f
uel
pressureisexc
essiv
elyhi
gh.
pressurei
se x
cessi
velyhig
h.
P1250 LPGv
apo
riz
erm
alf
unc
tio
n • LPGf
uelp
res
sur
eise
xce
ssi
vel
ylo
w.
P1320 I
gni
tio
nsi
gna
lsystem • I
gni
tio
ns i
gnalhasnotbeenc
ont
inu
ous
lygeneratedw
hil
e ON 2
t
heengineisrunn
ing
.
P1805 Brakes
wit
chs
ign
alc
irc
uit • Brakes
wit
chs
ign
alc
irc
uiti rshor
sopeno 1ed
. ON 2
P1812 I
nch
ing brake s
wit
ch
• Wheni
nch
ingbrakes
wit
chhasbeenl
ock
edON. -
m
atf
unc
tio
n
P1813 In
chi
ng brake s
wit
ch
• Wheni
nch
ingbrakes
wit
chhasbeenl
ock
edOF
巨
m
alfu
nct
ion

N
ote
:Numbero
ftr
ipsv
ari
esdependingond
iag
nos
i .
scontent

EC-60
 TROUBLEDIAGNOSIS

S
elf
-di
agn
osi
sFu
nct
ion(
wit
hou
tSST)(
Con
t'd
)
Tr
ip1 :Ifa malfunct
i o
ni sd etecte
dbys e l
f-diag
nosisbetweent h
e
timeign
itio
ns wi
tchist urnedON( engi
nei srunning
)andt henturn
ed
OFF( th
isisd efin
edas" t
rip
")，MILi si
l.
tThecorrespondingDTCi s
recordedimmediatelyafte
rd et
ection
.
Tr
ip2:Whenam alfunctionisdetectedbys el
f-diag
nosisforthefi
rs
t
timeint hef i
rs
tt rp，a t
i entat
ive DTC i sr ecorded.Ift he same
malfu
nctioni sd e
tecteda ga
i n by self
-diagnosi
si nt hen exttri
p
(secondtri
p)，MILisli
tandt hecorrespondingfina
lDTCi s陪 cord
ed.
Evenwhen1s ttr
ipDTCi sbeingmemorized， theapprop
r i
atetroubl
e
codeisd i
splayedass elf
-diagno
sticresulsbyMIL
t .

CONDITIONSTOTURNOFFMIL
• TheMIL，markedw ith，*i
st urn
ed0何 wheni gn
itio
nswitchis
turnedON(enginest
art
s)againa
fternormalsta
teisresumed.
• Foro th
ers
elf-d
iagn
osti
citems，se
lf-d
iagnos
ticresu
ltssha
llbe
erasedbytur
ningign
iti
ons
witchtoOFFa ft
ernormaloper
ation
i
sresumed 岡

DIAGNOSTICTESTMODE1・HEATEDOXVGEN
SENSORMONITOR
• Inthsmode，s
i tat
usofair-
fuelr
ati
oisd is
playedbyblink
ingo
f
MIL.
• Makes uretha
tMILb lin
ksa tle
ast5t imeswit
hin10seconds
ON(LEAN)
aft
er warming up engine and keeping engine speed a
t
OFF(RICH) appro
ximate
ly2，000rpm.
NOTE:
・ Althoughair-fuelratiofeedbackcontrolisactiveatidle，increase
x
-x
NE
AC

A
((

))
ほ R

++
ロu n D
，、FaE

nunu
M同
tvs
t

υ内 n u
fnv
o

c
e
-
r
nu

enginespeedandc
hec
k.
u

-
pu
Hu

J
目
'

.E

UH

• Duringa
ir-
fue
lr a
tiofeedbackcont
rol
ECM0285
Heatedoxygensensoro utputisla
rge(r
ich
):OFF
Heatedoxygensensoro utputiss
mall(Ie
an):ON
・ Ai
r-fu
el悶 t
iofeedbackcontr
olisstoppe
d:OFF
• Ai
r-f
uelrat
iofeedbackc ontrolisclamped: S
tat
eim
med
iat
ely
befo
reclampingismaintain
ed .

SSTReferenceValuei
nDataMonitor
• Valuesinthetablearer eferen
c evalues.
• Valuesinthetablea rev alue
sd e
te c
tedi nECMo rinput
/out
put
valuessentfromECM.Thus，t heymayd iffe
rfroma ct
ualp a
rt
valu
es.[Example:i g
nitio
nt imingcheckedu singti mi
ngl i
ghtand
displ
ayon "IGNTIMING“screen i n "DATAMONITOR" mode
could be di
ffere.
nt This happens because values on "IGN
TIMING"screeni sc alcula
tedbyECMu si
ngi nputsignalfrom
variou
ss en
sors. Theya rec rankshaftp os
ition sensor(POS)
ando the
rigni
tiontimingrelatedsensors.]

EC-61
 TROUBLEDIAGNOSIS

SSTReferenceValuei
nDataMonitor(
Con
t'd
)

M
oni
tori
tem Measuringc
ond
iti
on Referencev
alu
e

ENGSPEED Almosti
naccordance
MASA
lFSE • Af
terenginewarmingup AtI
dle A
ppr
ox.1.3V
• Sel
ectorlev
er:N A
ppr
ox.1.6V
Ata
ppr
ox.2，
000rpm
• Nol o
ad
BIFUELSCHDL •Afterenginewarmingup AtI
dle Approx.2.5・4msec
• Se
lectorlev
er:N
Ata
ppr
ox.2，
000rpm
• Nol o
ad
A
lFALPHA •A
fte
renginewarmingup AtI
dle Approx.90・110%
COOLANTTEMP/S •A
fte
renginewarmingup Approx.80・Co
rmore
H02S1 •A
fte
renginewarmingup AtI
dle Changesbetweena
ppr
ox.0
.1・
0.4V骨 0
.6・0.9V
M
ain
tai
nata
ppr
ox.2，
000rpm Changesbetweena
ppr
ox.0
.1・
O
.4V骨 0.6・0.9V
H02S1MNTR •A
fte
renginewarmingup AtI
dle Switchess
low
lybetween
LEAN骨 RICH.
M
ain
tai
nata
ppr
ox.2，
000rpm SwitchesbetweenLEAN骨 RICHa
t
lea
st5t imesfo
r10seconds.
VHCLSPEEDSE • D
rie，andcomparew
v itht
hevalued
isp
lay
edonspeedometer. Almosti
naccordance
BATIERYVOLT • I
gni
tio
nsw
itc
h:ON(
wit
henginestopped) Approx.11・14V
ACCELSEN1 •A
fte
renginewarmingup AtI
dle Approx.0.6・0.65V
ACCELSEN2 Approx.0.75・0.8V
Approx.2，
000rpm
Ign
itions
witchONwit
hacceler
atr Approx.4.1・4.3V
o
pedaldepressed(
Withengine
stopped)
THRTLSEN1 •A
fte
renginewarmingup A
tId
le Approx.0.5・0.55V
THRTLSEN2 Approx.0.65・0.7V
Approx.2，
000rpm
Igni
tionsw
itchONwit
hacceler
atr A
o ppr
ox.0
.7-0.75V
pedaldepressed(
Withengine
stopped)
P/NPOSIS W • I
gni
tio
nsw
itc
h:ON Np
osi
tio
n ON
Otherthanabove OFF
LOADSIGNAL • I
gni
tio
nsw
itc
h:ON Headlamps
wit
ch:ON ON
Aboves
wit
ch:OFF OFF
IGNITIONS W • I
gni
tio
nsw
itc
h:ON→ OFF ON→ OFF
BRAKESW • I
gni
tio
nsw
itc
h:ON Brakepedaldepressed ON
Brakepedalr
ele
ase
d OFF
I
NJPULSE •Afterenginewarmingup AtI
dle Approx.2・4msec
• Se
lectorlev
er:N
Ata
ppr
ox.2，
000rpm
• Nol o
ad
IGNTIMING •Afterenginewarmingup AtI
dle Approx.15
・BTDC
• Se
lectorlev
er:N Approx.30・40・BTDC
Ata
ppr
ox.2，
000rpm
• Nol o
ad
I
nca
lcu
lab
le •Afterenginewarmingup AtI
dle A
ppr
ox.0-20%
• Se
lectorlev
er:N
Ata
ppr
ox.2，
000rpm Approx.14・28%
• Nol o
ad
FUELPUMPRLY • For1secondafte
rigni
tio
nsw
itchisON ON
• Whileenginei
srunn
ingandcra
n k
ing
• Otherthanabove OFF
THRTLRELAY • I
gni
tio
nsw
itc
h:ON→ OFF ON→ OFF
H02S1HTR •A
fte
renginewarmedup(
ati
dl) Approx.?rpmo
e rmore OFF
Ot
herthanabove ON

EC-62
 TROUBLEDIAGNOSIS

M
oni
tori
tem Measuringc
ond
iti
on Referencev
alu
e

IDLANLEARN •Afterenginewarmedup( a
tidle
)Ildl
ea i
rvolumel
ear
nin
g DONE
•AIIelec
tri
calloadswit
ches:OFF Icompleted.
• Se
lectorlev
er:N
I
ldl
ea i
rvolumel
ear
nin
gno
tye
t YET
・ T
hrott
levalvec l
osedpos
ition
I
completed.
le
arningcゅmpleted .I

F
ail
-Sa
feF
unc
tio
n
• When any o ft hecri
ti
calsensorso r systems sends a
mal
functi
on message，thef a
il-
safefunct
ione stim
atesthe
dr
ivin
gc ond
iti
onswithotherinp
uts i
gnals and s
ele
ctssaf
er
co
nditio
nsforeng
ine(v
ehic
le)c
ontrl，
o basedond atapr
evi
ous
ly
st
oredinECM.

