EPAlR MANUAL

WM 31

INTRODUCTION
USING THIS MANUAL
To provide simplicity and ease of use, this manual has been divided into various Groups with each group representing a major section of the vehicle. Each Group is then broken down into "Parts" which refer to a specific or localized part of the vehicle. Where applicable, Parts contain a Description, Operation, Diagnosis and Testing, Removal and Installation, Disassembly and Assembly procedures for the component covered in the Part. Diagnosis Charts are also included to help systematically locate and correct problems encountered. In most cases, specifications are included at the end of each Group. Set the parking brake and securely chock the wheels when working on the vehicle. Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. Keep yourself and your clothing away from moving parts, when the engine is running, especially the fan and drive belts to alternator etc. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold,tail pipe, and muffler. Do not smoke while working on a vehicle. To avoid injury, always remove rings, watches, loose hanging jewellery, and loose clothing before beginning to workon a vehicle.

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This Repair Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This manual cannot possibly ant~cipate such variations and provide advice or cautions as all to each. Accordingly, anyone who departs from the instructions provided in this manual must first establish that he compromlses neither his personal safety, Australian Design Rules, nor the vehicle integrity by his choice of methods, tools, or parts.

REPLACEMENT PARTS
Replacement parts are made to the same exacting standards and tolerances as the original factory-fitted components. Only genuine FORD and MOTORCRAFT replacement parts, or parts meeting specifications of the Ford Motor Company, should be used as service replacements.

SPECIAL TOOLS AND EQUIPMENT

Special Tools and Equipment may be required, to successfully complete a particular repair operation.

FORD SALES COMPANY OF AUSTRALIA LIMITED

The illustrations, information and specifications presented and referred to herein were correct at the time this publication was approved for printing. However, Ford Motor Company of Australia Limited and/or Ford Sales Company of Australia Limited reserve(s) the right, subject to the laws of Australia and/or any applicable State or Territory thereof and/or the regulations of any compeTent authority which may apply from time to time, at theii or its discretion, and without notice, to discontinue or change the specification or design of the products referred to herein and any options therefore at any time without incurring any liability whatsoever to any purchaser therof. Reproduction in any manner, in whole or in part, is prohibited without the express permission in writing of Ford Sales Company of Australia Ltd., Customer Service Office, Sydney Road, Campbellfield, Victoria, 3061.

NOTICES, CAUTIONS AND WARNING

As you read through the procedures, you will come across NOTES, CAUTIONS and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular1 procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle. Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.

METRIC CONVERSION TABLE

Dimensions and specifications contained in this manual are provided in metric form. To assist technicians who are not familiar with the metrication program, the following quick reference tables are provided:

Divide

by

to get equivalent number of:

Divide

by

to get equivalent number of:

LENGTH milljmetres (mm) . . . . . . . . . . . metres (m) . . . . . . . . . . . . . . . . metres (m) . . . . . . . . . . . . . . . . kilometres (km) . . . . . . . . . . . . AREA millimetres2(mm2) . . . . . . . . . . centimetres2(cm2) . . . . . . . . . . metres2(m2) . . . . . . . . . . . . . . . metres2(m2) . . . . . . . . . . . . . . .

TEMPERATURE

. . .Inch . . . Foot
. . . Yard
. . .Mile

"C

-("F - 32) or "C = 0.556 ("F - 32)

9 5 "F=(-xC)+320r0F=(1.8x0C)+32 9
ACCELERATION metre/sec2 (m/s2) . . . . . . . . . .0.304 . . . . . . . . metre/sec2 (m/s2) . . . . . . . . . .0.025 . . . . . . . . TORQUE newtons-metres (Nm) . newtons-metres (Nm) . POWER kilowatts (kW)

. . . Inch2 . . . Inch2 . . . Foot2 . . .Yard2

VOLUME mm3 . . . . . . . . . . . . . . . . . . . . .16,387.00 . . . . Inch3 16.387 . . . . Inch3 cm3 . . . . . . . . . . . . . . . . . . . . . 0.016 . . . .Inch3 litres (l) . . . . . . . . . . . . . . . . . . . 0.946 . . . .Quart litres (l) . . . . . . . . . . . . . . . . . . . litres (l) . . . . . . . . . . . . . . . . . . . 3.785 . . . .Gallon 0.764 . . . . Yard3 metres3(m3) . . . . . . . . . . . . . . . MASS kilograms (kg) . . . . . . . . . . . . . 0.453 . . . .Pound kilograms (kg) . . . . . . . . . . . . . 907.180 . . . .Ton tonne (t) . . . . . . . . . . . . . . . . . . . 0.907 . . . . Ton FORCE newtons (N) . . . . . . . . . . . . . . . newtons . . . . . . . . . . . . . . . . . . newtons . . . . . . . . . . . . . . . . . .

. .0.746 . . . . . . . .Horsepower

PRESSUREORSTRESS kilopascals (kPa) . . . . . . . . . .0.249 . . . . . . . .Inches of water kilopascals (kPa) . . . . . . . . . .6.895 . . . . . . . . Pounds/sq. in. kilograms/cm2 . . . . . . . . 0.070 . . . . . . . . Pounds/sq. in., ENERGY OF WORK joules (J) . . . . . . . . . . . . joules (J) . . . . . . . . . . . . joules (J = one W's) . .

9.807 . . . .Kilogram 0.278 . . . .Ounce 4.448 . . . .Pound

.. 1,055.000 BTU .. 1.355 Foot-pound . . 3,600,000.000Kilowatt-hour Or 3.6 X 106

LIGHT lumens/metre2 (lm.m2). . . . . . . l ,076 . . . . . . . . Foot candle FUEL PERFORMANCE kilometre/litre (km/I) . . . . . . . .0.425 . . . . . . . .Miles/gal. litres/kilometre (I/km). . . . . . . .2.352 . . . . . . . . Gallmile VELOCITY kilometres/hr. (km/h) . . . . . . . .1.609 . . . . . . . . MilesJhour

QUICK REFERENCE INDEX

Model UA Corsair
Foreword
This service manual has been prepared p, imarily forthe purpose of assisting service personnel in providing effective service and maintenance of the model UA Corsair series. This manual includes procedures for maintenance, adjustments, removal and installation, dissassembly and assembly of components, and trouble-shooting. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. If your car differs from the specifications contained in this manual, consult your Ford dealer for information. The right is reservedto make changes to specifications and methods at any time without incurring any obligation to make or install similar changes on vehicles and/or parts previously purchased.

I I I

II

I
I

CONi RCLLcD

;Orr

FORD MOTOR COMPANY OF AUSTRALIA LIMITED

Registered Office: CAMPBELLFIELD, VICTORIA (Incorporatedin Victoria. Coppyright - Ford Motor Company of Australia Limited Reproduction in whole or in part is prohibitedwithout written approval.

REF.LQ$.%.Q ..,...

rk ?

DATI..J.$,IIYI,..

GENERAL INFORMATION
p p

SECTION

" GI
1
... ..

CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . ...... . . HOW TO USE THIS MANUAL . . . . . . . .. ..... . . . ... . . HOW TO READ WIRING DIAGRAMS... . . . . . . .. ... . HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES . . IDENTIFICATION INFORMATION . . . . . . . . . . ... . . .... . LIFTING POINTS AND TOW TRUCK TOWING . . . . . . . . .. . . TIGHTENING TORQUE OF STANDARD BOLTS.. . . .
.

..

GI- 2 GI- 5 GI- 7 GI- l0 GI- 13 GI-16 GI- 19

PRECAUTIONS
Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle.

2. Before jacking up the vehicje, apply wheel chocks or other

tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. 4. Before starting repairs which do not require battery power, always turn off the ignition switch, then disconnect the ground cable from the battery to prevent accidental short circuit.

5. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe and muffler. Do not remove the radiator cap when the engine is hot.

PRECAUTIONS
6. Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint.

7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, 0-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set. 10. Arrange the disassembled parts in accordance with their assembled locations and sequence. 11. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. 12. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. 13. Use only the lubricants specified in MA section. 14. Use approved bonding agent, sealants or their equivalents when required. 15. Use tools and recommended special tools where specified for safe and efficient service repairs. 16. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. 17. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.

Precautions for E.C.C.S. Systems

1. Before connecting or disconnecting E.C.C.S. harness

connectors to or from any E.C.C.S. control unit, be sure to turn the ignition switch to the "OFF" position and disconnect the negative battery terminal. Otherwise, there may be damage t o control unit. 2. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure t o release fuel pressure t o eliminate danger (refer Section MA). 3. Be careful not to jar components such as control unit and airflow meter.

PRECAUTIONS

Precautions for Catalyst

If a large amount of unburned fuel flows into the converter, the converter temperature will be excessively high. To prevent this, follow the procedure below: 1. Use unleaded petrol only. Leaded petrol will seriously damage the catalytic converter. 2. When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on inflammable material. Keep inflammable material off the exhaust pipe.

Clean floor
SG1290

Precautions for Fuel

Use only unleaded petrol with a minimum octane rating of 92 R.O.N. (research octane number).

Precautions for starting with flat battery

1. No attempt should be made to start vehicle by pushing, rolling or towing, as this may cause damage to the catalytic converter. 2. Because the gases given off by the battery are explosive, sparks and naked flame should be kept away from it. Battery fluid is a corrosive sulphuric acid solution which can cause severe burns to the skin, clothing or painted surfaces. If battery fluid should be splashed on the skin etc. immediately flush the contaminated area with water. 3. The use of jumper leads and a booster battery t o start an engine can be dangerous if not carried out correctly. The procedure detailed in the vehicle owners handbook should be adhered to.

HOW TO USE THIS MANUAL

1. A QUICK REFERENCE INDEX, a black tab ( e . g . y ) is provided on the first page. You can quickly find the first page of each section by mating it to the section's black tab. 2. THE CONTENTS are listed on the first page of each section. 3. THE TITLE is indicated on the upper portion of each page and shows the part or system. 4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. "BR-5"). 5 . THE LARGE ILLUSTRATION is an exploded view (See below.) and contains tightening torques, lubrication points and other information necessary to perform repairs. The illustration should be used in reference to the service matters only. When ordering parts, refer to the appropriate parts catalogue.

to sliding portion

0 (1.7 -2.0, 12- 14)

: Ndm (kg-m, ft-lb)

SBR364A

6. THE SMALL ILLUSTRATION shows the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustration. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle etc. are presented in a step-by-step format where necessary. 7. The following SYMBOLS AND ABBREVIATIONS are used:

m
@

: :

8
m@

: : : :

C m * *

: : : : S.D.S. : L.H., R.H. :

Tightening torque Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. Should be lubricated with oil. Sealing point Checking point Always replace after every disassembly. Apply petroleum jelly. Apply A.T.F. Select with proper thickness. Adjustment is required. Service Data and Specifications Left-Hand, Right-Hand

M/T A/T Tool A.T.F. D1 D 2 D 3 D 4 O.D. 2 2 2 1 1 2 11

: : : : : : : : : : : : :

Manual Transaxle Automatic Transaxle Special Service Tools Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear

HOW TO USE THIS MANUAL

8. The UNlT given in this manual are primarily expressed with the SI UNlT (International System of Unit), and alternately expressed in the metric system and in the yardlpound system. "Example" Tightening torque: m 59 78 N m (6.0 8.0 kg-m, 43 - 58 ft-lb) 9. TROUBLE DIAGNOSES AND CORRECTIONS are included in section dealing with complicated components. 10. SERVICE DATA AND SPECIFICATIONS is contained at the end of each section for quick reference of data. 11. The captions WARNING and CAUTION warn you of steps that must bd followed to prevent personal injury andlor damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENT except WARNING and CAUTION gives you helpful information.

HOW TO READ WIRING DIAGRAMS

WIRING DIAGRAM
Symbols used in WIRING DIAGRAM are shown below:
Example
r CONNECTOR This shows that these connectors are white 6 terminal connectors.
k

POWER SUPPLY .This shows the ignition switch position in which the system can be operated. .See POWER SUPPLY ROUTING in EL section for the detailed wiring diagram.

r~~~~~~ MIT model

This shows that continuity exists between terminals @ and 0 , when the switch is turned t o ON position.

--@: @:
M/T model A/T model LOCATION NUMBER This number shows where the connector is located. See HARNESS LAYOUT in E L section. The number is identical with the one in HARNESS LAYOUT.
I

GROUND

B W R G L

=Black =White =Red =Green =Blue

Y = Yellow LG = Light Green

BR OR P PU GY SB

=Brown =Orange = Pink = Purple =Gray =Sky Blue

ABBREVIATIONS

When the wire color is striped, the base color is given first, followed by the stripe color as shown below: ,Example:
LNU = Blue with White Stripe

I Instrument :
harness

M: Main harness
SG1543

SWITCH POSITIONS
Normally open

4 L

4 0--

Wiring diagram switches are shown with the vehicle in the following condition. m Ignition switch "OFF". m Doors, hood and trunk lidlback door closed. m Pedals are not depressed and parking brake is released.

Normally closed

HOW TO READ WIRING DIAGRAMS

Example

CONNECTOR SYMBOLS
All connector symbols in wiring diagrams are shown from the tsrminal side.

Connector symbol 2

SG 1362

Example Male terminal

Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

Connector symbol

Connector symbol

3 3
-BIY
-WIB

Guide

Connector

Female terminal

Guide

Connector

MULTIPLE SWITCH
The continuity of the multiple switch is identified in the switch chart in wiring diagrams.

SG1363-

Example

WIPER SWITCH

Continuity circuit of wiper switch

SWITCH POSITION
OF F

CONTINUITY CIRCUIT
3-4 3-4,5-6

INT

L0
HI WASH

3-6

-L/Y B
Y

2-6
1-6

Example: Wiper switch in L 0 position Continuity circuit: Red wire - @ terminal - @ terminal - Wiper switch ( LO)- @ terminal - @ terminal - Black wire

@ - @:

SG 1365
2

HOW TO READ WIRING DIAGRAMS

SUPER MULTIPLE JUNCTION (S.M.J.)
The "S.M.J." indicated in wiring diagrams is shown in a simplified form. The terminal arrangement should therefore be referred to in the foldout at the end of the Service Manual. The foldout should be spread to read the entire wiring diagram.

Example

< B

(Main harness)

-BR+ (Instrument harness)

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

Example Only
INSPECTION START

CHECK POWER SUPPLY.

terminal @ and ground. Battery voltagn should exist.

e5
-

SGI 561

Check the following items 1) Harness continuity between crank angle sensor and battery 2) E.C.C.S. relay-l (See page ES - 170) 3) "BR" fusible link. 4) Power source for E.C.U. (See page ES- 170) 5) Ignition switch Check the following items 1) Harness continuity between N.G. crank angle sensor and
+

CHECK GROUND CIRCUIT.

2) Disconnect crank angle 3) Turn ignition switch "OFF". 1) sensor harness connector. Check resistance between
terminal @ and ground. Resistance: Approximately 052

m m

2) ground c~rcuit E.C.U. Ground for (See page ES- 170)

SG 1562

l O.K.

NOTICE
The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check" or the "Symptom Chart". 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pinpoint Check. If you must perform circuit continuity between harness connectors in more detail, such as in case of sub-harness is used, referto Wiring Diagram and Harness Layout in ELsection for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be "OFF". 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected.

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

HOW TO FOLLOW THIS FLOW CHART Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example.

CHECK POWER SUPPLY. 1) Turn ignition switch "ON". 2) Check voltage between terminal @ and ground. Battery voltage should exist.

1 -

Check item being performed. Procedure, steps or measurement results

O.K.

Measurement results Required results are indicated in bold type in the corresponding block, as shown below: These have the following meanings: Battery voltage + 1 14V or approximately 12V 1 Voltage: Approximately O + Less than 1V V

@l reference of Cross

work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. For example, symbol indicated in the left upper portion of each illustration corr~spondswith the symbol in the flowchart for easy identification. More precisely, the procedure under the "CHECK POWER SUPPLY" outlined previously is indicated by an illustration
Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol.

@l Symbols used in illustrations

Example View from terminal

Connector symbol

@
Single line

Direction mark

m,
M
SG 1364

Direction mark A direction mark is shown to clarify the side of connector (terminal side or harness side). Direction marks are mainly used in the illustrations indicating terminal ins~ection.

All connector symbols shown from the terminal side are enclosed by a single line.

View from terminal side

... T.S.

View from harness side

\
Connector

All connector symbols shown from the harness side are enclosed by a double line.

View from harness side

... H.S.

Direction mark

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

-

Key to symbols signifying measurements or procedures

L

Symbol

Symbol explanat~on Check after dlsconnectlng the connector to be measured Check after connectlng the connector to be measured Insert key Into lgnltlon swltch Turn ~ g n ~ t l o n swltch to "OFF" posltlon Turn lgnlt~onsw~tch "ON" to posltlon Turn ~ g n ~ t ~ o n to "START" sw~tch posttlon Turn ~ g n ~ t ~ o n sw~tch from "OFF" to "ACC" posttlon Turn ~gn~tton swltch from "ACC" to "OFF" posltlon Turn lgntt~on sw~tch from "OFF" to "ON" posltlon Turn lgn~tlon sw~tch from "ON" to "OFF" posltlon Do not start engtne, or check wlth englne stopped

Symbol

Symbol explanat~on Current should be measured with an ammeter

&

E
E

Procedure wlth CONSULT

.m@ m
@AQ

Bg e

Procedure w~thoutCONSULT

B
a*2

A/C swltch

IS

"OFF"

A/C sw~tch s ' ON" 1 Fan sw~tch "ON" (At any poslIS t~on except for "OFF" posltlon) Fan sw~tch 'OFF' IS

fm
,

a
& L

L@

3@
@F

'a-,
"G
--

-k$?Jg,

Apply battery voltage dlrectly to components

Drlve vehlcle

@F

Disconnect battery negatlve cable

Start englne, or check wlth englne runnlng

- ,

Apply parklng brake

Release parklng brake

m"

Check after englne sufflclently

IS

warmed up

&!A
I
MYIT

a
\D(

G G
-TOI

Depress brake pedal

Release brake pedal

Depress accelerator pedal

Release accelerator pedal Pln term~nal check for S M J type E C U and A/T control un~t connectors For details regarding the termlnal arrangement, refer to the foldout page.

Voltage should be measured wlth a voltmeter

Clrcu~treststance should be an measured w ~ t h ohmmeter

IDENTIFICATION INFORMATION
Model Variation

Model Code 23941 ZK

Body

Engine CA2OE

Transaxle RL4F02A

Final drive ratio 4.133: 1 4.167:l 3.876: 1 3.895:l

Road wheel 5.5JJx 14 Steel or 5.5JJ X 14 Alloy

23941 ZP 23943 FK 23943 FP

Sedan

RS5F50A RE4F02A KA24E RS5F50A

Model Coding

Sedan:

41 -

-P
P: MANUALTRANSAXLE

K: AUTOMATIC TRANSAXLE

GL: 41

Z: 2.0 LITRE

GHIA: 43

F: 2.4 LITRE

IDENTIFICATION INFORMATION
Vehicle Identification
Vehicle identification Compliance plat

ENGINE SERIAL NUMBER

MANUAL TRANSAXLE NUMBER

AUTOMATIC TRANSAXLE NUMBER

IDENTIFICATION INFORMATION

VEHICLE DIMENSIONS
Overall length Overall height Overall width Front track (unladen) Rear track (unladen) Wheelbase Minimum ground clearance Turning circle (kerb t o kerb) "dependant on rear parallel links - refer page RA-6

4523 mm 1375 mm 1690 mm 1460 mm 1444 mm or 1453mm' 2550 mm 110mm

10.8 m

KERB WEIGHTS (Nomina0

Model
GL GHlA "Note: ADD 25kg FOR AIR CONDITIONING. Manual Auto

1130' 1190'

1166' 1220'

LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand
WARNING: Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle.
Place wheel chocks at the front wheels when the rear

wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.

Safety stand position

LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift

WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines.

Lift pad

Put the sill in the slit of the lift pad t o prevent the sill from deforming. I f the pad does not have the slit, prepare a suitable attachment with slit.

Tow Truck Towing

CAUTION: All applicable local laws regarding the towing operation must be obeyed. It is necessary to use proper towing equipment to avoid possible damage to the vehicle during a towing operation. When towing with the rear wheels on the ground, release the parking brake. When towing with the front wheels on the ground: Turn the ignition key to the "OFF" position and secure the steering wheel in a straight-ahead position with a rope or similar device. Never place the ignition key in the "LOCK" position. This will result in damage to the steering lock mechanism.

TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND

Observe the following restricted towing speeds and distances Speed Below 50 km/h (30 MPH) Distance Less than 65 km (40 miles)

LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont'd)
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH REAR WHEELS RAISED (With front wheels on ground)
Never tow an automatic transaxle model with rear wheels raised (with front wheels on ground) as this may cause serious and expensive damage to the transaxle. If it is necessary to tow it with rear wheels raised, always use a towing dolly under the front wheels.

It is recommended that vehicle be towed with the driving (front) wheels off the ground as illustrated.

TOWING HOOK
Always pull the cable straight b u t from the vehicle. Never pull on the hook at a sideways angle.

Grade

Bolt size

Bolt diameter* mm

Tightening torque (Without lubricant) Pitch mm N-m Hexagon head bolt kg-m ft-lb Hexagon flange bolt N-m kg-m ft-lb

M6 M8 4T M10

6.0 8.0 10.0

1. O 1.25 1.O 1.5 1.25 1.75 1.25 1.5 1. O 1.25 1 .O 1.5 1.25 1.75 1.25 1.5 O 1. 1.25 1. O 1.5 1.25 1.75 1.25 1.5

5.1 13 13 25 25 42 46 74 8.4 21 22 41 43 71 77 127 12 29 31 59 62 98 108 177

0.52 1.3 1.3 2.5 2.6 4.3 4.7 7.5 0.86 2.1 2.2 4.2 4.4 7.2 7.9 13.0 1.2 3.0 3.2 6.0 6.3 10.0 11.0 18.0

3.8 9 9 18 19 31

6.1 15 16 29

0.62 1.5 1.6 3.0 3.1 5.2 5.7 9.0 O 1. 2.5 2.7 4.9 5.2 8.6 9.4 15.0 1.5 3.6 3.8 7.1 7.5 12.0 14.0 O 21 .

4.5 11 12 22 22

30
51 56 88 10 25 26 48 51
84

M12 M14 M6 M8

12.0 14.0 6.0 8.0

38
41

34
54 6.2 15 16 30 32 52 57 94 9 22 23 43 46 72 80 130

65
7 18

20
35

7T

M10 M12 M14 M6 M8

10.0 12.0 14.0 6.0 8.0 10.0 12.0 14.0

38
62

92 147 15 35 37 70 74 118 137 206

68
108 11 26 27 51

9T

M10 M12 M14

54
87 101 152

1.

2.

Special parts are exduded. This standard is applicable to bolts having the following marks embossed on the bolt head. Grade Mark

*: Nominal diameter
M

6
Nominal diameter of bolt threads (Unit: mm) Metric screw threads

MAINTENANCE
SECTION

MA

ELI

CONTENTS
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MA- 2 ... MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MA- 3 RECOMMENDED FUEL & LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MA- 4 . ENGINE MAINTENANCE CA20E ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MA- 6 ENGINE MAINTENANCE KA24E ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MA-1 1 CHASSIS AND BODY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MA- 16 SERVICE DATA AND SPECIFICATIONS (S.D.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MA-22
!

PREPARATION
SERVICE TOOLS
Tool supplier: Litchfield Tool number Tool name E71 18-1 Adapter Harness (KA24E Engine) E7 1 18-2 Adapter Harness (CA20E Engine) . ESD28079 Diagnostic link bridge (CA20E Engine) lgnition coil adapter to connect external tachometer lgnition coil adapter to connect external tachometer Diagnostic link to bridge diagnostic terminals

I Description

I s

SCHEDULED MAINTENANCESERVICES
M A I N T E N A N C E INTERVAL Months MAINTENANCE ITEM k m x 1000
ENGINE Engine valve clearance GL ONLY Drive Belts *l Engine timing belt *2- GL ONLY Engine oil *3 Oil Filter '3 Cooling System Engine coolant (with reservoir) FUEL SYSTEM Idle speed GHIA ONLY Air cleaner element '4 Fuel lines,hoses and connections Fuel filter
~~ ~ ~

1.6

N u m b e r o f M o n t h s o r Km, whichever o c c u r s first IL 18 24 ro $ 8 4 2 4 8 6 4 8 0 1 8 7.5 i s 22.6 ro $7.5 4 5 52.6 8 0 87.5 7 5 82.5

8

72 80

78 87.5

84 10s

81

88

102 127.5

101

114

129

1rr.s 120

rrr

142.5 i c e

A A I C R

A C R R C R

A C R R C R C R R C R

A C C

A C C R R R C

A C R R R C R C R R C R

A C R . R C

R R R R R R R R R C C C Replace every 24 months C R

I

C
I

C
I I

C R I R C R C

C I I

C
I I

R C C C C R C C C C

C R I R

C I I

C R I R C R C

C
I I

C R I R

IGNITION SYSTEM Ignition timing Spark Plugs - check & regap ELECTRICAL SYSTEM Battery electrolyte level and specific gravity EMISSION CONTROL SYSTEM P.C.V. SYSTEM CHASSIS AND BODY Clutch Operation Brake lines, hoses and connections Brake Pedal Brake Fluid *5 Parking Brake Power Brake unit and hoses Disc Brakes Power Steerina Fluid and line Steering Operation and gear housing Steering linkages, rack guide &tie rod ,ends Steerina stoos " Manual transaxle oil Automatic Transaxle Fluid level Front Suspension ball joints Wheel Nuts Wheel Brngs. - smooth rotationlend Play

C C C

C R
C

C C C

C
C C

C
R C

C C I C I C
I

C C I C R C I C
I

C C I C I C I C
I

C C I C R C I C I C C L I I C T C

C C I C I C
I

C
C I C R C I C I C C

C
C I C I C I C
I

C C I C R C I C
I

C C I C I C I C I

C C I C R C I C I C C L I I C T C

C I C I C
I

C I

C I L I I I T C L I I T L I I T C L I I T

C C L I I C T C L I I T L I I T C L I I T

C C L I I T L I I T C L I I T L I I L I I T L I I T C L I I T

L I I T

L I I T C

L I I T

L I I C T C

C T C

Legend " K Adjust. "C" Check specificationor operation, correct if necessary "I" Visually inspect, correct or replace if necessary. "C' Lubricate. "R" Replaceor change. "T" Tighten.
'1.