M
alf
uncti
on
Relatedsensors F
ail
-sa
fe MIL
con
dit
ion

Massa
irf
lowsensor Sameass elf
- • Sele
ctsf u
elinje
ctionpulsewidthdependingonenginespeed ON
diag
nosis andthrot
tlepo
sitionsot h
ev eh
iclecanbed ri
ven
.However ，
fue
l
malf
uncti
ondete
cti
on i n
jecti
onwil
lbei nhibi
ted(fu
elcut-
off
)whenenginespeed
co
nditi
ons. exceedsapproximately2，400rpm.
• Id
lespeedi s800rpm.
Enginec ool
ant • Usest heestimatedenginecoola
nttemperature(v
arie
swith ON
temperaturesensor elapsedtimeafterst
art
)t ope斤ormcontro
lssot h
ev e
hicl
ecan
bed r
iven.
A
ccele
ratorpedal • Fue
linje
cti
onwi
llbeinhi
bit
edwhen1ci
rcu
itisopened.Release ON
p
osi
tionsensor v
alv 創I
emechanic yunt
ili
tcandriv
eatlowspeedwhen
d
iscon
nectingc
onne
ctor.
T
hro
ttl
epo
sit
ionsensor • Fixesou
tputtoapresetval
uesot heveh
iclecanbedri
ven 目 ON
However，fu
elin
ject
ionwi
llbei n
hib
ited(
fue
lcut-
off
)when
enginespeedexceedsapprox
imately2，
500r p
m.
MIL • Fue
li n
jec
torw
il
lbei nh
ibite
da ta
pproxim
ately2，500rpmto
pre
ventMILmalfunc
tioni
fexhaustperformanceanddri
vin
g
pe吋ormancemalf
unction
sa reoc
cur
ring.

EC-63
 POWERSUPPL
YANDGROUNDSYSTEM

ECMInput
/OutputS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

T
erm
ina
l S
ign
alname Measurementc
ond
iti
on Measuredvalue

111 ECM&IGNc
oilr
ela
y Forapproximately10secondswith Approx.1V
ig
niti
onswitchONanda ft
erign
iti
on
swi
tchOFF
Approximately10secondso
rmorea
fte
r B
att
eryv
olt
age
ign
itio
ns witchOFF
109 I
gni
tio
nsw
itc
h I
gni
tio
nsw
itc
hON
119 Powersupplyf
orECM
120
121 Powersupplyf
orECM(
Bac
k-u
p) Always
1 Ground Approx.OV
115
116

C
irc
uitDiagram
Toi
gn
i!
io
n∞iI

官
119
120

1
11 115
116
ECM
1
21

1
09

ECM0286

EC-64
 CRANKSHAFTPOSITIONSENSOR1 (POS)
0

ECMInput
/OutputS
ign
alS
pec
ifi
cat
ion
s
Checkwaveformbetweent
erm
ina
lsshownbelowandgroundu
sin
g
anosc
illo
scope
.

T
erm
ina
l Si
到 gn
伊 a
創I
問附 nam
悶 附 A
tcr
ank
ing A
.
tid
lea
fte
rwarmin9up A
tappro
比 2，
000rpm

叩3
1 I
Cr
ank
sha
ftp 儲倒l
t
甘
凶io
n A
tcr
ank
ing
:Ap
pro
x.2.6V A
tid
li
ng
:Approκ2.5V 司.
Appro 2.5V
sensor1・(POS)
(
V) (
v) (
v)
6 ←
国 6
r-
叶 r
-同 4円 1同 11同 f
『戸
4
2 1 1 211
111
11111
1sI 1
111
1
0 ILW I
L」
ぃ I
W.
.J DIULI
ULJU
lLI
L I
Uリ

!→← ト~.~m~ 同 Q，5ms

111
E
CM0
287 E
CM0
288 E
CM0
289

Nu
mer i
calv al
ues(
ref
ere
ncev
alu
es)a
reo
bta
ine
dus
ingana
nal
og
c
irc
uittes
ter
.

C
irc
uitDiagram
ECMr
el
ay
1
19
1
20

1
1
1
ECM
C
rank
shaf
jpo
sit
!on.
s
en.
so
r 日出
(
int
egr
ate
din
toth
edi
st
ri
but
口r
) 凶よ~

晶 1
3

E
CM0
290

ComponentP
art
sIn
spe
cti
on
CRANKSHAFTPOSITIONSENSOR
• Remove d i
str
ibu
tor(wi
tht h
eh arne
ssc onn
ectorc
onn
ect
ed)
fromtheengin
e.
~ö-I)圃 T
S
u
l
r
o
ni
wl
g
yt
n
it
u
i
o
r
ns
nt
w
h
it
c
ec
hON.
ra
nksh
aftposit
ionsen
sorshaf
tbyhandand
checkvolta
gebetweenter
minal3andgrou
nd.
3・Ground( 1
's i
gna
l):
Approx.0.2or5V
CAUTION:
• Check v ol
t a
g eafte
r disconnecting the in
jec
tor fuse to
inh
ibitinj
ectoroperat
ion.
E
CM0
291 Malfuncti
on smayo rmaynotbea ccur
atelydetected by
self-
diagnosisdependingonhowt heshaftistur
ned.Note
tha
tt he
rei snom al
functioninthiscase.

EC65
聞
 CRANKSHAFTPOSITIONSENSOR120 (REF)SIGNALCIRCUIT
0

ECMInput
/OutputS
ign
alS
pec
ifi
cat
ion
s
Checkwaveformbetweent er
min
alsshownbelowandgroundusi
ng
anoscil
losco
pe.
Numeri
calv alu
es(r
efe陪 nceval
ues)ar
eo b
taine
du s
ingana n
alog
ci
rcu
ittes
ter
.

T
erm
ina
l S
ign
alname A
tcr
ank
ing Ati
dlea
fte
rwarmingup A
tap
pro
x.2，
000rpm

14 Cran
kshaftpos
itio
n A
tcr
ank
ing
:Ap
pro
x.0.5V A
tid
lin
g:A
ppr
ox.0.5V A
ppr
ox.0.5V
sensor120・(REF)
(
v) (
v)
(
v)6
6月 6
4 4 lU
!
t
l 11
1
。
2
。2
。
2

『 ー
-I
I O
ms 1
0ms 4 ・ 同 10ms
I1
E
CM0
292 E
CM0
293 E
CM0
294

C
irc
uitDiagram
ECMr
ela
y
1
19
1
20

1
1
1
ECM
C
ranks
haf
tpo
sit
ion~en~or 山剖
(
int
egr
ate
din
tot
hedistnb
ut o
r) 也民j

連
語 1
4

E
CM0
295

ComponentP
art
sIn
spe
cti
on
CRANKSHAFTPOSITIONSENSOR
Remove d i
stri
butor(w
itht h
e harness co
nnectorc
onn
ect
ed)
fromtheengine
.
5SEι 字
通 •
T
S
u
l
r
o
ni
wl
g
yt
n
it
u
i
o
r
ns
nt
w
h
it
ec
chON
ra
nks
haf
圃

tposit
ionsensorshaf
tbyhandand
checkvoltag
ebetweent er
minal4andground.
4-Ground( 1
20.sign
al):Approx.0.2or5V
CAUTION:
• Check v oltageaft
er disconnecting the in
jec
tor fuse to
inh
ibitinject
oropera
tion.
Malfunctionsmayo rmayn otbea c
c ur
atelydetected by
E
CM0
296 self-d
iagnosisdependingonhowthes haftistur
ned.Note
thatthe開 isnomalfunctioninthiscase.