'2 '3

Refer Mlnor Matntenance- drive Belts for details Falldreto replacettmlng belt may result In aamage toenglne If vehlcle Isoperated frequently under follow~ng cond~t~ons,s suggestea that tne englne lt 1 oll and oll fllter be changed more frequently (a) driving in dusty conditions

'4.

'5

extended perlods of idling or low speed operation (b) driving for a prolonged perlod In cold temperatures, or driving short distances only. (c) driving in hot weather in "Rush Hour" traffic. (d) continuous hard driving e.g. Motor Sport, Rallylngetc. (e) If thevehicle isoperated in verydusty orsandy areas, replace moreoften than normally recommended intervals. Replaceeverytwo years If there has been continuous hard drlvlng, mountalndrlvlng, or 11 brakes are used extens~vely the veh~cle operated ~n tne or IS extremely humld climates. the brake fluid should be changed every 12 months

MAINTENANCE
RECOMMENDED FUEL AND LUBRICANTS
APPROXIMATE REFILL CAPACITIES AND SPECIFICATIONS Engine Crankcase Specification Manual transaxle 5 speed specification Automatic transaxle 4 speed specification Cooling System Including heater

Motorcraft R1.300 API SG ESE-M2C 153E 75W-90 API GL4

Incl. filter 3.6 litres Without filter, 3.2 litres

SAE VISCOSITY NUMBER

ENGINE OIL
20,
40

2ow so

1 6 W 60 I O W 30 I O W 40 I O W 60

4.7 litres

Motorcraft RI-35 Dexron II ESR-2MC-163A

6.8 litres (CA20E) 7.4 litres (KA24E)

GEAR OIL

Motorcraft RI-32/33 Ethylene-Glycol inhibited antifreeze 50% MES-MN- 121A

7.6 litres

NOTE: Engine and Manual Transaxle Oils The proper oil viscosity for your engine and manual transaxle should be determined by the average outside temperature.

Brake 81Clutch System Specification Power Steering Fluid Specification Manual Steering Rack Multi Purpose Grease

Heavy duty brake fluid ESZ MGC-55A Motorcraft RI-35 Dexron II ESR-2MC- 163A Semi fluid grease ESA-MIG-75A Lithium Soap Base NLGI-No 2

Maintain to level on reservoir

Temperature range anticipated before n e x t o i l change.

l.O litre

as required as required 6 0 litres approx.

Fuel Tank Capacity-Usable Specification 9 1 Octane (RON) minimum

MAINTENANCE

ENGINE MAINTENANCE

CAPOE~

Adjusting Intake and Exhaust Valve Clearance

Adjustment should be made while engine is warm but not running. 1 Set No 1 cyl~nderat top dead center on its compresslon stroke, and adjust valve clearances and @ 2 Set No 4 cylinder at top dead center on lts compresslon stroke, and adjust valve clearances @, 0, and @ Valve clearance: @l, @ @ and Intake 0.30 mm (0.012 in) Exhaust @, @ and @ 0.30 mm (0.012 in) Adjusting screw lock nuts: 18 22 Nmm (1.8 2.2 kg-m, 13 - 16 ft-lb)

S, a,

a,

G],

m: -

I Power steering oil pump

or idler

Alternator

Checking Drive Belts

1. Inspect for cracks, fraying, wear or oil adhesion. If necessary, replace with a new one. 2. lnspect drive belt deflections by pushing on the belt midway between pulleys. Adjust if belt deflections exceed the limit.

Lock nut

Lock bolt 7

AIC compressor idler pulley

Lock

Models without air conditioning

Unit: mm
SMA515B

Used belt deflection Water pump pulley Limit Alternator 12 12.5 Adjust deflection 6-8 7-9

Set deflection of new belt 5-7 6-8

P' P
Alternator7 Power steering oil pump or idler

Applied pushing force: 98 N ( l 0 kg, 221b)

P/S oil

Pump . or idler

Crank pulley

Unit: mm
Used belt deflection Limit Adjust deflection 5-7 7-9 Set deflection of new belt 5-7 6-8

Alternator Power steering oil pump or idler Air conditioner compressor

10 12.5

3-4

3-4

'

Applied pushing force: 98 N (10 kg, 221b)

ENGINE MAINTENANCE
Changing Engine Coolant
WARNING: To avoid being scalded, never change the coolant when the engine is hot.
1. Set heater temperature lever t o maximum "HOT".

2. Open drain cock at the bottom of radiator, and remove

radiator cap. Be careful not to allow coolant to contact drive belts. 3. Remove cylinder block drain plug. 4. Close drain cock and tighten drain plug securely. 5. Fill radiator with water and warm up engine. 6. Stop engine and wait until it cools down. 7. Repeat step 2 through step 6 until clear water begins to drain from radiator. 8. Drain water. Apply sealant to the thread of drain plug. 54 74 N-m (5.5 7.5 kg-m, 40 54 ft-lb) 9. Fill radiator with coolant up to spec~fiedlevel. Follow instructions attached to anti-freeze container for mix~ng ratio of anti-freeze to water. Coolant capacity (With reservoir tank): 7.6 Q (6-3/4 Imp qt) Pour coolant through coolant filler neck slowly to allow air in system to escape.

m: -

MAX. MIN.

10. Remove reservoir tank, drain coolant, them clean reservoir tank. 11. Fill reservoir tank with coolant up to "MAX" level. 12. Run engine and warm it up. 13. Stop engine and cool it down, then add coolant as necessary.

SMA412B

Checking Fuel Lines

lnspect fuel lines and tank for proper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts. Inspect fuel delivery rail and "0" ring fittings. If necessary, repair or replace faulty parts.

CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Tightening torque specifications are the same for all rubber hose clamps. Ensure that screw does not contact adjacent parts.
(0.10 - 0.15 kg-m, 0.7 - 1. l ft-lbI

Changing Fuel Filter

1. Remove fuse for fuel pump. 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. 4. Turn ignition switch off and install fuse for fuel pump.

5. Loosen fuel hose clamps. 6. Replace fuel filter. Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. Use high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. When tightening fuel hose clamps, refer to "Checking Fuel Lines".

Cleaning and Changing Air Cleaner Filter

Viscous paper type The viscous paper type filter does not need cleaning between renewals.

ENGINE MAINTENANCE Checking Positive Crankcase Ventilation (P.C.V.) System

p 1

CHECKING P.C.V. VALVE Disconnect hose and check P.C.V. valve to see it i s operating properly. Finger is sucked into P.C.V. valve when finger is put on P.C.V. valve during idling.

Changing Engine Oil and Oil Filter

1. Warm up engine, then stop it, and check for oil leakage from engine components. 2. Remove oil filler cap and drain oil. WARNING: Be careful not t o burn yourself, a the engine oil may be hot. s 3. Clean and install oil pan drain plug with washer. : Drain plug 29 - 39 N.m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) 4. Remove oil filter. 5. Wipe oil filter mounting surface. 6. Smear a little engine oil on rubber gasket of oil filter.

7. Install oil filter. When installing oil filter, screw it in until a slight resistance i s felt, then tighten additionally more than 213 turn. 8. Refill engine with recommended engine oil. With filter change 3.6 litres.

9. Check oil level. 10. Start engine and check area around drain plug and oil filter for any sign of oil leakage. 1 1. Run engine for a few minutes, then turn it off. After several minutes, check oil level.

ENGINE MAINTENANCE
Replacing Spark Plugs
1 . Blow out each plug cavity with compressed air. 2. Disconnect spark plug wire a t boot. Do not pull on the wire. 3. Remove spark plugs with spark plug wrench. 4. Check spark plug gap. Gap: 1 .O - 1 . l m m (0.039 - 0 . 0 4 3 in) 5. Install spark plugs. Reconnect high tension cables according to the numbers and colours indicated on them. Grey -Exhaust side. Black - Intake side. : Spark Plug 2 0 - 2 9 N-m (2.0 - 3 . 0 kg-m, 1 - 2 2 ft-lb) 4

Side electrode

SMA476

Checking lgnition Wiring

1. Check the ignition wires for cracks, damage, burned terminals and proper fit. 2. Measure the resistance of the ignition wires, by shaking them and checking for intermittent breaks. Resistance: Less than 3 0 k l2

lgnition Timing
SMAOl BA

To check and/or adjust ignition timing refer Section ES.

Camshaft Timing Belt

For the procedure to replace the camshaft timing belt refer Section EM.

ENGINE MAINTENANCE
Checking Drive Belts

1 ~ ~ 2 4 ~ 1

lnspect for cracks, fraying, wear or oil adhesion. If necessary, replace with a new one. 2. lnspect drive belt deflections by pushing on the belt midway between pulleys. Adjust if belt deflections exceed the limit. Belt deflection: Inspect drive belt deflections when engine is cold.
Unit: mm (in)

1.

Used belt deflection Limit Alternator Power steering oil pump Air conditioner compressor (where fitted) Applied pushing force Deflection after adjustment 6-7
8 (0.3 1)

Deflection of new belt

5-6
(0.20-0.24) 4-5 (0.16-0.20)

(0.24-0.28) 5-6

8 (0.31)

(0.20-0.24)
98 N (10 kg, 22 Ib)

ENGINE MAINTENANCE
Changing Engine Coolant
Air conditioner switch

WARNING: To avoid being scalded, never change the coolant when the engine is hot. 1. Move heater "TEMP" control lever all the way to "HOT" position.

Lever type control shown

SMA9620

2.

Open drain cock at the bottom of radiator, and remove radiator cap.

Drain plug

Remove cylinder block drain plug. Close drain cock and tighten drain plug securely. Apply sealant to the thread of drain plug. 34 44 N-m (3.5 4.5 kg-m, 25 33 ft-lb) 5. Open air relief plug. 6. Fill radiator with water and close air relief plug and radiator cap. 7. Run engine and warm it up sufficiently. 8. Race engine 2 or 3 times under no-load. 9. Stop engine and wait until it cools down. 10. Drain water. 11. Repeat step 2 through step 10 until clear water begins to drain from radiator.

3.

4.

m: -

12. Open radiator cap and air relief plug. 13. Fill radiator with coolant up to specified level. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity (With reservoir tank): 7.5 litres

ENGINE MAINTENANCE Changing Engine Coolant (Cont'd)

Pour coolant through coolant filler neck slowly to allow air in system to escape. After radiator is filled with coolant, attach radiator cap, and shake radiator upper hose up and down. Open radiator cap, and see if coolant level has dropped. Add coolant if any drop in coolant level is found.

MAX.

MIN.

14. Close air relief plug. 15. Remove reservoir tank, drain coolant, then clean reservoir tank. 16. Install reservoir tank and fill it with coolant up to "MAX" level and then install radiator cap. 17. Run engine and warm it up sufficiently. 18. Race engine 2 or 3 times under no-load. 19. Stop engine and cool it down, then add coolant as necessary.

SMA412B

Checking Fuel Lines

Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts.

SMA803A

CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Ensure that screw does not contact adjacent parts.

Changing Fuel Filter

WARNING: Before removing fuel filter, release fuel pressure from fuel line. 1. Remove fuse for fuel pump. 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. 4. Turn ignition switch off and install fuse for fuel pump.
P -

SEF832G

ENGINE MAINTENANCE Changing Fuel Filter (Cont'd)

5. 6.
8

1~

~ 2 4 ~

Loosen fuel hose clamps. Replace fuel filter. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. When tightening fuel hose clamps, refer to "Checking Fuel Lines".

Changing Air Cleaner Filter

The viscous paper type filter does not need cleaning between renewals.

Changing Engine Oil and Oil Filter

1. Warm up engine, then stop it, and check for oil leakage from engine components. 2. Remove oil filler cap and drain oil. WARNING Be careful not to burn yourself, as the engine oil may be hot. 3. Clean and install oil pan drain plug with washer. : Drain plug 29 - 39 N-m (3.0 -4.0 kg-m, 22- 29 ft-lb)

4. Remove oil filter. 5. Wipe oil filter mounting surface. 6. Smear a little engine oil on rubber gasket of oil filter.

7. Install oil filter. When installing oil filter, screw it in until a slight resistance is 1 felt, then tighten additionally more than 2 3 turn. 8. Refill engine with recommended engine oil. With filter change 3.6 litres.

ENGINE MAINTENANCE Changing oil and filter (Cont'd)

9. Check oil level 10. Start engine and check area around drain plug and oil filterfor any sign of oil leakage. 1 1. Run engine for a few minutes, then turn it off. After several minutes, check oil level.