EC-66
 MASSAIRFLOWSENSORSYSTEM

SSTDataMonitorD
isp
lay
Monitori
tem Ati
dlea
fte
rwarmingup t
A.approx.2，
000rpm

MASA/FSE ApprOlι1.3V Appro

況.1.6V

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

Z
t
a

m一
O一
A-

r
nv-

nv
I

nu--
nu-4E
仰一 A

-
℃
ぽ 一P
m
附n
花加 i
川n
冶
1a
凶l Si
割 gn
伊問a
山 am Atcranking Ati
dlea
.ft
erwarmin9up

一-V
問

-r
一
-
一政
。

5
v
5
引 1
胸Ma邸
ssa
前i
r刊
fl
刷 側 鵠n
陥SOr
ぴ Approx.1.5V Approι1.3V
67 Massairf
lowsensor
Approx.OV
ground

C
irc
uitDiagram

ECMr
ela
y
119
120 5
I
lMassairflowsensor
5
1 3
1
11 67
ECM 34
計In脚 a
irt
empe
悟

官
ECM0297

ComponentP
art
sIn
spe
cti
on
MASSAIRFLOWSENSOR
1
. Removemassa irflowse
nsor.
崎 D誕
f?
T週 2
. T
f
u
l
o
rnigni
tio
ns wi
wsensorfromt
tc
ht
hea
oON.Whileb
ircle
ane
lo
w
rcases
i
i
nga
e，
d
i
ri n
tot
checkou
h
t
emassa
putv
olta
i
g
e
r

betweentermina
l3andg roun
d.
Noairblowing:
Approx.1V
Withairblowing:
Approx.1.3V
σhemorethea i
risblown，thehigherthevoltagei
s.)
NOTE:
ECM0298 I ・f
Iai
risblownfromt
hea
ird
ucts
ide，
thev
olt
agebecomesl
owe
r.

EC-67
 ENGINECOOLANTTEMPERATURESENSORSVSTEM

SSTdatamonitord
isp
lay
Monitori
tem AtI
dle Ata
ppr
ox.2，
000rpm

COOLANTTEMP/S A
fte
rwarmingupe
ngi
ne:Approx.80・
C(176・
F)o
rmore

ECMInput
/OutputS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
(
V)
acir
cui
tte
ste
r.

.
，. Terminal S
ign
alname AtI
dle IAtapp肌 2，
000
. ￨rpm
，.
号3.5 7
3 Enginec ool
ant Enginecool
anttemperaturea
tappr
ox.20・c
> temperaturesensor (68・)・
F Appr回 .3.5V
Enginecool
anttemperaturea
tappro軍. c
80・
1
.2 (176下
)・ Appro究.1.2V

NOTE:
C
ooI
antt
emp
era
tur
e
ECM0389
・I
fenginec
ool
antt
emp
era
tur
esensorhasa m
alf
unc
tin，t
o he
v
alueofenginecool
antt e
mper
aturesignalischangedal
ong
w
ithst
art
-uptimebyfa
il-
saf
etoenablenormalop
erat
ion.

C
irc
uitDiagram

E
ngi
nec
ool
antt
emp
era
tur
ese
nso
r
2

ECM0300

ComponentP
art
sIn
spe
cti
on
ENGINECOOLANTTEMPERATURESENSOR
kQ)
(
Checkr esistanc
ebetweent e
rmin
als1and2ont h
eenginec
ool
ant
2
0 tem
pe raturesensor
.
210 Resistance
，.
.
;
2
5
a
:
:
:
Coolanttemperaturea
Approx.2.5kQ
tapprox.20・C(68・F
):

Coolanttemperatureatapprox.80.C(176・円:
0
.3 Approx.0.
3kQ
0
.1

C
ooI
antt
emp
era
tur
e
ECM0390

EC-68
 HEATEDOXYGENSENSORSYSTEM

SSTDataMonitorD
isp
lay
M
oni
tori
tem Ati
dlea
fte
rwarmingup A
tap
pro
x.2，
000rpm

H02S1 Changesbetweena
ppr
ox.0
.1・ O
.4V骨 approx.0.6・ 0.9V
H02S1MNTR RICHandLEANa
lte
rna
tes
low
l目
.
y RICHandLEANa
lte
rna
tea
tle
ast5timesi
n
10seconds

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Checkwaveformbetweent
erm
ina
lsshownbelowandgroundu
sin
g
anosc
illo
scope
.

T
erm
ina
l S
ign
alname Ati
dlea
fte
rwarmingup Ata
ppr
ox.2，
000rpm

35 Heatedoxygensensor Aircondi
tionerOFF Changesbetweena p
pro
x.0-0.3V→
;Clampsbetweena p
prox.0-0.7V approx.0.5・ 1.0V
Aircondi
tionerON
;Changesbetweena pp
rox.0・ 0.3V→
approx.0.5・ 1.0V

(
v)
1
.5
.0
1
11 11 II
(1{
。 。
1
0.~ 1'1 v 0
.
5

ト1
. .
，
E
CM0
302 E
CMO
:却3

Numericalvalu
es(
ref
ere
ncev
alu
es)a
reo
bta
ine
dus
ingananalog
ci
rcui
ttest
er.

C
irc
uitDiagram
る

H
eat
edo
xyg
ens
ens
or

2
4
3
5 ECM

7
8

E
CM0
304

EC-69
 VEHICLESPEEDSENSORSVSTEM

SSTDataMonitorD
isp
lay
Monitori
tem AtI
dle D
riv
ing

VHCLSPEEDSE Almosti
naccordancew
itht
hespeedometerd
isp
lay

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Checkwaveformbetweent
erm
ina
lsshownbelowandgroundu
sin
g
anosc
illo
scope
.

T
erm
ina
l S
ign
alname AtI
dle V
ehi
cler
unn
inga
tap
pro
x.40kmlh

63 V
ehi
clespeeds
ign
al Approx.4.6Vo
rOV Approx.2.3V

(
V6
)
4 I
nln
ln

。
~tf I
UIUUU U

トー 20ms

E
CM0
305

EC-70
 THROTTLEPOSITIONSENSORSYSTEM

SSTDataMonitorD
isp
lay
Monitori
tem Ati
dlea
fte
rwarmingup Ata
ppr
ox.2，
000rpm

THRTLSEN1
Approx.0.5・0.55V Approx.0.65・ 0.7V
THRTLSEN2

ECMInput
JOutputS
ign
alS
pec
ifi
cat
ion
s
Measurevo
ltag
ebetweent
erm
ina
lsshownbelowandg
rou
ndu
sin
g
acir
cui
tte
ste
r.

Terminal S
ign
alname Ati
dlea
fte
rwarmingup Ata
ppr
ox.2，
000rpm

47 Sensorpowersupply(
Thr
o悦l
epo
sit
ions
ens
or) Approx.5V
66 削ep
Sensorgroundσhro osi
tio
nse
nso
r) Approx.OV
50 T
hro
ttl
epo
sit
ionsensor1 Approx.0.6V Approx.0.7V
69 T
hro
ttl
epo
sit
ionsensor2 Approx.4.5V Approx.4.
4V

C
irc
uitDiagram

守，，内 H V ρ h u
aaEFhJvpnu
d
E
if
il
且 l
j
i
lE
A
ccele
r百t
orpe
dal
p
osi
tions
ens
or
惑
も 9 ECM
6 s
ign
al

5
4
5，
亨マ寸3
3
1
04

E
CM0
307

ComponentP
art
sIn
spe
cti
on
THROTTLEPOSITIONSENSOR1， 2(ELECTRIC
G
祖伝道 亙 C
Tr THROTTLECONTROLACTUATORASSEMBL Y)
ECMcon
nect
or Checkv
olt
agebetweenECMt
erm
inl50，
a 69andgr
oun
d.
5
0，69 Re
fertoECse
cti
on，"ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s"f
or
t
hevol
tag
e.
CAUTION:
• Make sure t hatthereis no moisture around connector
when removing and i nst
alli
ngt hr
ott
lep ositi
on sensor
connector.Iftherea eanywaterdrops，
r completelywipe
E
CM0
308 them0何.
• 00notapplyv olt
agetot h
rott
leposit
ionsensort e
rmina
l.
• Perform " Thr
ottl
eV alve Closed Pos
it i
o nL earning" i
f
disconnecting connecto
r. Perform ifr eplacinge le
ctr
ic
thr
ottlec o
ntrola c
tuator
.( Referto EC se ctin，"
o Th
rott
le
Valve Closed P osit
ion Learning and I dleA ir Volume
Learning
".)
• 00notdisassemblee le
ctri
ct h
rott
lecon
trola ctuat
or.

EC-71
 ACCELERATORPEDALPOSITIONSENSORSVSTEM

SSTDataMonitorD
isp
lay
M
oni
tori
tem AtI
dle Ata
ppr
ox.2，
000rpm

ACCELSEN1
Approx.0.6・0.65V Approx.0.75・0.8V
ACCELSEN2

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

Terminal S
ign
alname AtI
dle Ata
ppr
ox.2，
000rpm

82 Sensorground Approx.OV
83 A
cce
ler
ato
rpedalp
osi
tio
nsensor2ground Approx.OV
90 Sensorpowersupply Approx.5V
9
1 A
cce
ler
ato
rpedalp
osi
tio
nsensor2powersupply Approx.2.5V
98 A
cce
ler
ato
rpedalp
osi
tio
nsensor2 Approx.0.3V Approx.0.35V
106 A
cce
ler
ato
rpedalp
osi
tio
nsensor1 Approx.0.6V Approx.0.65V

NOTE:
・ Whentheacceleratorpedalisdepressedslowlyfromthefully-
closedpo
sit
ion，t
hev ol
tagemustincr
eas
einpropoはi
ontoth
e
opening01t
heth
rott
le.[I
gni
tio
nswi
tchON( e
ngi
nestop
ped
)]

Igni
tio
nswitchONw ithengine Igni
tio
nswitchONw it
hengine
Terminal S
ign
alname stoppedAc
celerato
rpedalisful
ly stoppedAc
celerato
rpedali
sfu
lly
depressed r
el e
ased

98 A
cce
ler
ato
rpedalp
osi
tio
nsensor2 Approx.0.3V Approx.2V
106 A
cce
ler
ato
rpedalp
osi
tio
nsensor1 Approx.0.6V Approx.4.2V

C
irc
uitDiagram
-F54﹄O E﹄OF国﹄由一ω054

6一

Powersup
ply 9
0
5一

p
ed
A~.leratora
l Signa
l1 1
06
3-4

p
osi
tio
nse
nsor1

品
Ground 8
2
ECM
一271

PO盟竺盟p l
y 9
1
A∞~.Ierator ped~ Signal
2 9
8
p
osi
tio
nse
nso
r2
Ground 8
3

ECM0309

EC-72
 ACCELERATORPEDALPOSITIONSENSORSYSTEM

ComponentP
art
sIn
spe
cti
on
ACCELERATORPEDALPOSITIONSENSORS1，
2
倒厄うc通
ii
C
T (ACCELERATORWORKUNIT)
ECMc
onn
ect
or Checkvolta
gebetweenECMter
minl98，106andg
a ro
und.
1
06，9
8 Refe
rt oECs e
ction，"ECMI
nput
/Outp
utSig
nalSp
ecifi
cat
ion
s"f
or
thevo
ltag
e.
CAUTION:
00notapplyvoltagetoacc
elera
torp
edalpo
sit
ionsensor
ter
min
al.
• 00notdisassembleac
cel
erato
rworkunit
.
ECM0310

EC-73
 PNPSWITCHSVSTEM

SSTDataMonitorDisplay
M
oni
tori
tem N
eut
ralo
rN/Pp
osi
tio
n Otherthant
hel
ef
t

P/NPOSIS W ON OFF

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

Terminal S
ign
alname N
eut
ralo
rN/Pp
osi
tio
n Otherthanthel
ef
t

102 PNPs
wit
ch Approx.OV Batt
eryvol回 ge(
AITmodels)
Appro質.4.8V(M庁 models)

C
irc
uitDiagram
I
nhi
bit
orr
ela
y
T
ost
art
erm
olo
r

102 ECM

PNPs
wil
ch

ECM0313

ComponentP
art
sIn
spe
cti
on
INHIBITERSWITCH
Refert
o吋NHIBITERSWITCH".

NEUTRALSWITCH
Refert
o"POSITIONSWITCH".

EC-74
 STOPLAMPSWITCHSYSTEM

SSTDataMonitorDisplay

M
oni
tori
tem Brakepedalr
ele
ase
d Brakepedaldepressed

BRAKESW OFF ON

ECMInputlOutputS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

Terminal S
ign
alname Brakepedalreleased Brakep
eda
ldepressed

1
01 Stoplamps
wit
ch Approx.OV 社e
Ba r
yvo
lta
ge

C
irc
uitDiagram

S
topl
amps
wit
ch
1
01 ECM

ECM0314

ComponentP
art
sIn
spe
cti
on
STOPLAMPSWITCH
側1eD 圃 Checkc onti
nuitybetweens
Brakepedalr e
leased
:
to
plamps w
itc
hte
rmi
nal
s1and2
.

Continuityshouldnotexit
s.
Brakepedaldepressed:
Continuityshouldexit
s.

ECM0315

EC-75
 ELECTRICLOADSWITCHSVSTEM

SSTDataMonitorD
isp
lay
M
oni
tori
tem Headlamps
wit
chOFF Headlamps
wit
chON

LOADS
IGN
AL OFF ON

ECMInput
/OutputS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

oe
w
H一

O一

N
e
a

p一

d
p

Fr-
Fr-

e
H

m
Au-

制一色
句
---
eu-nu

h
釦 一A
明一

側一切
﹄
H

負M -
Terminal S
ign
alname

-
-

川-円
w
-

一
一
一丸
W
P
一山判

也
一川

白
u

抱
V
8
4

品川崎
Headlamps
wit
ch

u
e
C
irc
uitDiagram

ECM
Headlamp5
wit
ch 8
4

ECM0316

EC-76
 IGNITIONSVSTEM

SSTDataMonitorD
isp
lay
M
oni
tori
tem Ati
dlea
fte
rwarmingup A
. 直.
tappro 2，
000rpm

IGNTIMING Appro
司.15・
BTDC Approx.30・40・
BTDC

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Checkwaveformbetweent
erm
ina
lsshownbelowandgroundu
sin
g
anosc
illo
scope
.

T
erm
ina
l S
ign
alname A
tcr
ank
ing A
tid
lea
fte
rwarmingup Ata
ppr
ox.2，
000rpm

62 I
gni
tio
nsign
al(power Approx.0.5V Approx.0.5V Approx.0.9V
t
ransm
iss
iondri
ve
(
v) (
v) (
V)
s
ign
al)
6 s e
4 4 4
。
z
。 。
』
2 2
Wll

5me s
5m 5ms

ECM0317 ECM0318 ECM0319

Num
er i
calv al
ues(
ref
ere
ncev
alu
es)a
reo
bta
ine
dus
ingana
nal
og
c
irc
uittes
ter
.

C
irc
uitDiagram

ECM
1
21

109

62
工工工工工工
連
迫
ECM0320

ComponentP
art
sIn
spe
cti
on
SPARKPLUG
• Checke l
ectro
deford
it，damage，andwearandi
r nsu
lat
orf
or
damage.
・ Replacespa
rkp l
ugf
inece
ssa
ry.
CAUTION:
• Checkt erminalsforlooseness.
• Checki nsul
atorforcracksordamage.
• Checkf orcontaminationbyo il， ，
wateranddust
.
• Makesuret h
atthesparkpluggapi snormal，
usingaf
eel
er
gauge.
ECM0321
Sparkpluggap:
0
.8・0 .
9m m( 0
.031・0.035in)

EC-77
 IGNITIONSVSTEM

ComponentP
art
sIn
spe
cti
on(
Con
t'd
)
POWERTRANSISTOR
D
1
16
3f圃
-
Checkr es
istan
cebetweenter
minalsofthepowertran
sisto
rby

一a4rMUP
•

1qu弓
︼
F
71E3
I戸内〆﹄
app
lyingande xchangi
ng(+and- )t heinsp
ecti
onr od
so fan

m-
r
F
n
-
一
analogci
rcu
ittes
ter
.
Inspect
ionTerminalsandResults(atroomtemperature)

対
B
P
o

P
o
s

s
i

i
t

t
i

i
v

v
eprobet
Except0o
eprobet
Except0o
o8andn
r∞Q
o7andn
r∞Q
e

e
g

g
a

a
t

t
i

i
v

v
eprobet

eprobet
o7

o8
:

P
ositiveprobeto5andn egativeprobeto8:
ECM0322 Except0o r∞Q
P
ositiveprobeto8andn egativeprobe5:
∞Q
P
ositiveprobeto7andn egativeprobe5:
∞Q
P
ositiveprobeto5andn egati
veprobet o7:
Except0o r ∞Q
CAUTION:
・ 00notuseadigitalcircuittesterbecausethestandardis
d
iff
ere
nt
.

Checkd i
str
ibu
tio
nfu
nct
ion
s(r
oto
randd
ist
rib
uto
rca
p)o
fth
e
di
str
ibu
tor
.
IGNITIONCOIL
• Checkr esist
anceofthefol
low
ing
:
Primarycoilresistan
ce(5・6):
Approx.2.2k.Q
Secondaryc oi
lr es
istanc
e:
Approx.11.5k.Q
(Betw 鵠 nc o
iltowert i
pmetaland6w
iththed
ist
rib
uto
r
capremoved.)

ECM0323

HIGH-TENSIONCABLE
1. Removalandins
tal
lati
on
1) Removeinta
kemanifoldco
ver
.
2) Disco
nnec
tsparkplugsid
e.
3) Disco
nnec
tdist
ribu
torsid
eandremoveh
igh
-te
nsi
onc
abl
e.

CAUTIONFORINSTALLATION
Se
cur
elyin
st
al
ld i
str
ibu
torcap and h
igh
-te
nsi
on codewhen
ma
tchin
gbo
thcyl
inde
rnumber
s.