Replacing Spark Plugs

1. 2. 3. 4. Blow out each plug cavity with compressed air. Disconnect spark plug wire at boot. Do not pull on the wire. Remove spark plugs with spark plug wrench. Check spark plug gap. Gap: 1 . - 1 .lm m (0.039- 0.043 in) O 5. Install spark plugs. Reconnect high tension cables.
: Spark Plug

20 29 N-m (2.0 3.0 kg-m, 14 - 22 ft-lb)

Checking lgnition Wiring

1. Check the ignition wires for cracks; damage, burned terminals and proper fit. 2. Measurethe resistance of the ignition wires, by shaking them and checking for intermittent breaks. Resistance: Less.than 30 kS2

Checking Positive Crankcase Ventilation (P.C.V.) System

CHECKING P.C.V. VALVE
Disconnect hose and check P.C.V. valve to see it is operating properly. Finger is sucked into P.C.V. valve when finger is put on P.C.V. valve during idling.

lgnition Timing & Idle Speed

To check and/or adjust ignition timing or idle speed, refer section ES.

CHASSIS AND BODY MAINTENANCE Checking Exhaust System

Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration.

SMA211A

Checking Clutch Fluid Level and Leaks

If fluid level is extremely low, check clutch system for leaks.

Checking Clutch System

Check fluid lines and operating cylinder for improper attachment, cracks, damage, loose connections, chafing and deteriorat~on.

Checking MIT Oil

l L -

Ll

Never start engine while checking oil level. 1. Check for oil leaks. 2. Check oil level. Filler plug: 25 - 34 N-m (2.5 3.5 kg-m, 18 25 ft-lb)

m:

l
1

'--a

F~ller plug
r

'

SMA144A

Checking Inhibitor Switch Operation (A/T)

Apply park brake firmly and place foot firmly on brake pedal. Shift automatic gear selector lever t o each gear position and attempt t o start engine. Ensurestarter motor doesnot operatein positions 1,2, Dand R. Ensure starter motor does operate in positions P and N.

C H A W S k W BODY MAINTENANCE
-

Checking A/T Fluid Level

1. Check for fluid leakage. 2. Check fluid level. Fluid level should be checked using "HOT" range on dipstick at fluid temperatures of 50C (after vehicle has been driven approximately 5 minutes in urban areas after engine is warmed up. But it can be checked at fluid temperatures of 30C using "COLD" range on dipstick for reference after engine is warmed up and before driving. However, fluid level must be rechecked using "HOT" range.

COLD

1) Park vehicle on level surface and set parking brake. 2) Start engine and then move selector lever through each gear range, ending in "P". 3) Check fluid level with engine idling. If the vehicle has been driven for a long time at high speeds, or in city traffic in hot weather, or if it is being used to pull a trailer, the accurate fluid level cannot be read. You should wait until the fluid has cooled down (about 30 minutes). 4) Remove dipstick and wipe it clean with lint-free paper. 5) Reinsert dipstick into charging pipe as far as it will go. 6) Remove dipstick and note reading. If level is at low side of either range, add fluid to the charging pipe. Do not overfill.

3. Check fluid condition. Check fluid for contamination. If fluid is very d a d or smells burned, or contains frictional material (clutches, band, etc.), check operation of AIT. Refer to section AT for checking operation of AIT.

Check f l u ~ d contamination. for

SMA853B

CHASSIS AND BODY MAINTENANCE Checking Brake Fluid Level and Leaks
If fluid level is extremely low, check brake system for leaks.

Checking Brake System

Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc.

Changing Brake Fluid

1. Drain brake fluid from each air bleeder valve. 2. Refill until new brake fluid comes out from each air bleeder valve. Use same procedure as in bleeding hydraulic system t o refill brake fluid. Refer to section BR. a Refill with recommended brake fluid "DOT4" a Never reuse drained brake fluid. a Be careful not to splash brake fluid on painted areas.

Checking Brake Booster, Vacuum Hoses, Connections and Check Valve

Check vacuum lines, connections and check valve for improper attachment, air tightness, chafing and deterioration.

Checking Disc Brake

Check condition of disc brake components.

ROTOR
Check condition and thickness.

Front disc brake: Standard 22.0 m m Minimum 20.0 m m Rear disc brake: Standard 1 0 . 0 m m Minimum 8 . 0 m m

CHASSIS AND BODY MAINTENANCE

CALIPER
Check operation and for leakage.

PAD
Check for wear or damage. Front disc brake: Standard thickness 11.0 mm Minimum thickness 2.0 mm Rear disc brake: Standard thickness 8.0 mm Minimum thickness 2.0 mm

CWAS4S AND BODY MAINTENANCE Checking Foot Brake Pedal Operation

H: Free height M/T - 185-1 9 5 mm A/T - 175-1 8 5 mm D: Depressed height Under force of 4 9 0 N (50 kg, 1 1 0 Ib) with engine running, 9 0 mm A: Pedal free play 1 .O-3.0 mm (0.039-0.1 1 8 in)

Checking Parking Brake

1. Pull lever with specified amount of force. Check lever stroke and for smooth operation. Number of notches [At pulling force of 196 N (20 kg, 44 Ib)]: 9-1 1 If not to specification refer Section Br.

Checking Steering Gear and Linkage

STEERING GEAR
Check gear housing and boots for looseness, damage or grease leakage. Check connection with steering column for looseness.

STEERING LINKAGE
Check ball joint, dust cover and other component parts for looseness, wear, damage or grease leakage.

Checking Power Steering System Fluid and Lines

Check fluid level, when the fluid is cold.

Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

CHASSIS AND BODY MAINTENANCE Body

LUBRICATING HOOD LATCHES, LOCKS AND HINGES

SMA961B

CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS Front seat belt
Check anchors fo loose mounting.

Check retractor Check function of buckles and tongues when buckled and released.

CAUTION: 1. If the vehicle has been involved in an accident replace the entire belt assembly, regardless of nature of accident.

2.

If the condition of any component of a seat belt is questionable, do not repair seat belt, but replace it as a belt assembly. If webbing is cut, frayed, or damaged, replace belt assembly.

4.

5.

Never oil tongue or buckle. Use a genuine seat belt assembly.

3.

(O)

Anchor 24 31 (2.4 3.2.17

- 23)

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Maintenance

INSPECTION AND ADJUSTMENT Valve clearance (Hot)
CA20E Engine Intake Exhaust 0.30 (0.012) 0.30 (0.012) Unit:mm (in) Engine Type Gap (mm) KA24E AGPR 43CU 1 1 1.0-1.1 20-29

Spark Plugs
CA2OE Intake Side Exhaust side AGPR 32CU 1 1 AGPR 42CU 1 1 1.o-1.1 20-29

Drive belt deflection Applied pushing force: 98 N (10 kg, 22 Ib)

CA2OE without air conditioning Used belt deflection Limit Adjust deflection 6-8 (0.24-0.3 1) 7-9 (0.28-0.35) Set deflection of new belt 5-7 (0.20-0.28) 6-8 (0.24-0.3 1) Unit: mm (in)

Torque (Nm)

Ignition Timing & Idle Speed Refer t o Section ES.

Alternator Power steering oil pump or idler

(0'47)

12'5 (0'492)

CA2OE with air conditioning Used belt deflection

'

Unit: mm (in)

Limit

Adjust deflection 5-7 (0.20-0.28) 7-9 (0.28-0.35) 3-4 (0.12-0.16)

Set deflection of new belt 5-7 (0.20-0.28) 6-8 (0.24-0.3 1) 3-4 (0.12-0.16)

Alternator Power steering oil pump or idler Air conditioner oil pump or idler

l0 (0'39)

2'5 (0'492)

(0'24)

KA24E Deflection after adjustment 6-7 (0.24-0.28)

Unit: mm (in) Deflection of new belt 5-6 (0.20-0.24)

Limit

Alternator Power steering oil pump Air conditioner compressor (where fined)

(0'3 l )

(0'31)

5-6 4-5 (0.20-0.24) (0.16-0.20)

SERVICE DATA AND SPECIFICATIONS (S. D.S.)

Chassis and Body Maintenance

Brake
Standard thickness (mm) Front disc pad Front disc rotor Rear disc pad Rear disc rotor 11.0 22.0 8.0 10.0 Minimum thickness (mm) 2.0 20.0 2.0 8.0

Brake

Pedal Free height

M/T

mm (in) 185-195 (7.28-7.68) 175-185 (6.89-7.28) 1-3 (0.04-0.12)

A/T Free play Depressed height [Under force of 490 N (50 kg, 110 Ib) with engine running] mm (in) Parking brake Number of notches [at pulling force 196 N (20 kg, 44 Ib)]

90 (3.54) or more

9-1 1

ENGINE MECHANICALl
. . . . . . .

. . .

SECTION

EM
, ,

CONTENTS

L KA24E

PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM- 2 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM- 3 ..

OUTER COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM- 6 . COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM- 8 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,. . . . . . . . . . . . . . . . . . . . . EM- 9 TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM- 11 OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM- 16 . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM- 18 . ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM-32 . CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-34 SERVICE DATA AND SPECIFICATIONS (S.D.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-46 CA2OE
, , , , , , , ,

OUTER COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM-56 COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-57 . TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM-58 . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM-63 OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-75 . OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM-76 ENGINE R E M O V A L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM-78 ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-80 SERVICE DATA AND SPECIFICATIONS (S.D.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM-90

PRECAUTION

q f*)"
Grow Bolt hole
SEM371C

LIQUID GASKET APPLICATION PROCEDURE

a. Before applying liquid gasket, use a scraper to remove ail traces of old liquid gasket from mating surface. b. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.) m Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide (for oil pan). Be sure liquid gasket Is 2.0 to 3.0 m m (0.079 to 0.118 in) wide (in areas except oil pan). c. Apply liquid gasket to inner sealing surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) d. Wait at least 30 minutes before refilling engine oil and engine coolant.

PREPARATION
SERVICE TOOLS
Tool Supplier: Litchfield I Tool Number Description Tool Name E7007 Valve spring compressor

Engine application

CA

KA

Angle gauge

E71 12 Sump seal cutter

Removing oil pan

E7181A Camshaft pulley holder

E7145 Chain stopper

installer

E7004 Valve stem seal installer

Intake only

E7005 Valve stem seal installer Exhaust onlv E7008 Camshaft seal installer

PREPARATION
COMMERCIAL SERVICE TOOLS
Engine application Tool name Description

CA
Valve guide d r i f t
Intake:

KA

A = 10.5mm (0.413 in1 dia. B = 6.6 mm (0.260 in1 dia. Exhaust: A = 11.5 mm (0.453 in1 dia. B = 7.6 mm (0.299 in) dia.

Removina and installing valve

k : '

guide

Valve guide reamer

Intake:

Exhaust:

7.0 mm (0.276 in1 dia. 11.2 mm (0.441 in1 dia. 8.0 mm (0.315 in1 12.2 mm (0.480 in) dia.

Reaming valve guide ( @ ) o r hole f o r oversize valve guide

(0)

PREPARATION

OUTER COMPONENT PARTS

m
0
Front

y J
Front

7
Col lector Throttle chamber

0 0

OUTER COMPONENT PARTS

Tightening Procedure of each Part
INTAKE MANIFOLD
(nl: 16 21 Nom (1.6

I~

~ 2 4 ~ 1

- 2.1 kg-m, 12 - 15 ft-lb)

SEM593C

EXHAUST MANIFOLD
(nl: 16

- 21 N-m (1.6 - 2.1

kg-m, 12

- 15 ft-lb)

0 0

SEM594C

INTAKE MANIFOLD COLLECTOR

(nl: 16

- 21 Nom (1.6 - 2.1 kg-m, 12 - 15 ft-lb)

Front

SEM595C

THROlTLE CHAMBER
(nl: Bolts should be tightened twice. 1st: 9 11 Nom (0.9 1.1 kg-m, 6.5 8.0 ft-lb) 2nd: 18 22 Nom (1.8 2.2 kg-m, 13 16 ft-lb)

0 O from A 0 View SEM596C

@B

COMPRESSION PRESSURE
Measurement of Compression Pressure
1. Warm up engine.

2. 3. 4. 5.

Turn ignition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable.

6. Attach a compression tester to No. 1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. a Always use a fully-charged battery to obtain specified engine revolution. Compression pressure: kPa (kg/cm2, psi)/rpm Standard 1,206 (12.3, 175)/250 Minimum 1,010 (10.3, 146)/250 Difference limit between cylinders 98 (1.0, 14)/250 10. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through spark plug holes and retest compression. a If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is leakage past the gasket surface. If so, replace cylinder head gasket.

OIL PAN
Removal
1. Remove the following parts: Front exhaust tube Front side gusset Center member 2. Remove oil pan bolts.

I~

~ 2 4 ~

3. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. Do not insert screwdriver, or oil pan flange will be deformed.

(2) Slide Tool by tapping its side with a hammer, and remove oil pan.

Installation
1. Before installing oil pan, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.

2. Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent.