2. Ins
p e
cti
on
• Checkresis
tan
ceofhig
h-t
ensio
ncabl
e.
ForNo.1cyli
nde
r:Approx.2.7k.Q
ForNo.2cyli
nde
r:Approx.2.
8k.Q
ForNo.3cyli
nde
r:Approx.4k.Q
ForNo.4cyli
nde
r:Approx.5k.Q
ForNo.5cyli
nde
r:Approx.5.
2k.Q
ForNo.6cyli
nde
r:Approx.6.
1k.Q

EC-78
 FUELINJECTORSYSTEM

SSTDataMonitorD
isp
lay
M
oni
tori
tem A
tid
lea
fte
rwarmingup A
tap
pro
x.2，
000rpm

I
NJPULSE 長 2・ 4
Appro msec
B/FUELSCHDL Approx.2.5・4msec

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Checkwaveformbetweent
erm
ina
lsshownbelowandgroundu
sin
g
anosc
illo
scope
.

T
erm
ina
l S
ign
alname A
tcr
ank
ing A
tid
lea
fte
rwarmingup A
tap
pro
x.2，
000rpm

21 I
nje
cto
rdr
ives
ign
al A
ppr
ox.10.5V B
att
eryv
olt
age Re
lat
ivel
ylo
wert
hanb
att
ery
22 v
oltag
e
23 I
V
) I
V
I
4
0 4
0 I
V
l
40 3
0 3
0 4
0
41 2
0 2
0 3
0
42 1
0 !
日
。 2
0
D
→ -2
0ms ￨→トー ト 2
0ms
1
0
。
」 -
2
一一陪0m
s
E
CM0
324 E
CM0
325
E
CM0
326

Num
er i
calv al
ues(
ref
ere
ncev
alu
es)a
reo
bta
ine
dus
ingananalog
c
irc
uittes
ter
.

C
irc
uitDiagram

…
1
09
2
3
4
2 卜
一 s
e
C
rns
orS
Ign
ap
o
lsI
tIo
n

五 torl
~
E
E
1r
E
」 三E
;J

ーーーーーーーー「。
2
1
1
15
4
0 1
16

E
CM0
327

ComponentP
art
sIn
spe
cti
on
INJECTOR
3ぽ 圃
@ D E
CT • Checkr e
sistan
ce between each c
yli
nde
ri nje
cto
rte
rmi
nal
s1
and2.
Standardr esi
stance(a
llcyli
nders
):
Approx.14.sn;(atroomtemperature)

E
CM0
328

EC-79
 FUELPUMPSYSTEM

SSTDataMonitorDisplay
Monitori
tem F
uelpumpi
sno
tac
tiv
ate
d F
uelpumpi
soperated

F
uelpump OFF ON

ECMInput
/OutputS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

Fora
ppr
ox.1seconda f
teri
gni
tio
n
T
忌rm
ina
l S
ign
alname Atc
ran
kin
g，enginer
unn
ing
swi
tchi
sturnedON

113 F
uelpumpr
ela
y Approx.1V Approx.1V
代:
(A e
rap
pro
x.1second:B
att
eryv
olt
age
)

C
irc
uitDiagram

舟 --ηLrhu-
﹃内‘u-FnV4p
l
寸Taz
I
gn
rt C
ran
ksh
aftpos
rti
on
s
ens
orsig
nal

ECM

J
L
1
13

ECM0329

ComponentP
art
sIn
spe
cti
on
FUELPUMP
Checkresist
ancebetweente
rmi
n a
ls3and6.
Resistance:Approx.1n(atroomtemperature)

EC-80
 THROTTLECONTROLMOTORSYSTEM

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Measurevo
ltag
ebetweent
erm
ina
lsshownb
elo
wandg
rou
ndu
sin
g
acir
cui
tte
ste
r.

Terminal S
ign
alname Ati
dlea
fte
rwarmingup Ata
ppr
ox.2，
000rpm

5 T
hro
ttl
eco
ntr
olmotor2(
Clo
se) 誕 2・ 2
Appro .5V
4 T
hro
ttl
eco
ntr
olmotor1(Open) Approx.0.1・0.15V

C
irc
uitDiagram

守
a
a Fhd 仰向u
，，
T
hro社le

冒
︽ Hvphuw
(11213¥ p
osit
ion
se
nsor1

・3
1
日汁
¥4I5
16 ) T
hHnvau
PS
m釧m
e 判2
制 川o 6
9
ECM
A∞e
p
s
o
s
i
g
i
n
l
t
i
a
l
e
o
ra
t
ns
o
e
rp
n
e
d
鈎「
a
l

121X 什
Thro
mot
世l
o
rr
e∞n

5
r
e
lay
t
r

二 円3
o
l
i
I~~~……u帯e
5
4
3
1
04

ECM0330

ComponentP
art
sIn
spe
cti
on

側D
1
tT圃 ELECTRICTHROTTLECONTROLMOTOR
(ELECTRICTHROTTLECONTROLACTUATOR
ASSEMBLY)
Checkresi
stanc
e between e
lec
tri
ct h
rot
tleco
ntr
olm
oto
r(t
hro
ttl
e
po
siti
onsenso
rc o
nnect
or)term
inals3and6.
R
esi
stance:Approx.1-15Q;[at25C( 77F)
]
0 0

CAUTION:
• Make suret hatthereis no moisture around connector
when removing and i nst
alli
ngt hr
ottl
ep os
ition sensor
ECM0332 connector.Iftherea eanywaterdrops，completelywipe
r
themo f
f.
• 00 not apply v
term
inal.
o
ltaget oe le
ctri
ct hr
ottlec o
ntrol motor

• Perform " Thr

ott
disconnecting c
l
eV
onn
ec
a
t
l
o
v
r
e Closed Po
. Perform i
si
fr
ti
e
o
nL
plac
e
i
a
n
rn
ge
in
l
g
e
c
"i
tr
i
f
c
thr
ottlec o
ntrolactuato
r.( Refe
rt o ECs ecti
on)，" Th
rott
le
Valve Closed P osit
ion Learning and I dl
eA ir Volume
Learningへ}
• 00notdisassemblee lec
tri
ct h
rott
lecontro
la ctu
ator.

EC-81
 MILSYSTEM

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

w一

oF-w
w 一副
-
.

N-

n
n
m一

a--
m-m
O一

W
m一

p一
陥一丸

w
GM 一代

町一

nv-HU

F
nH-4

﹁
-
-
Terminal Signalname

H
一p

aM
u
a
B
p

j
30 MIL

C
irc
uitDiagram
ECMr
ela
y

曹
1
19
1
20

Tod
ist
rib
uto
r
1
11

ECM

30
M
alf
unc
tio
nin
di句 torlampI 1
15
10
9 1
16

ECM0333

EC-82
 HEATEDOXVGENSENSORHEATERSVSTEM

SSTDataMonitorD
isp
lay
M
oni
tori
tem Ati
dlea
fte
rwarmingup

H02S1MTR ON

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Measurevol
tagebetweent
erm
ina
lsshownbelowandgroundu
sin
g
acir
cui
tte
ste
r.

e一
A
t-

r
a
r
n-
e-

i
m-
由一
t

W 一丸
-

nvF
M

HM-
花m Approx.3，

円
川 i
n Sign
問aInam 600rpmo
rmore

uo-
U
附 割 伊 附附
創 問 附

一3
一
''
o
一
一
一
一
mA
o
N

h
24 I
Heatedoxygensensorh
eat
er叩 剖切
0pensi 副!
炉na
g問 Ba
枇:e
ryv
olt
age

C
irc
uitDiagram

事
H
eat
edo
xyg
ens
ens
or

2
4
35 ECM

7
8

ECM0334

ComponentP
art
sIn
spe
cti
on
HEATEDOXYGENSENSORHEATER
側猛打 圃 CT Checkresist
ancebetweenheatedoxygensensort
erm
ina
ls2and3
.
Resistance:Approx.3.3・3.SQ

ECM0335

EC-83
LPGASSISTANCEINJECTORSYSTEM

ECMI
npu
tlO
utp
utS
ign
alS
pec
ifi
cat
ion
s
Checkwaveformbetweent
erm
ina
lsshownbelowandgroundu
sin
g
anosc
illo
scope
.

T
erm
ina
l I S
ign
alname A
tId
le

24 I
LPGa
ssi
sta
nce町 e
cto
r Ba
世:e
ryv
olt
age

C
irc
uitDiagram

ECMr
ela
y
1
19
1
20

Toi
gn
it
in∞
o l
i
1
11
ECM
皿
叫

LPGa
ssi
sta
ncei
nje
cto
r
主 1
1

E
CM0
349

EC-84
 PCVGASRESTORATIONOEVICE

SystemOiagram

ヱE 二

h
T
¥ PCVpassage
(
12:combinedusef
orfr
ont
o
fengineandpushrodhol
e)

〈コ Atmosphere
..PCVgas

ECM0350

RemovalandI
nst
all
ati
ono
fPCVValve
1
. Removeandi
ns
ta
llPCVho
se.
2
. Removeandi
ns
ta
llPCVv
alve.