OIL PAN
Installation (Cont'd)
Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide.
Cut here.

e
Liquid jot
S LC906

q,
Groove

-I" qJ$+:
hole SEM9098

7 mm (0.28 in)

3. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. 4. Install oil pan. a Wait at least 30 minutes before refilling engine oil.

TIMING CHAIN

I KA24E I

Camshaft sprocket

(ql 118 - 157 (12 - 16-87 - 116)

Chain tensioner

Oil pump drive boss

(kg-m, ft-lb)
y liquid gasket.

(12 - 16,87

- 116)

(0.7 0.8.5.1
To main bearing beam

- 5.8)
SEM550C

(ql

1 6 - 2 1 (1.6-2.1.12-1

CAUTION: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.

TIMING CHAIN
Removal

1 ~ ~ 2 4 ~ 1

1. Place wheel chocks at both front and back of rear wheels. 2. Place safety stands under designated front supporting points. Remove front right side wheel. 3. Remove dust cover and under cover. 4. Drain engine oil.

5. Set No. 1 piston at T.D.C. on its compression stroke.

6. Remove the alternator and compressor drive belts. 7. Remove the following parts. @ Alternator and adjusting bar @ Oil separator @ Power steering pump pulley, pump stay and bracket. @ Compressor and bracket. @ Crank shaft pulley and oil pump drive boss.

8. Remove oil pan. (Refer to OIL PAN.) 9. Remove oil strainer securing bolt. 10. Remove front cover securing bolts (cover to block and head to cover).

TIMING CHAIN
Removal (Cont'd)

1 ~ ~ 2 4 ~ 1

11. Remove rocker cover. 12. Support engine with hoist or chain block. 13. Remove right-side engine mounting bracket and lower the engine.

14. Remove front cover.

15. Remove the following parts: Chain tensioner Chain guides Timing chain and sprocket

Inspection
Check for cracks and excessive wear at roller links. Replace if necessary.

TIMING CHAIN
Installation
1. Install crankshaft sprocket. Make sure that mating marks of crankshaft sprocket face engine front.

2. Install camshaft sprocket. 3. Confirm that No. 1 piston is set at T.D.C. on its compression stroke. 4. Install timing chain. Set timing chain by aligning its mating marks with those of crankshaft sprocket and camshaft sprocket.

m: Punchmark

5. Tighten camshaft sprocket bolt whilst holding gear with E7 18 1A tool.

6. Install chain guide and chain tensioner

TIMING CHAIN
Installation (Cont'd)
7. Apply liquid gasket to front cover.

1 ~ ~ 2 4 ~ 1

8. lnstall front cover. a Be careful not t o damage cylinder head gasket. a Do not forget oil seal.

9. Install rubber plug onto cylinder head. (Refer to "Installation" of CYLINDER HEAD.) 10. lnstall oil pan. (Refer to OIL PAN.) 11. lnstall engine mounting. 12. Install any parts removed.

OIL SEAL REPLACEMENT

VALVE OIL SEAL
1. Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove valve spring and valve oil seal with suitable tool.

Piston concerned should be set at T.D.C. to prevent valve from falling.

4. Apply engine oil to new valve oil seal and install it with Tool.

Before installing valve oil seal, install valve spring seat.

Unit: m m (in)

SEM246C

I
OIL SEAL INSTALLING DIRECTION

FRONT OIL SEAL

1. Remove crankshaft pulley. 2. Remove front oil seal. Be careful not to damage crankshaft.

OIL SEAL REPLACEMENT

pZ.1

Apply engine oil to new oil seal and install it using suitable tool.

REAR OIL SEAL

1. 2. 3. 4.
Remove Remove Remove Remove transaxle. flywheel or drive plate. rear oil seal retainer. traces of liquid gasket using scraper

5. Remove rear oil seal from retainer.

6. Apply engine oil to new oil seal and install it using suitable tool.

7. Apply liquid gasket to rear oil seal retainer.

CYLINDER HEAD

[q

7 - 10 (0.7 - 1.O, 5.1 - 7.2) Refer t o "Installation" of CYLINDER HEAD.

Valve rocker cover

Rocker cover gasket

(3.8 4.2.27

- 30)

Valve and spring

Intake

Valve cotter -

Cylinder head gasket

For cylinder head bolt tightening procedure, refer t o "Installation" of CYLINDER HEAD.

CAUTION: a When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new englne oil on their sliding surfaces. a When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts.

O.K.
ocker arm with

a Hydraulic valve lifters are Installed in each rocker arm. If

hydraulic valve lifter is kept on its side, even when installed in rocker arm, there is a posslblllty of air entering it. After removal, always set rocker arm straight up, or when laying it on its side, have it soak in'new englne oil.

SEM878B

N.G.

a Do not disassemble hydraulic valve lifter. a Attach tags to valve lifters so as not to mix them up.

SEM8688

Removal
1. Drain coolant from radiator. 2. Relieve fuel pressure to zero Refer to ES section "FUEL INJECTION CONTROL SYSTEM INSPECTION". 3. Remove the following parts: a Exhaust manifold a Air duct a lntake manifold collector a lntake manifold stay
4. Disconnect hoses. a Vacuum gallery hoses, which are installed on intake manifold. a Fuel tube hoses

a
5. Disconnect water hoses as shown in figure.

CYLINDER HEAD
Removal (Cont'd)
6. Remove intake manifold. 7. Remove rocker cover. When removing rocker cover, do not knock rocker cover against rocker arms.

8. Set No. 1 piston at T.D.C. on its compression stroke.

9. Loosen camshaft sprocket bolt. Support timing chain by using Tool as shown in figure.

10. Remove camshaft sprocket.

CYLINDER HEAD
Removal (Cont'd)
11. Remove front cover tightening bolts to cylinder head.

12. Remove cylinder head. Head warpage or cracking could result from removing In incorrect order. Cylinder head bolts should be loosened in two or three steps.

Disassembly
1. Remove rocker shaft assembly. a. When loosening bolts, evenly loosen from outside in sequence. b. Bolts should be loosened in two or three steps. 2. Remove camshaft. Before removing camshaft, measure camshaft end play. (Refer to "Inspection".)

3. Remove valve components with Tool (E7007). 4. Remove valve oil seals. (Refer to OIL SEAL REPLACEMENT.)

CYLINDER HEAD
Inspection
CYLINDER HEAD DISTORTION

1 ~ ~ 2 4 ~ 1

Head surface flatness: Less than 0.1 mm (0.004 in) If beyond the specified limit, replace it or resurface it. Resurfacing limit: The resurfacing limit of cylinder head is determined by the cylinder block resurfacing in an engine. Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing is "B" The maximum limit is as follows: A B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced. Nominal cylinder head height: 98.8 - 99.0 mm (3.890 3.898 in)

CAMSHAFT VISUAL CHECK

Check camshaft for scratches, seizure and wear.

CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal. Runout (Total indicator reading): 0 0.02 mm (0 0.0008 in) 2. If it exceeds the limit, replace camshaft.

CAMSHAFT CAM HEIGHT

1. Measure camshaft cam height. Standard cam height: 44.839 45.029 mm (1.7653 1.7728 in) Cam wear limit: 0.2 mm (0.008 in) 2. If wear is beyond the limit, replace camshaft.

CAMSHAFT JOURNAL CLEARANCE

1. Install camshaft bracket and rocker shaft and tighten bolts to the specified torque. 2. Measure inner diameter of camshaft bearing.

Standard inner diameter: 33.000 - 33.025 mm (1.2992

1.3002 in)

CYLINDER HEAD
Inspection (Cont'd)
3. Measure outer diameter of camshaft journal. Standard outer diameter: 32.935 32.955 mm (1.2967 1.2978 in) 4. If clearance exceeds the limit, replace camshaft andlor cylinder head. Camshaft journal clearance: Standard 0.045 0.090 mm (0.0018 0.0035 in) Limit 0.12 mm (0.0047 in)

1-

CAMSHAFT END PLAY

1. Install camshaft in cylinder head. 2. Measure camshaft end play. Camshaft end play: Standard 0.07 - 0.15 mm (0.0028 Limit 0.2 mm (0.008 in)

- 0.0059 in)

CAMSHAFT SPROCKET RUNOUT

1. Install sprocket on camshaft. 2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.12 mm (0.0047 in) 3. If it exceeds the limit, replace camshaft sprocket.

SEM232C

VALVE GUIDE CLEARANCE

1. Measure valve deflection In a right-angled direction with camshaft. (Valve and valve gulde mostly wear In thls dlrection )

Valve deflection limit (Dial gauge reading): 0.15 mm (0.0059 in)

Micrometer

2 a b

> .

;
_

<

S E M ~ ~ ~ C

If ~t exceeds the Ilm~t, check valve to valve gulde clearance. Inner drameter Measure valve stem d~ameterand valve g u ~ d e Check that clearance IS wlthln speclflcatlon Valve to valve guide clearance: Standard 0.020 - 0.053 mm (0.0008 - 0.0021 in) (Intake) 0.040 - 0.070 mm (0.0016 - 0.0028 in) (Exhaust) Limit 0.1 mm (0.004 in) replace valve or valve guide. If ~t exceeds the Ilrn~t,

CYLINDER HEAD Inspection (Cont'd)

VALVE GUIDE REPLACEMENT
1. To remove valve guide, heat cylinder head to 150 to 160C (302 to 320F).

2. Drive out valve guide with a press [under a 20 kN (2 t, 2.2 US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.

3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts) : Intake 11.175 11.196 mm (0.4400 Exhaust 12.175 - 12.196 mm (0.4793

- 0.4408 in) - 0.4802 in)

4. Heat cylinder head to 150 to 160C (302 to 320F) and press service valve guide onto cylinder head. Projection "L": 14.9 15.1 mm (0.587 - 0.594 in)

5. Ream valve guide. Finished size: Intake 7.000 7.018 mm (0.2756 Exhaust 8.000 - 8.018 mm (0.3150

0.2763 in)

- 0.3157 in)

CYLINDER HEAD
Inspection (Cont'd)
VALVE SEATS
Check valve seats for any evidence of pitting at valve contact surface, and reseat or replace if it has worn out excessively. Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve seat. Cut with both hands to uniform the cutting surface.

REPLACING VALVE SEAT FOR SERVICE PARTS

Recess diameter

SEM795A

1. Bore out old seat until it collapses. The machine depth stop should be set so that boring cannot continue beyond the bottom face of the seat recess in cylinder head. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Intake 36.500 36.516 mm (1.4370 1.4376 in) Exhaust 42.500 42.516 mm (1.6732 1.6739 in) Reaming should be done to the concentric circles to valve guide center so that valve seat will have the correct fit.

3. Heat cylinder head to 150 to 160C (302 to 320F)

4. Cut or grind valve seat using suitable tool at the specified dimensions as shown in S.D.S. 5. After cutting, lap valve seat with abrasive compound. 6. Check valve seating condition. Seat face angle " a ": 45 deg. Contacting width "W" Intake 1.6 1.7 mm (0.063 0.067 in) Exhaust 1.7 2.1 mm (0.067 0.083 in)

CYLINDER HEAD Inspection (Cont'd)

VALVE DIMENSIONS

1-

Check dimensions in each valve. For dimensions, refer to S.D.S. When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.

VALVE SPRING
Squareness 1. Measure "S" dimension. Out-of-square: Outer lntake Less than 2.5 mm (0.098 Exhaust Less than 2.3 mm (0.091 lnner lntake Less than 2.3 mm (0.091 Exhaust Less than 2.1 mm (0.083 2. If it exceeds the limit, replace spring.

in) in)

in) in)

Pressure Check valve spring pressure. Pressure: N (kg, Ib) at height mm (in) Standard Outer lntake 604.1 (61.6, 135.8) at 37.6 (1.480) Exhaust 640.4 (65.3, 144.0) at 34.1 (1.343) lnner lntake 284.4 (29.0, 63.9) at 32.6 (1.283) Exhaust 328.5 (33.5, 73.9) at 29.1 (1.146) Limit Outer lntake 567.8 (57.9, 127.7) at 37.6 (1.480) Exhaust 620.8 (63.3, 139.6) at 34.1 (1.343) lnner lntake 266.8 (27.2, 60.0) at 32.6 (1.283) Exhaust 318.7 (32.5, 71.7) at 29.1 (1.146) If it exceeds the limit, replace spring.

CYLINDER HEAD Inspection (Cont'd)

ROCKER SHAFT AND ROCKER ARM

/~

~ 2 4 ~ 1

1. Check rocker shafts for scratches, seizure and wear. 2. Check outer diameter of rocker shaft. Diameter: 21.979 22.000 mm (0.8653 0.8661 in)

3. Check inner diameter of rocker arm.

Diameter: 22.012 22.029 mm (0.8666 - 0.8673 in) Rocker arm to shaft clearance: 0.012 - 0.050 mm (0.0005 0.0020 in) Keep rocker arm with hydraulic valve lifter standing to prevent air from entering hydraulic valve lifter when checking.