…
PCVValveI
nsp
ect
ion

.
I
t
His
s ingnois
ess ho
uldbeh eardfro
mt h
eai
rpassageo
fthe
I
r Rockercovers
ide va
lve.
• Checkc on
tinu
itywhenb l
owing
/su
ckinga
irt
o/f
romPCVval
ve
roc
k ercov
erside
.
Blowingair
:Airflowexi
sts
Suckingair
:Noa i
rflow

々
・… I
r

ECM0353

EC-85
 FUELCUTFUNCTION

I
nspectionProcedure
DATAMONITOR
⑥ WITHSST
DU開 NG附 NITORING I NODTC
1
. Check" INJPULSE"inDATAMONITORmode， andincr
easethe
ENGINESPEED 2500 rpm
engine speed t
oa pp
roxima
tely2，500 rpm af
terwarming up
IN
JPULSE.B1 3.0 msec engme.
2
. Makes uret h
at"INJPULSE"i ns
tant
lyd r
opstoa p
proxima
tely
0.6msecwhena cc
elera
torped
alisrele
ased.

RECORDSTART

即日 E I
脚 K L
lGHT I仰 Y

G
DATAMONITOR

DU剛 GMONITORI 叫 NODTC

ENGINESPEED 1350 rpm

I
NJPULSE.B1 0.6 msec

RECORDSTART

輔眠 I
BACK L
lGHT I岬 Y
ECM0354

猷 圃d
⑧ WITHOUTSST
E A D 1 ECT 1. Warmupt heenginesu
ffic
ien
tly
.
2
. D isc
onnec
tharnessc on
nectorofth
ein
jec
torandconnectat
est
la
mp.
3
. Release t h
ea ccele
ratorp edalatt h
e engine speed of
ap
proxi
mately2，500rpmo rmore，andconfi
rmtes
tlampgoes
ou
tforamomen .
t

Testlamp
(12V.3.4W)
ECM0355

EC-86
 REMOVALANDINSTALLATIONOFECMCOMPONENTS

RemovalandI
nst
all
ati
ono
fECM
1
. Disc
o n
nectECMconnec
tor.
2
. RemoveECMt oge
therwithECMb r
ack.
t
e
3
. RemoveECMb rack.
t
e
4
. In
st
allint
herev
erseorderofremova.
l
CAUTION:
・ Perform"ThrottleValveClosedPositionLearningandIdle
AirVolumeLearning" a
fte
ri n
sta
llati
onifr epl
aci
ng ECM.
(Referto EC sectin，"
o Th
rot
tle Valve Closed Po
siti
on
LearningandI
dleAirVolumeLear
ning".)

RemovalandI n
sta
llati
onofCrankshaft
Posit
ionSensor(Int
egrat
edIntothe
Dis
tribu
tor
)
R
efe
rtoEMs
ect
ion，
"RemovalandI
nst
all
ati
on"
.

RemovalandI
nst
all
ati
ono
fMassA
irFlow
Sensor
1. Removeh
arn
essco
nnec
tor
.
2
. Removemassai
rflows
ensorassemblyf
roma
irh
orn
.

ECM0391

RemovalandI nst
all
ati
ono
fEngineCoolant
TemperatureSensor
1
. D
isc
onn
ectr
adi
ato
rdr
ainp
lug，
andd
rai
nco
ola
n.
t
CAUTION:
・ Makesuretodrainwhenthecoolanttemperatureiscold.
2
. Removeharnessconne
ctor.
T
her問o
sta
t
ho
usin
g 3
. Removec o
olanttempera
tures e
nsoru sin
gas ocketspe
ciall
y
desi
gnedf o
rr e
moving and inst
all
ingc oo
lan
tt e
mperat
ure
sen
sors [ com
merci
ally a va
ilab
le: thermosensor s ock
et
manufa
ctu
redbyKTC( pa
rtNo.
:820 下1 9
)]andsimi
larpa
rts
.

ECM0392

EC-87
REMOVALANDINSTALLATIONOFECMCOMPONENTS

RemovalandIns
tall
ati
onofHeatedOxygen
Sensor(W
ithHeatedOxygenSensorHeat
er)
1. Removeharnessconnec
torfro
mheartedoxygensens
or.
2
. Removeh eat
ed oxygen s
ensorus
inga s ocke
td esig
nedf
or
hea
tedoxygensensorremov
alandins
tall
ati
on(SST
).
CAUTION:
・ Handlei
tca
ref
ull
yanda
voi
dim
pac
ts.

RemovalandI n
sta
llati
onofThr
ott
leP osit
ion
Sensor(El
ect
ricThro
ttleC
o n
trolActuator
Assembly)
REMOVAL
1
. Removea
irduc
tfroma
irhor
n.
2
. Removehar
nessc
onne
cto
r.
low
CAUTION:
• Also，removeharnessconnectorsofmassairfl
o ，
wsensor
LPGi nje
cto，
r andLPGf u
elpressuresensorsothatwhen
同orn removingandi ns
tal
lin
gairhorn，LPGinj
ecti
onhold
er(LPG
andCombined)i spe同ormedatt h
esamet i
me.

3
. Loosenbo
ltsdiagon
ally，removeai
rh o
rn，LPGinj
ecti
onho
lder
(LPGo rCombined)o rairhorns p
acer(Ga
sol
ine)，andthe
n
removeel
ect
ricth
rot
tlecont
rolact
uat
or.

n
jec
torh
old
er
~(LPGal

↓
コ
ペ
シ:
丈一一
一一一 Electricthrottle
c
ont
rola
ctu
ato
r

ECM0374

INSTALLATION
CAUTIONFORINSTALLATION
• Un
ifo
rml
yti
ght
enbol
tsdi
ago
nal
lyi
nse
ver
als
tep
s.
CAUTION:
• Make suret hattherei s no moisture around connector
when removing and i nstal
lingt hr
ott
lep osition sensor
connector.Iftherea reanywaterdrops， completelywipe
them0侃
• 00n ota pplyvolt
aget othr
ottleposit
ionsensort erm
inal.
• Penorm " Thr
ottl
e Valve Closed P os
it i
o nL e a
rning"i f
disconnecting connector. Penorm i fr eplacinge lect
ric
thr
ottlec o
ntrola ct
uator.( R
efert o EC se ction，"Throt
tle
Valve Closed P ositi
on Learning and I dleA ir Volume
Learnin
g".)
• 00n otdisassemblee lec
tricthro
ttlecon
trola ctuato
r.

EC-88
REMOVALANDINSTALLATIONOFECMCOMPONENTS

RemovalandI n
sta
lla
tio
no fAccelerator
PedalPosi
tio
nSensor( A
cceleratorPedal
Assembly)
R
efe
rto"RemovalandI
nst
all
ati
on"
.
CAUTION:
• 00 not disassemble a
ccele
rat
or pedal assembly and
removesensorsandswitch
es.

RemovalandI nst
all
ati
ono fI
nta
keAir
TemperatureSensor(Wit
hMassA i
rFlow
Sensor)
• RefertoECs e
ctio
n."RemovalandIn
sta
lla
tio
nofMassAi
rFlow
Sensor"becausei n
tak
eairtempe
ratur
esensorisjo
ine
dwith
massa i
rflo
ws en
sor.

RemovalandI
nstal
latio
nofI
gni
tio
nCo
il
(I
ntegr
ate
dinDis
tribu
tor)
R
efe
rtoEMs
ect
ion，"RemovalandI
nst
all
ati
on"
.

RemovalandI
nst
all
ati
ono
fFu
elI
nje
cto
r
R
efe
rtoEFs
ect
ion，
"RemovalandI
nst
all
ati
on"
.

RemovalandI
nst
all
ati
ono
fFu
elPump
Ref
erto FL s
ect
ion，"
Ful Gauge，F
e uelF
ilt
er，and F
uel Pump
A
ssemb
ly"
.

RemovalandI n
sta
lla
tionofT
hrottleCont
rol
Motor(Ele
ctr
icThr
ottleCo
ntrolActuator
Assembly)
Referto EFsect
ion，"Removalandins
tal
lat
ionofth
rot
tlep
osi
tio
n
sensor(
elec
tri
cthr
ott
lecon
trolac
tua
torass
embly
)".

EC-89
 REMOVALANDINSTALLATIONOFECMCOMPONENTS

RemovalandI
nst
all
ati
ono
fLPGI
nje
cto
r
Holder
REMOVAL
1
. Removea i
rdu
ctf r
omairhor
n.
2
. Remove harne
ssc onnec
torso f mass a
irflo
ws ens
or，LPG
in
ject
or，
andLPGf ue
lp r
essuresensor
.
3
. Loosenbol
tsi
nt u
rn，removeairhorn，andth
enremovein
jec
tor
ho
lder
.