Assembly
1. Install valve component parts. Always use new valve oil seal. Refer to OIL SEAL REPLACEMENT. Before installing valve oil seal, install inner valve spring seat. Install outer valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side. After installing valve component parts, use plastic hammer to lightly tap valve stem tip to assure a proper fit.
Cylinder head side
SEM638B

2. Mount camshaft onto cylinder head, placing knock pin at front end to top position. Apply engine oil to camshaft when mounting onto cylinder head.

3. Install camshaft brackets. Front mark is punched on the camshaft bracket.

CYLINDER HEAD Assembly (Cont'd)

(a) (ma)

Front

?I
1

R
lb) (a) (b) (a) lb)
11 a
f

4. Install rocker shaft with rocker arms. Four types of rockers are used. ldentification and subsequent locationisdeterminedfromtheidentificationmarkasshown.

Identification mark

lntake
11 1 a
1

1 Exhaust b
C

g
(cl
(d)

(C) (d)

H
d

EB E24

Front

Intake

Exhaust
SEM579C

a Install retainer with cutout facing direction shown in figure at

left.

5. Tighten bolts as shown in figure at left.

0 @ @ 0 0 0
L0
0 0
0

010

l0 @

010

@
SEM560C

CYLINDER HEAD
Installation
1. Set No. 1 piston at T.D.C. on its compression stroke as follows: (1) Align mark on crankshaft pulley with "0" position and confirm that distributor rotor head is set as shown in figure.

(2) Confirm that knock pin on camshaft is set at the top.

2. Install cylinder head with new gasket and tighten cylinder head bolts in numerical order. Do not rotate crankshaft and camshaft separately, or valves will hit piston heads. Tightening procedure (1) Tighten all bolts to 29 N-m (3.0 kg-m, 22 R-lb). (2) Tighten all 'bolts to 78 Nom (8.0 kg-m, 58 ft-lb). (3) Loosen all bolts completely. (4) Tighten all bolts to 29 Nom (3.0 kg-m, 22 ft-lb). (5) Turn all bolts 80 to 85 degrees clockwise with an angle wrench, or if an angle wrench is not available, tighten all bolts to 74 to 83 Nam (7.5 to 8.5 kg-m, 54 to 61 ft-lb).

CYLINDER HEAD
Installation (Cont'd)

p 1

3. Set chain on camshaft sprocket by aligning each mating mark. Then install camshaft sprocket to camshaft.

4. Tighten camshaft sprocket bolt whilst holding gear with E7181A

4p *
Liquid gasket

5. lnstall rubber plugs as follows: (1) Apply liquid gasket to rubber plugs. Rubber plugs should be replaced with new ones. a Rubber plugs should be installed within 5 minutes of applying liquid gasket.

3 mm (0.12 in) diameter

(liquid gasket) s ~ M 9 3B 1

(2) Install rubber plugs, then move them with your fingers to uniformly spread the gasket on cylinder head surface.
Rubber plugs should be installed flush with the surface. Do not start the engine for 30 minutes after installing rocker cover. Wipe clean excessive liquid gasket from cylinder head top surface.

W W
N.G.
Good
SEM933B

CYLINDER HEAD
Installation (Cont'd)
6. Check hydraulic valve lifter. (1) Push hydraulic valve lifter forcefully with your finger. Be sure to check it with rocker arm in its free position. (2) If valve lifter moves more than 1 mm (0.04 in), air may be inside of it. (3) Bleed air off by running engine at 1,000 rpm under no-load for about 20 minutes (After completing installation of all parts). (4) If hydraulic valve lifters are still noisy, replace them and bleed air off again in the same manner as in step (3).

7. Install rocker cover. m When installing rocker cover, be sure to avoid interference between rocker cover and rocker arms. 8. Tighten bolts as shown below: (1) Temporarily tighten 2 bolts to 3 N-m (0.3 kg-m, 2.2 ft-lb) in order as shown in figure.
0

0
(2) Tighten all bolts to 7 to 10 Nom (0.7 to 1.0 kg-m, 5.1 to 7.2 ft-lb) as shown in figure.

@l0

6
SEM591 C

(3) Retighten 4 bolts to 7 to 10 Nom (0.7 to 1.0 kg-m, 5.1 to 7.2 ft-lb) as shown in figure.

SEM592C

9. Install any parts removed.

ENGINE REMOVAL

1KA24E/

: N.m (kg-m, ft-lb)

ENGINE REMOVAL
WARNING: a. Situate vehicle on a flat and solid surface. b. Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself and/or fire may break out in fuel line. c. For safety during subsequent steps, the tension of wires should be slackened against the engine. d. Where possible, remove w i r i n g sub-harnesses with engine. Refer t o "Releasing Fuel Pressure" i n section ES. e. Before removing front axle from transaxle, place safety stands under designated front supporting points. Refer to G I section for lifting points and towing. 1. Be sure to hoist engine and transaxle in a safe manner. g. For engines not equipped w i t h engine slingers, attach suitable slingers and bolts. CAUTION: When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake lines, and brake master cylinder. In hoisting the engine, always use engine slingers in a safe manner. In removing drive shaft, be ctlretul not to damage grease seal of transaxle.

Removal
1. Drain coolant. 2. Disconnect adjacent wires, harness, pipes and hoses. 3. Remove the follwing parts: Drive belts Power steering pump e A/C compressor Alternator and adjusting bar Drive shafts Front exhaust tube 4. Lift up engine slightly with engine slingers and disconnect or remove all engine mountings. 5. Support engine and transaxle assembly by placing suitable jacks under oil pan and transaxle. 6. Lower engine and transaxle assembly. 7. Remove engine from transaxle.

Installation
Use reverse order t o removal.

CYLINDER BLOCK

/KA24EI

,-Cylinder

block Rear oil seal retainer TRear oil seal

Oil seal

Drive plate reinforcement

Piston rings

Snap

(01 Tighten in t w o stager:

1st

l4 - 16 (1.4- 1 6 10 - 12) .,
Main bearing

2nd 60 - 65 deg.

Drain plug

(0129 - 39 (3.0- 4.0.22

(01 :

N . m (kg-m, ft-lb)

: Apply liquid gasket.

CYLINDER BLOCK
Disassembly
PISTON AND CRANKSHAFT
1. 2. 3. 4. 5. 6. Place engine on a work stand. Drain oil. Remove oil pan. Remove water pump. Remove cylinder head. Remove timing chain.

Piston heater

7. Remove pistons. When disassembling piston and connecting rod, remove snap rings, then heat piston to 60 to 70C (140 to 158OF) or use piston pin press stand at room temperature.

EM156

8. Remove main bearing beam and crankshaft. Before removing main bearing beam, measure crankshaft end play. Bolts should be loosened in two or three steps.

Inspection
PISTON AND PISTON PIN CLEARANCE
1 Measure Inner d~ameterof plston pin hole "dp" Standard diameter "dp": 20.987 - 20.999 mm (0.8263 - 0.8267 in)

SEMl49B

CYLINDER BLOCK
Inspection (Cont'd)

F/ E
-

2. Measure outer diameter of piston pin "Dp". Standard diameter "Dp": 20.989 21.001 mm (0.8263 0.8268 in) 3. Calculate interference fit of piston pin to piston. dp Dp = 0 0.004 mm (0 0.0002 in) If it exceeds the above value, replace piston assembly with pin.

PISTON RING SIDE CLEARANCE

Side clearance: Top ring 0.04 0.08 mm (0.0016 0.0031 in) 2nd ring 0.03 0.07 mm (0.0012 0.0028 in) Max. limit of side clearance: 0.1 mm (0.004 in) If out of specification, replace piston andlor piston ring assembly.

PISTON RING END GAP

End gap: Top ring 0.28 0.43 mm (0.0110 0.0169 in) 2nd ring 0.45 0.60 mm (0.0177 0.0236 in) (For rings punched with R or T.) 0.55 - 0.70 mm (0.0217 0.0276 in) (For rings punched with N.) Oil ring 0.20 0.60 mm (0.0079 - 0.0236 in) Max. limit of ring gap: 0.5 mm (0.020 in) If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, rebore cylinder and use oversized piston and piston rings. Refer to S.D.S.

CONNECTING ROD BEND AND TORSION

Bend : Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length If it exceeds the limit, replace connecting rod assembly.

CYLINDER BLOCK
Inspection (Cont'd)
CYLINDER BLOCK DISTORTION AND WEAR 1. Clean upper face of cylinder block and measure the distortion.

Limit: 0.10 mm (0.0039 in)

2. If out of specification, resurface it. The resurfacing limit is determined by cylinder head resurfacing in engine. Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing is "B" The maximum limit is as follows: B = 0.2 mm (0.008 in) A Nominal cylinder block height from crankshaft center: 246.95 247.05 mm (9.7224 9.7264 in) 3. If necessary, replace cylinder block.

Less than 0.10 mm (0.0039 in)

PISTON-TO-BORE CLEARANCE 1. Using a bore gauge, measure cylinder bore for wear,
out-of-round and taper.

Unit: mm (in)

Standard inner diameter: 89.000 89.030 mm (3.5039 Wear limit: 0.2 mm (0.008 in) Out-of-round (X-Y) limit: 0.015 mm (0.0006 in) Taper (A-B) limit: 0.015 mm (0.0006 in)

- 3.5051 in)

If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. 2. Check for scratches and seizure. If seizure is found, hone it.

iston grade number

If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block upper surface.

Front

SEM257C

CYLINDER BLOCK Inspection (Cont'd)

3. Measure piston skirt diameter. Piston diameter "A" :

1 ~ ~ 2 4 ~ 1

Refer to S.D.S. Measuring point "a" (Distance from the top): Approximately 52 mm (2.05 in) 4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance "B": 0.020 - 0.040 mm (0.0008 0.0016 in)

5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to S.D.S. 6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A". Rebored size calculation: D = A + B - C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps, and tighten to the specified torque to prevent distortion of cylinder bores in final assembly. 8. Cut cylinder bores. When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. 10. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or cracks. 2. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X-Y): Main journal Less than 0.01 mm (0.0004 in) Crank pin Less than 0.005 mm (0.0002 in) Taper (A-B): Main journal Less than 0.01 mm (0.0004 in) Crank pin Less than 0.005 mm (0.0002 in)

Taper : A - B
Out-of-round : X

-Y
SEM316A

3. Measure crankshaft runout. Runout (Total indicator reading): Less than 0.10 mm (0.0039 in)

CYLINDER BLOCK
Inspection (Cont'd)
BEARING CLEARANCE
Method A (Using bore gauge and micrometer) Main bearing 1. Set main bearings in their proper positions on cylinder block and main bearing cap.

SEM448C

2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. Refer to "Assembly". 3. Measure inner diameter "A" of each main bearing.

4. Measure outer diameter "Dm" of each crankshaft main journal. 5. Calculate main bearing clearance. Main bearing clearance = A - Dm

Standard: 0.020 - 0.047 mm (0.0008 0.0019 in) Limit: 0.1 mm (0.004 in) 6. If it exceeds the limit, replace bearing. 7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing.

a. When grinding crankshaft journal, confirm that "L" dimension in fillet roll is more than the specified limit. "L": 0.1 mm (0.004 in) b. Refer to S.D.S. for grinding crankshaft and available service parts.

8. If crankshaft, is reused, measure main bearing clearance and thickness of main bearing. If crankshaft is replaced with a new one, it is necessary to select thickness of main bearings as follows: a. Grade number of each cylinder block main journal is punched on the respective cylinder block.
Front

SEM266C

Journal grade number

CYLINDER BLOCK
Inspection (Cont'd)
b. Grade number of each crankshaft main journal is punched on crankshaft.

c. Select main bearing with suitable thickness according to the following table.

Main bearing grade number:

Main journal Crankshaft journal grade number

0
1

0
1

2
3
4

2
3

For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 2

= 3

Inside micrometer

Connecting rod bearing (Big end) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Measure inner diameter "C" of each bearing.

4. Measure outer diameter "Dp" of each crankshaft pin journal. 5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C - Dp

Standard: 0.010 0.035 mm (0.0004 0.0014 in) Limit: 0.09 mm (0.0035 in) 6. If it exceeds the limit, replace bearing. 7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to step 7 of "BEARING CLEARANCE - Main bearing"

CYLINDER BLOCK
Inspection (Cont'd)
Crank pin

8. If crankshaft is replaced with a new one, select connecting rod bearing according to the following table.

Connecting rod bearing grade number:

Crank pin grade number Connecting rod bearing grade number 0
1

0
1
SEM567B

Method B (Using plastigauge) CAUTION: Do not turn crankshaft or connecting rod while plastigage is being inserted. When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then if excessive bearing clearance exists, use a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained.

CONNECTING ROD BUSHING CLEARANCE (Small end)

1. Measure inner diameter "C" of bushing.

2. Measure outer diameter "Dp" of piston pin. 3. Calculate connecting rod bearing clearance. C-Dp= 0.005 - 0.017 mm (0.0002 0.0007 in) (Standard) 0.023 mm (0.0009 in) (Limit) If it exceeds the limit, replace connecting rod assembly andlor piston set with pin.