INSTALLATION
1. C a
uti
onfo
rins
tal
lat
ion
• Un
ifo
rml
ytight
enbol
tsd
iag
ona
llyi
nse
ver
als
tep
s.
CAUTION:
• Make sure t
hatt hereis no moisture around connector
whenremovingandi nsta
llin
geachc onnector.I
ft hereare
anywaterdrops，completelywipethem0符.
• 00n o
tapplyv o
ltagetoeacht erm
inal.

E
lec
tri
cthr
ott
le
c
ont
rolac
tuator

問 N'm(
kgm，
・ f
t-I
b)¥。
園 N'm(k
刊， i
n ECM0375

LPGI
nje
cto
rDr
iveU
nit
HOWTODISCONNECTLPGINJECTORDRIVEUNIT
CONNECTOR
1
. Pu
llcenteroflev
erforw
ard，andt h
end i
sconne
ctt a
bf ro
mle
ver
L
eve
r
andli
f
ttiup.
2
. Rais
et heleverun
ti
lticli
cks，andful
lypresstheleve
rtodr
ive
un
itsid
e.
3
. Pu
llconnectorfo
rwar
d.andt hendisc
onnec
ttifromuni.
t

HOWTOCONNECTLPGINJECTORDRIVEUNIT
CONNECTOR
1
. Pr
es st h
el ev
erind ri
veu n
itc onn
ectorwhil
ep re
ssin
gtito
c
onne c
torend.
2
. Pre
s sinthelev
erun
ti
lticl
ick
s.
3
. Rai
s ethelev
erunt
ilt
iclic
ks，engagethetab
stotheback01t
he
l
everandc on
nector，
andt he
ns ec
urelyco
nnectth
em.

EC-90
 SERVICEOATAANOSPECIFICATIONS(SOS)

Standard，
RepairL
imi
t
Fuelpressure[kPa(
ba，kg
r /cm2，p
si)
] 353(
3.3，
5 3
.6，
51)

I
dlespeed(rpm) I
N pos 650:
:50
1

I
gni
tio
nti
min
gCBTDC/rpm) I
Np o
sit
ion 10
::2
1 /650
F
iri
ngorder 5・
1・ 3・
6・2・
4
Sparkplug I
Man由 c
tue内 pe/gap[mm(
r in
)] BPR4ES[
0.8・0
.9(
0.3
1・0
.35
)]
I
gni
tio
nadvancedevice E
lec
tro
nic
all
yco
ntr
oll
edi
gni
tio
nadvance
Densityo
fCOa
tid
lespeed(%)/
Den
sit
yofHCa
tid
lespeed(ppm) 0
.1/
50o
rle
ss

EC-91
 S間

CONTENTS
STARTINGSYSTEM ..
・ ・
H.
.
・ ・.
.
H.
.
・ ・.
.
・ ・.
.・ ・
H .
..
.
.EL ・
2
H H CHARGINGSYSTEM. .…
・山一.
..・ ・
..
.
.
..
・ ・..
..
.
.
H.
.
・ ・ .EL・
3 H H

ComponentPa
rtsL
ocati
on …… ・・.
.・ ・
H.
.
.
..
・ ・
H .
EL・
2 H H ComponentP a
rtsLoc
ation・. ・.
.
..
.
・ ・・・ .
.
…・.
H EL-3 H H H

St
arte
rM o
tor・
"
' ・
H..
……
..
..
..・ ・
.
..
.
.・ ・
H..
.
..
.
.・ ・-… EL
H ・
2 H ComponentsofAlt
ernat
or・.
.・.
.・ ・.
H.
…'
"・ ・-
・… .EL・
5 H H

Al
tern
ator..
.
..
.
..
.
・ ・
H..…
… ・・
H -冒 ・・
H .
.
..
.
・ ・..
.
.
.
H・ ・..EL・
5
H H H

ASSEMBLYOFHIGH-TENSIONCABLE ・..・ .
..EL・12 H
 STARTINGSVSTEM

ComponentP
art
sLocation

~吋タタJi

、
、
、

TerminalB

S
tar
termotor ミ
込
Crankshaftp
ull
eys
ide

T
erm
ina
lS
同:N-m{kgf-m} ELM0243

CAUTION:
・ Be sure to disconnect negative batte町 c
abl
ebe
for
e
o
per
ati
on.

S
tar
terMotor
REMOVAL
n
DRR

B
n

S
m・m・F町U
ov

a
so
1 4﹄ 沼

剖
-川、弁明
・

Au
町削剥
4Enζqu

nHah-
陪
氾mm

h悶 h b
v
ee
ov
o

d
内
白M

VE-
dd

INSTALLATION
• I
ns
ta
lli
nth
ere
ver
seo
rde
rofremova
.l

EL-2
 CHARGINGSYSTEM

ComponentP
art
sLocation

Crankshaftp
ull
eys
ide

悶:N-m{kgf-m}
ELM0244

EL-3
 CHARGINGSYSTEM

Rotor

Rearb
ear
ing

d
Bearingr
eta
ine
r
悶
4ゅ 2 P

1f
phJu-au

F
ron
tcover

同川

Brush

。
s智

EL-4
 CHARGINGSVSTEM

Components0
1Al
ter
nat
or

Rearend∞v
er

Rearendframe

D
riv
eendframe

Brushh
old
er

I
Cre
gul
ato
r

C144F038

A
lte
rna
tor
REMOVAL
1. Disconnectnegat
iveb att
erycable
.
2
. Loosena lt
erna
torbolt，andd i
sconnectal
ternato
rbel.
t
3
. Removea d
justi
ngbar.
4
. Removea l
tern
atorbol.
t
5
. Disconnectgroundpo i
ntbolt，al
ternat
o ，andnutsf
rconnector or
term
inalB.
6
. Removea l
tern
atorfromt heveh
icle.

INSTALLATION
• I
nst
alla
lte
rna
tor，andad
justt
ens
iono
fthealt
ern
ato
rbe
l.
t
(
Refert
o"Enginedri
vebel
t"i
nETsec
tio
n.)
CAUTION:
・ TightentheterminalBnutcaref凶 Iy.

EL-5
 CHARGINGSVSTEM

A
lte
rna
tor(
Con
t'd
)
DISASSEMBL
Y
PULLEY
Secureshaf
thexagonalp
artw
ithaboxwrench，l
oos
enp
ull
ey
nut，andremovep
ulle
y.
CAUTION:
・ Hexagonal box wrench must be used. Twelve-fold box
wrenchmaycrushs
haf
theadands
lip
.

C144F030

REARENDCOVER
• Removescrewandt
erm
ina
lB n
ut，andt
henremover
earend
co
ver
.

C144F031

BRUSHHOLDER
• ，
Removescrewandt
henremoveb
rus
hho
lde
r.

C144F032

I
CREGULATOR
• ，
Removescrewandt
henremoveI
Cre
gul
ato
r.
CAUTION:
・ Lengthsofscrewsaredifficult
.Arrangeremovedscrews，
andsecurelyi
nst
alli
ntheo
rig
ina
lpo
sit
ion
.

C144F033

EL-6
 CHARGINGSYSTEM

A
lte
rna
tor(
Con
t1d
)
RECTIFIER
• Remove screws s
ecu
rin
gwi
reso
fre
cti
fie
r and s
tat
or，and
remover
ect
ifi
er.

C144F034

REARENDFRAME
• Removeb
olt
sandn
uts，
andthenremover
earendf
ram
e.

Re
arend
f
rame

C144F035

ROTOR
• Keepdriv
eendframeonal
eve
lus
ingb
loc
ks，andt
henp
res
s
outr
oto
r.

Block

95F148
C0

RETAINERPLATE
• Removescrews，
andremover
eta
ine
rpl
ate
.

C144F036

EL-7
 CHARGINGSVSTEM

A
lte
rna
tor(
Con
t'd
)
BEARING

DRIVEENDSIDE
• Keepdr
iveendframeonal
eve
lus
ingb
loc
ks，andt
henp
res
s
D
riv
eendframe
ou
tbea
ringusi
ngajig
.

SNAPRINGSIDE
P
ullo
utb
eari
ngu
sin
gap
ull
er.
Block

C0
95F149

• CAUTION:
Securesof
tlyusi
ngavi
se • Spe
ci1i
catio
nusesbearing1 0rhighspeed.Alwaysusei
t
50asn o
tt odamage
whenr ep
lacin
g，andavoidimpactt t
.
oi

C095F150

INSPECTION
BEARING
• Rotatebea
ringbyh an
d.
• Checkfornoiseorbin
din
g.
• Replacef
in e
cess
a r
y.

C095F151

STATOR
• Measure r es
istan
ce between each l
eadwir
eu si
nga c
irc
uit
te
ster
.
Standard:1Qorl ess
• Measurer esist
ancebetweenstat
orcoreandlea
dwir
e.
Standard:∞
• Replacefinecessa
ry.
CAUTION:
• Open0 1sta
torcoilit
sel
1isnotc o
nsid
erabl
e.Checkthe
0109F317
connectionpa同 0
1wiresi1c
ont
inu
ityshouldnote
xit
s.