CYLINDER BLOCK

1 ~ ~ 2 4 ~ 1

Inspection (Cont'd)
REPLACEMENT OF CONNECTING ROD BUSHING (Small end)
1. Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes. 2. After driving in small end bushing, ream the bushing so that clearance between small end bushing and piston pin is specified valve. Clearance between small end bushing and piston pin: 0.005 0.017 mm (0.0002 0.0007 in)

SEM062A

FLYWHEELIDRIVE PLATE RUNOUT

Runout (Total indicator reading): Flywheel (MIT model) Less than 0.1 mm (0.004 in) Drive plate (AIT model) Less than 0.1 mm (0.004 in)

Assembly PISTON
1. Install new snap ring on one side of piston pin hole.

ber

2. Heat piston to 60 to 70C (140 to 158OF) and assemble piston, piston pin, connecting rod and new snap ring. Align the direction of piston and connecting rod. Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly.

SEM262C

EM156
3

CYLINDER BLOCK
Assembly (Cont'd)

3. Set piston rings as shown.

Punchmark side

Oil ring expander

Top ring upper rail

2nd rlng

lower rail

8.
:0'

9%

CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block and ,main bearing beam. Confirm that correct main bearings are used. Refer to "Inspection" of this section.

No. 2

2. Install crankshaft and main bearing beam and tighten bolts to the specified torque. Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction. Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.

3. Measure crankshaft end play. Crankshaft end play: Standard 0.05 0.18 mm (0.0020 0.0071 in) Limit 0.3 mm (0.012 in) If beyond the limit, replace bearing with a new one.

CYLINDER BLOCK
Assembly (Cont'd)
-Align
oil hole.

4. lnstall connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used. Refer to "lnspection". e lnstall bearings so that oil hole in connecting rod aligns with oil hole of bearing.

5. lnstall pistons with connecting rods. a. lnstall them into corresponding cylinders with Tool. Be careful not to scratch cylinder wall by connecting rod. Arrange so that front mark on piston head faces toward front of engine.

lnstall connecting rod bearing caps. Tighten connecting rod bearing cap nuts to the specified torque. Connecting rod bearing nut: (1) Tighten to 14 to 16 N-m (1.4 to 1.6 kg-m, 10 to 12 ft-lb). (2) Tighten bolts 60 to 65 degrees clockwise with an angle wrench, or if an angle wrench is not available, tighten them to 38 to 44 Nom (3.9 to 4.5 kg-m, 28 to 33 ft-lb). Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.2 0.4 mm (0.008 0.016 in) Limit 0.6 mm (0.024 in) beyond the limit, replace connecting rod andlor crankshaft.

REPLACING PILOT BUSHING

1. Remove pilot bushing (MIT) or pilot convertor (AIT).

CYLINDER BLOCK
Assembly (Cont'd)
2. Install pilot bushing (MIT) or pilot convertor (AIT).

1 ~ ~ 2 4 ~ 1

Crankshaft side

AIT
SEMI636

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
Engine model Cylinder arrangement Displacement Bore X stroke Valve arrangement Firing order Number of piston rings Compression Oil Number of main bearing Compression ratio cm3 (cu in) mm (in) KA24E 4, in-line 2,389 (145.78)

pizl

89 X 96 (3.50 X 3.78)
O.H.C. 1-3-4-2

2 1

5
8.6

Unit: kPa (kglcma,psi)/rpm Compression pressure Standard Minimum Differential limit between cylinders

1,206 (12.3, 175)/250

1,010 (10.3, 146)/250

98 (1.0,14)/250

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment
CYLINDER BLOCK

Standard Distortion Grade Inner diameter Cylinder bore Out-of-round (X-Y) Taper (A-B) Difference i n inner diameter between cylinders Piston-to-cy linder clearance Cylinder b l o c k height ( F r o m crankshaft center) Wear l i m i t

Unit: m m (in) Limit

0.1 (0.004)

89.000 - 89.010(3.5039- 3.5043)

Grade 2 Grade 3

89.010- 89.020 (3.5043 3.5047)

89.020- 89.030(3.5047- 3.5051 )
Less than 0 0 5 (0.0006) .1 Less than 0.010(0.0004) Less than 0.05 (0.0020)

0.2 (0.008)'

0 2 (0.008) .

0.020- 0.040(0.0008 0.0016) -

0.2 (0.008)"

246.95 - 247.05 (9.7224 9.7264)

* * Total amount o f cylinder head resurfacing and cylinder b l o c k resurfacing

CYLINDER HEAD
Unit: m m (in) Standard
I

Limit
1

Height (HI Surface distortion

0.03 (0.0012)

0.1 (0.004)

T o t a l amount o f cylinder head resurfacing and cylinder b l o c k resurfacing

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment (Cont'd)
VALVE GUIDE

SEM225C

Unit: mm (in) Standard Intake Length (L) Outer diameter (D) Inner diameter (d) (Finished size) Cylinder head hole diameter Interference f i t Stem to guide clearance Tapping length (Q) 0.020 - 0.053 (o.ooo8 - 0.0021 1 52.6 (2.071) 11.023 - 11.034 (0.4340 - 0.4344) 7.000 - 7.018 (0.2756 - 0.2763) 10.975-10.996 (0.4321 - 0.4329) Exhaust 56.0 (2.205) 12.023 - 12.034 (0.4733 - 0.4738) 8.000 - 8.01 8 (0.3150 - 0.3157) 11.975-11.996 (0.471 5 - 0.4723) Intake 52.6 (2.071 ) 11.223 - 11.234 (0.4418 - 0.4423) 7.000 - 7.018 (0.2756 - 0.2763) 11.175-11.196 (0.4400 - 0.4408) Service Exhaust 56.0 (2.205) 12.223 - 12.234 (0.4812 - 0.4817) 8.000 - 8.018 (0.3150 - 0.3157) 12.175-12.196 (0.4793 - 0.4802) Limit

0.027 - 0.059 (0.001 1 - 0.0023) 0.040 - 0.070 (0.0016 - 0.0028) 0.020 - 0.053 (o.ooo8 - 0.0209) 0.040 - 0.070 (0.0016 - 0.0028)

0.1 (0.004)

14.9 - 15.1 (0.587 - 0.594)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment (Cont'd)

I~

~ 2 4 ~ 1

Standard

Service

SEMI78
Unit: mm (in) Standard Intake Cylinder head seat recess diameter Valve seat outer diameter (D, ) Exhaust Intake Service Exhaust

36.000 - 36.016 (1.4173 - 1.4179) 36.080 - 36.096 (1.4205- 1.4211) 4O 5 1.6 - 1.7 (0.063 0.067)

42.000 - 42.016 (1.6535 - 1.6542) 42.080 - 42.096 (1.6567 - 1.6573) 45" 1.7 - 2.1 (0.067 - 0.083)

36.500 - 36.516 (1.4370 - 1.4376) 36.580 - 36.596 (1.4402 - 1.4408) 45"

l.6 - 1.7 (0.063 - 0.067)

42.500 - 42.516 (1.6732 - 1.6739) 42.580 42.596 (1.6764 - 1.6770) 45" 1.7 - 2 . 1 (0.067 0.083)

Face angle (a)

Contacting width (W)

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd)

VALVE

T (Margin thickness)

SEM188A

Unit: mm (in) Standard In. Valve heed diameter (D) Ex. 34.0 - 34.2 (1.339 - 1.346) 40.0 - 40.2 11.575 - 1.583) 119.9 - 120.2 (4.720 - 4.732) 120.67 (4.7508 Limit

In. Valve length (L) Ex.

- 120.97 - 4.7626)

In. Valve stem diameter (d) Ex. In. Valve face angle (U) Ex. In. Valve head margin (T) Ex.

6.965 - 6.980 (0.2742 - 0.2748) 7.948 - 7.960 (0.3129 - 0.3134) 45O30' 45" 30' 1.15- 1.45 10.0453 - 0.057 1 1.35 - 1.65 (0.0531 - 0.0650)

0.5 (0.020)

VALVE SPRING
Unit: mm (in) Standard Intake Outer Free height (H) Inner Outer 53.34 (2.1000) 604.1 (61.6, 135.8) at 37.6 (1.480) 284.4 (29.0.63.91 at 32.6 (1.283) 47.95 (1.8878) 640.4 (65.3, 144.0) at 34.1 (1.343) 328.5 (33.5.73.9) at 29.1 (1.146) 57.44 (2.2614) Exhaust 53.21 (2.0949) Intake Limit Exhaust

620.8 (63.3, 139.6) at 34.1 (1.343) 318.7 (32.5, 71.7) at 29.1 (1.146) 2.3 (0.091) 2.1 (0.083)

567.8 (57.9, 127.7) at 37.6 (1.480) 266.8 (27.2.60.0) at 32.6 (1.283) 2.5 (0.098) 2.3 (0.091 )

Pressure N (kg, Ib) at height

lnner Outer

Out-of-square
Inner

SERVICE DATA AND SPECIFICATIONS (S.D.S.1

Inspection and Adjustment (Cont'd)
CAMSHAFT AND CAMSHAFT BEARING

EM120

U n i t : mm ( i n ) Standard Cam helght ( A ) Valve l i f t ( h ) Wear l i m i t o f cam height Camshaft journal t o bearing clearance Inner diameter o f camshaft bearing Outer diameter o f camshaft journal (D) Camshaft runout Camshaft end play a b
C

Limit

44.839- 45.029(1.7653 1.7728) 10.4(0.409)

0.2 (0.008) 0.12(0.0047)

0.045- 0.090(0.0018 0.0035) 33.000- 33.025(1.2992- 1.3002) 32.935- 32.955 ( 1.2967 - 1.2974) 0 - 0.02 (0- 0.0008)

0.2 (0.008)

0.07 - 0.15(0.0028 0.0059)

248 240 3 57 12 56

Valve t i m i n g (Degree o n crankshaft) d

e

ROCKER A R M AND ROCKER SHAFT

Unit: m m ( ~ n ) Rocker arm t o shaft clearance

0.012 - 0.050 (0.00050.0020) 21.979- 22.000 (0.8653 0.8661) 22.012 - 22.029 (0.8666 0.8673)

Rocker shaft diameter Rocker arm rocker shaft hole diameter

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment (Cont'd)
PISTON, PISTON RING AND PISTON PIN Piston
Standard TOP Side clearance 2nd 0.040 - 0.080 (0.0016 - 0.0031 1 0'030 - 0'070 (0.0012 - 0.0028) 0.28 - 0.43 (0.0110 - 0.01 69) 0.45 - 0.60 (0.0177 - 0.0236)*1 0.55 - 0.70 (0.0217 - 0.0276IX2 0.20 - 0.60 (0.0079 - 0.0236)

p G q
Unit: mm (in) Limit 0.1 (0.004)

Piston ring

0.1 (0.004)

TOP

0.5 (0.020)

Ring gap

2nd

o.5 (o.020)

SEM444C

Unit: mm (in) Grade NO.1 Standard Piston skirt diameter (A) Grade NO.2 Grade No. 3 0.5 (0.020) ,0 (0.039) 88.970 - 88.980 (3.5027 - 3.5031 88.980 - 88.990 (3.5031 - 3.5035) 88.990 - 89.000 (3.5035 - 3.5039) 89.470 - 89.500 (3.5224 - 3.5236) 89.970 - 90.000 (3.5421 - 3.5433)

Oil (rail ring)

0.5 (0.020)

* l : For rings punched with R or T. *2: For rings punched with N.