EL-8
 CHARGINGSVSTEM

A
lte
rna
tor(Confd)
ROTORCOIL
S
lipr
ing • Measure r es
istan
ce between each snap r
ingusi
nga ci
rcu
it
te
ster
.
Standard:2.90
• Measurer esist
ancebetweensnapr ingandr o
torcor
eus
inga
ci
rcui
tteste
r.
Standard: ∞
• Replacefinecessa
ry.

C095F153

SNAPRING
• Checksnapr i
ngfordir
tanddamage.
• Wipeticlea
nw ithac lot
hthatisdippedi
nalc
oho
lfiiti
sdir
ty
.
• Pol
ishwit
hsandpaper(#500t o600)ifth
erei
ssli
ghtdamage.
• Measuresnapr i
ngouterdiame
ter.
Snaprin gouterdiameter:
Standard:
14.4mm
Usablel imi
t:
14.4mm
• Replacef
iou tsid
et heusableli
mi.
t
BRUSH
• Measuree xcessivebrushleng
thfrombrushhol
der
.
Excessivel engthofbrush:
Standard:
10.0mm
Usablel i
mit
:
2.0mm
• Replacefioutsidetheusableli
mi.
t
• Makes uret h
atb rus
hissli
ghtl
ymovinginbrushhol
der
.

C0
95F155

RECTIFIER
• Checkcont
inui
tybetweeneachrec
tif
ierdiodewi
thcir
cui
ttest
er
P2 P3
i
nkOr a
nge.
• I
tisnormalthatc
onti
nuitysh
ouldexi
tinones ideofdiodeand
co
ntin
uityshou
ldnotexi
stinano
thersideofdio
de.
CAUTION:
・ 00notuse500Vmegatesterthatbreaksrectifier.

C144F037

EL-9
 CHARGINGSYSTEM

A
lte
rna
to ・
r(Contd)
NOTE:
• Rec
tifie
rc o
nditio
ncannotbejudgedbyf orwa
rdresist
ance.On
thechara
cteri
sticofad io
de，forwa
rdc u
rrenti
sgreat
lychanged
byba 杭eryvolt
age.Indi
catio
nofteste
rchangeswithd i
fferen
ces
oftes
tertypeandr esis
tanceran
ge.Recti
fierc
ond
itionisjudged
，
P byresistan
ced i
ffere
ncesbetweenfo附 ardandreve
rsecurre
nts.

0109F322

I
CREGULATOR
Checkc on
tinu
itybetweenI Cre
gulat
orter
min
alBandFw i
thcir
cui
t
t e
ste
rinkQr ang
e.
• I
tisnormalthatc
ontin
uitysho
uldex
itinones
ideandc
ont
inui
ty
shou
ldn o
te x
isti
na n
othersid
e.
CAUTION:
・ 00notuse500VmegatesterthatbreaksICregulator.
NOTE:
• ICregu
lat
orcan becheckedwiththefoll
owi
ng procedure i
f
0109F323 I th
ereisa const
antvolt
age power s
upp
lyt h
at can change
vo
lta
gebetween10to20Vrange
.
CAUTION:
• Regulatormaybedestroyed i fICreg
ulato
rmisconnects
only for a moment. Perform i
nsp
ectio
na ft
er checking
wlrlng.

• ConnectI
ci
rcu
itt e
st
Cr
e
r，
egul
andl
a
to
a
ru
mps
.
n
itw i
thc ons
tantv o
lta
gepowers uppl弘

，
SW •• (
S
T
e
u
rnS W1and2OFF
tapowers u p
plyvol
.
)
tageto12 Y
.
L

•
4
TurnS W1ON. Makes uret h
atL1t urnsONb ri
ght
ly，andL2
tur
nsONd imlyatth
ist i
me.
IG
• Tur
OFF
nS W2ONw
，andL2t ur
n
hileS W1s
sONb rig
htl
ta
ya
ysON.Makes
tth
istime
.
u
rethatL1t ur
ns

• R
t
a
u
i
r
n
seba 世eryv
sOFFwhenb
olt
a
a
t
g
t
ef
e
r
r
yv
om 12Vg
o
ltagei
r
sa
a
p
d
p
u
a
r
l
o
l
y
x
i
. Makes
mate
ly14.
u
ret
5:!:
O
h
.
6
tL2
a
Y.
C095F158

lR
OUBLEDIAGNOSIS
PRELIMINARYPRECAUTIONS
• The troubl
ed iagno
sisc ont
entsa ref o
r onboard troub
le
di
agnosis
.
• Bec ar
efulofsuddencooli
ngf anrot
ati
onwhi
let heengineis
run
nlng.
・ Check fithef us
et otheS -
term
inalisb urn
ed-ou
tb ef
ore
perf
ormingthet
roubl
edia
gnosis
.

EL-10
 CHARGINGSYSTEM

A
lte
rna
tor(
Con
t'd
)
SYSTEMDESCRIPTION
C
irc
uitd
iag
ram

Chargin
g ・T 1
wamingl amp: ..
・三:
(0円 c
ombin
alio円
meler)

c
l
l
il ー ELM0245

ALTERNATORINPUT/OUTPUTSIGNALSPECIFICATIONS

Measuringc
ond
iti
on
T
erm
ina
l S
ign
alname Standard(
V)
O
per
ati
ono
rco
ndi
tio
n

B A
lte
rna
toro
utp
ut I
gni
tio
nsw
itc
hOFF Approx.12
Enginei
dli
ng Approx.13・Approx.14
Enginespeed:Approx.2，
500・3，
000 Approx.1
4.1・Approx.1
4.7
S Rotore
xci
tat
ion I
gni
tio
nsw
itc
hOFF Approx.12
Enginei
dli
ng Approx.13・Approx.14
L Chargewarninglamp Enginestopped Approx.0• Approx.2
.5
Enginei
dli
ng Approx.13・Approx.14
E Ground I
gni
tio
nsw
itc
hON(
wit
henginesωpped) Approx.O

CAUTION:
・ Themeasurementsabovearemadewithnoelectricalload
a
ppl
ied
.

TROUBLEDIAGNOSISCHART

Symptom I
nsp
ect
ion P
oss
ibl
ecause

Chargewarninglampdoes T
ermin
al BI
Atidl
e: Blownc
har
gin
gwarninglampb
ulb

.
nottur
nONw it
hi g
nit
ion v
olt
age Approx.13・ 14V

.
swit
chON.( Otherwarning
Atidle
: Warninglampc i
rcu
itopeno rshorte
d
lampsandi n
dicato
rsare
Approx.12Vo
rle
ss Open o rs ho
rti n harness between combination meter and

.
normal.
) alt
ernat
or

.
目

Alt
ernatorv
oltagecont
rolcir
cui
topeno rshorted

Chargingwarninglampdoes T
ermin
alS Ati
dle
: . M
A
l
a
t
l
e
r
f
n
u
n
a
t
c
o
ti
rv
o
o
l
n
i
t
a
n
g
ga
ec
o
l
n
t
t
r
e
o
rn
a
lc
i
t
r
o
c
u
r+s
i
idediode.
topeno
rshorted

.
notturnOFFifenginest
art
s. v
olt
age 13Vormore
T
e
v
o
r
l
m
t
a
i
g
n
a
e
l BI
Atidle
:
Approx.12Vo
rle
ss . M
a
M
a
l
l
f
u
f
u
n
n
c
t
c
t
i
i
o
n
o
n
i
i
n
ga
n
ga
l
t
l
t
e
e
r
n
r
n
a
a
t
o
t
o
rrot
orc
rbrush
oi
lord
iod
e.

CAUTION:
・ Thediagnoses aboveare madewith no electrical load
a
ppl
ied
.

EL-11
 ASSEMBLYOFHIGH-TENSIONCABLE

Assemblehig
h-ten
sio
ncablebyp
ull
ingi
tto
rock
ercoversid
e

ミ
斗
Crankshaftp
ull
eys
ide

，
ー、
，
-、
‘
、，
、
.
r
;
'“
、，
、ー'

CLIPC CLIPC
Assembly I Ass
泡mbly I NOTE:C
lipl
ayo
utshowst
heviewfromc
ran
ksh
aftp
ull
eys
ide

ELM0246

EL-12
No.ME・TB45AE
I
ssu
ed: December，2004

TC
I¥
Vt CORPORATI

INTERNATIONALMARKETINGDIVISION: 1
-1 5，
5・ Nishi-shimbashi，
Minato-ku， Tokyo
105・0003，Japan
FAX:JAPAN+81-3・35918152， 3-35918153

A
IIr
igh
tsr
ese
rve
d JB
・0412030(HO)P
rin
tedi
nJapan
TC
Ntc
仰 O附 ON