CONNECTING ROD

Service (Oversize)

Dimension (a) Piston pin hole diameter (d) Piston-to-cylinderbore clearance

Approx~mately (2.05) 52 20.987 - 20.999 (0.8263 - 0.8267)

0.020 - 0.040 (0.0008 - 0.0016)

SEM570A

Unit: mm (in) Standard Limit

Piston pin
Unit: mm (in) Standard Piston pin outer diameter Interference fit of piston pin to piston pin hole 20.989 - 2 1.001 (0.8263 - 0.8268) 0 - 0.004 (0 - 0.0002) 0.005 - 0.017 (0.0002 - 0.0007) Limit

Center distance (S) Bend [per 100 mm (3.94 in)] Torsion [per 100 mm (3.94 in)]

164.95 - 165.05 (6.4941 - 6.4980)

21.000 - 21.012 (0.8268 - 0.8272) 53.000 - 53.013 (2.0866 - 2.0871 ) 0.2 - 0.4 (0.008 - 0.016)

0.15 10.0059)
--

0.3 (0.012)

Piston pin bushing inner diameter (d) Connecting rod big end inner diameter (D)* Side clearance Without bearing

Piston pin to connecting rod bearing clearance

0.023 (0.0009)

0.6 (0.024)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment (Cont'd)
CRANKSHAFT

SEM394

Unit: mm (in) NO.0 Main journal diameter (Dm) Grade No. 1 NO.2 NO.0 Pin journal diameter (Dp) Grade No.1 NO.2 Center distance (r) Standard

59.967 - 59.975 (2.3609 2.3612)

59.959 - 59.967 (2.3606 - 2.3609)

- 49.974

59.951 - 59.959 (2.3603 - 2.3606) 49.968 (1 9672 - 1.9675)

49.962 - 49.968 (19670 - 1.g6721 49.956 49.962 (1 .g668 - 1.g6701 47.97 - 48.03 (1.8886 - 1.8909)
Limit

Taper of journal and pin

[@ - @ l

Journal Pin

0.01 (0.0004) 0.005 (0.0002) 0.01 (0.0004) 0.005 (0.0002) 0.10 (0.0039) 0.3 (0.012)

Out-of-round of journal and pin

Journal Pin

[@-@I
Runwt [T.I.R.] Free end play Fillet roil Total indicator reading

0.05 - 0.18 (0.0020 - 0.0071)

More than 0.1 (0.004)

BEARING CLEARANCE
Unit: mm (in) Standard Main bearing clearance Connecting rod bearing clearance Limit

0.020 - 0.047 (0.0008 - 0.0019) 0.010 - 0.035 (0.0004 - 0.0014)

0.1 (0.004) 0.09 (0.0035)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment (Cont'd)
AVAILABLE M A I N BEARING Standard
Grade number Thickness mm (in) Identification color Black Brown Green Yellow Blue

AVAILABLE CONNECTING ROD BEARING Standard

Grade number 0 1 2 Thickness mm (in) 1.505 - 1.508 (0.0593 - 0.0594) 1.508 - 1.51 1 (0.0594 - 0.0595) 1.511 - 1.514 (0.0595 - 0.0596) ldentif ication color

Brown Green

Undersize (service)
Unit: mm (in) Thickness Crank pin journal diameter "Dp"

Undersize (service)
Unit: mm (in) Thickness 1.952 - 1.g60 (0.0098) Main journal diameter "Dm" Grind so that bearing specified value. 0.08 (0.0031 0.12 (0.0047) 0.25 (0.0098) 1.540 - 1.548 (0.0606 - 0.0609) (0.0614 - 0.0617) 1.625 - 1.633 (0.0640 - 0.0643)

'560 - '568

Grind so that bearing clearance is the specified value.

MISCELLANEOUS COMPONENTS
Unit: mm (in) Camshaft sprocket runout LT.I.R.1 Flywheel runout Drive plate runout 1T.I.R.J [T.I.R.] Less than 0.1 2 (0.0047) Less than 0. l (0.004) Less than 0.1 (0.004)

Total indicator reading

NOTES:

ENGINE COMPONENTS -Outer

Parts-

1 c A ~ O EI

Collector 18-22 (1.8 2.2, 13 - 16)

Manifold stay

A\\

LL

La,

Oil filter 7

Water pump pulley

16 2 0 (1.6 2.0, 12 14)' Water pump Oil level gaugeJ Idle pulley (With air conditioner)

L ~ a t e pump belt r

"h

' .\
L

(CI1

44 5 4 Air conditioner compressor

[4) : N.m (kg-m, ft-lb)

CHECKING COMPRESSION PRESSURE

Wrench w ~ t h magnet a to hold spark plug

1. Warm up engine. 2. Remove one bank of spark plugs. (either intake or exhaust). Use a suitable plug wrench.

10.63 i n )

SEM294A

3. Disconnect distributor harness connector

11

4. Attach a suitable compression tester. 5. Depress accelerator pedal td fully open throttle. 6. Crank engine and read gauge indication of each cylinder. Compression pressure: kPa (bar, kg/cm2, psi) a t 350 rpm Standard 1,196 (11.96, 12.2, 173) Minimum 902 (9.02, 9.2, 131) Differential limit between cylinders: kPa (bar, kg/cm2, psi) at 350 rpm 98 (0.98, 1.O, 14) 7. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through the spark plug holes and retest compression. If adding oil helps the compression pressure, chances are that piston rings are worn or damaged. If pressure stays low, valve may be sticking or seating improper1y. If cylinder compression in any two adjacent cylinders is low, and if adding oil does not help the compression, there is leakage past the gasket surface.

TIMING BELT
CAUTION:

ICA20E I

a. Do not bend or twist timing belt too tightly. b. After removing timing belt, do not rotate crankshaft and camshaft separately because valves will hit
piston head. c. Ensure timing belt, timing belt camshaft pulley, crankshaft timing pulley and belt tensioner are clean and free from oil or water. d. Before installing timing belt, confirm that No. 1 cylinder is set a t T.D.C. on compression stroke. e. Align arrow on timing belt forward. f. Align white lines on timing belt with punch mark on camshaft pulley and crankshaft pulley. g. Adjust belt tension with all spark plugs removed.
Timina belt,

1 - 141

sprocket

123 132 (12.5- 13.5, 90 - 98)

L Crankshaft pulley

: N.m (kg-m, ft-lb)

r ~lighing mark

TIMING BELT -Removal1 . Remove radiator shroud, fan and pulleys.

~~I

2. Remove all spark plugs.

I
Power steering oil pump

3. Remove the following belts.

Power steering oil pump drive belt Compressor drive belt Alternator drive belt.

Adjust

: Checking point

Set No. 1 cylinder a t T.D.C. on i t s compression stroke.

Set at T . D . C . . (Black paint mark)

SEM837A

5. Remove front upper and lower belt covers. 6. Loosen timing belt tensioner bolts and remove return spring, then remove timing belt. After removing timing belt, do not rotate crankshaft and camshaft separately because valves will hit piston head.

TIMING BELT -InspectionVisually check the condition of the timing belt. Replace if any abnormality is found.
Item to check Belt is broken. Problem Cause Improper handling Poor belt cover sealing Coolant leakage at water pump

IcA2oEI

SEM393A

Tooth is broken1 tooth root is cracked.

Camshaft jamming Distributor jamming Oil leakage at camshaftlcrankshaft oil seal

SEM394A

Back surface is crackedlworn.

Tensioner jamming Overheated engine Interference with belt cover

SEM395A

TIMING BELT -InspectionItem to check Side surface is worn. Problem Cause Improper installation of belt Malfunctioning crank pulley plateltiming belt plate

Side surface of belt is worn to such an extent that there is no trace of cutoff performed during manufacturing process. Belt corners are worn and round. Wicks are frayed and coming out. Teeth are worn.
SEM396A

Poor belt cover sealing Coolant leakage at water pump Camshaft not functioning properly Distributor not functioning properly Excessive belt tension
C -

Canvas on tooth face is worn down. Canvas on tooth is fluffy, rubber layer is worn down and faded white, or canvas texture is unclear. SEM397A

OilICoolant or water is stuck to belt.

Poor oil sealing of each oil seal Coolant leakage at water pump Poor belt cover sealing

T l MlNG BELT -Installation-

-1

1. Confirm that No. 1 cylinder is set at T.D.C. on i t s compression stroke.

2. Install tensioner and return spring. Temporarily tighten bolts so that tensioner can swing smoothly.

3. Set timing belt. a. Ensure that timing belt and 'pulleys are clean and free of oil or water. Do not bend timing belt. b. Align white lines on timing belt with punch mark on camshaft pulleys and crankshaft pulley. c. Have arrow on timing belt pointing toward front belt covers. 4. Tighten belt tensioner and assemble spring. To set spring, first hook one end on bolt (B) side, then hook the other end on tensioner bracket pawl. After rotating crankshaft two turns clockwise, tighten bolt (B) and then bolt (A), and belt tension will automatically be the specified value. : 15-20N-m(1.5-2.0kg-m,11-14ft-lb) 5. Install timing belt covers.

CYLINDER HEAD

ICA20E I

Valve rocker cover

Rocker cover gasket

Valve and sprlng Intake

&

: N.m (kg-m, ft-lb)

F r o n t 011seal

When installing sliding parts such as rocker arms and camshaft, be sure to apply engine oil on the sliding surfaces. Use new gaskets and oil seals. When installing welch plug, apply sealant.

CYLINDER HEAD -Removal1. Remove timing belt. Set No. 1 cylinder a t T.D.C. on its compression stroke. After removing timing belt, do not rotate crankshaft and camshaft separately, because valves will hit piston heads.

2. Remove rocker shafts with rocker arms and securing bolts. Before removal, fully loosen valve clearance adjusting screws. The bolts should be loosened in two or three stages.

3. Loosen camshaft bolt whilst holding sprocket with E7 18 1A Remove bolt and camshaft sprocket.

4. Remove cylinder head with manifolds. Bolts should be loosened in two or three stages. Head warpage or cracking could result from removing in incorrect order.

5. Remove manifolds from cylinder head.

CYLINDER HEAD -Disassembly1. Remove camshaft locate plate. 2. Remove camshaft and camshaft oil seal.

3. Remove valve component parts using E7007 tool.

4. Remove valve oil seals.

CYLINDER HEAD --InspectionCYLINDER HEAD DISTORTION Cylinder head distortion: Less than 0.1 mm (0.004 in) If beyond the specified limit, resurface it. Nominal cylinder head height: 116.6 - 117.0 mm (4.591 - 4.606 in) Resurfacing limit: The resurfacing limit of cylinder head is determined by the cylinder block resurfacing in an engine. Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing i s "B" The maximum limit i s as follows: A + B = 0.2 mm (0.008 in) After resurfacing the cylinder head, check that.camshaft rotates freely by hand. If resistance is felt, the cylinder head must be replaced.

Measuring points

Warpage of surface: L- than 0.1 mm (0.004 in)

SEM595A

VALVE GUIDE CLEARANCE Valve guide clearance should be measured parallel with rocker arm. (Generally, a large amount of wear occurs in this direction.) Stem to guide clearance: Maximum limit 0.10 mm (0.0039 in) Maximum allowable deflection (Dial indicator reading) 0.2 mm (0.008 in) To determine the correct replacement part, measure valve stem diameter and valve guide bore. For dimensions, refer to S.D.S.

CYLINDER HEAD --Inspection-

ICA20E I

VALVE GUIDE REPLACEMENT 1. To remove valve guide heat cylinder head to 150 to 160C (302 to 320" F 1.

2. Drive out valve guide with a press [under a 20 kN (2t, 2.2 US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.

3. Ream cylinder head valve guide hole. Cylinder head valve guide hole diameter "a" (For service parts): mm (in) 11.l - 11.l96 (0.4404 - 0.4408) 85

4. Heat cylinder head to 150 to 160C (302 to 320F) and press servide valve guide into cylinder head.

5. Ream valve guide. Finished size: mm (in) 7.000 - 7.018 (0.2756 - 0.2763)

CYLINDER HEAD -Inspection-

1 ' 1

VALVE SEATS Check valve seats for any evidence of pitting a t valve contact surface, and reseat or replace if excessively worn. When repairing valve seats, check valve and valve guide for wear beforehand. If worn, replace them. Then correct valve seat. The cutting should be done with both hands for uniform cutting.

SEM795A

REPLACING VALVE SEAT FOR SERVICE PARTS 1. Bore out old seat until it collapses. The machine depth stop should be set so that boring cannot continue beyond the bottom face of the seat recess in cylinder head. 2. Ream the cylinder head recess. Reaming bore for service valve seat (Oversize [0.5 mm (0.020 in)] ): Intake: 43.500 - 43.516 mm (1.7126 - 1.7132 in) dia. Exhaust: 37.500 - 37.516. mm (1.4764 - 1.4770 in) dia. 3. Heat cylinder head to a temperature of 150 t o 160C (302 to 320" F ) .
4. Press fit seal until it seats on the bottom, and peen more than 4 points.

SEM788A

5. Cut or grind valve seat using suitable tool a t the specified dimensions as shown in S.D.S. 6. After cutting, lap valve seat with a lapping compound. 7. Check contact condition of valve seat.

W: Refer to S.D.S.

SEM635A

CAMSHAFT VISUAL CHECK Check camshaft for Scratches, seizure and wear. CAMSHAFT END PLAY 1. Install camshaft and locate plate in cylinder head. 2. Measure camshaft end play. Camshaft end play: Standard 0.07 - 0.14 mm (0.0028 - 0.0055 in) Limit 0.2 mm (0.008 in)

CYLINDER HEAD --Inspection-

ICA20E)

CAMSHAFT JOURNAL CLEARANCE 1. Measure the inner diameter of camshaft bearing. Standard inner diameter: 46.000 - 46.016mm (1.81 - 1 8 16 in) 10 . 1

2. Measure the outer diameter of camshaft journal. Standard outer d iameter #l - #4 journal: 45.935- 45.955mm (1.8085 1.8092in) #5 journal: 45.915- 45.935mm (1.8077 1.8085in) If the clearance is greater than the maximum, replace camshaft andlor cylinder head. Maximum clearance: 0.10mm (0.0039in) CAMSHAFT RUNOUT Camshaft Runout [T. I.R. (Total Indicator Reading)] in) Limit 0.05mm (0.0020 If beyond the limit, replace.

CAMSHAFT CAM HEIGHT Standard cam height: 38.834 - 38.884 mm (1.5289 1.5309in) Cam wear : Limit 0 2 mm (0.008in) . If wear is beyond the limit, replace.

CAMSHAFT SPROCKET RUNOUT Install sprocket on camshaft and check for runout. If runout exceeds the specified limit, replace camshaft sprocket. Runout: (Total indicator reading) . in) Limit 0 1 mm (0.004

CYLINDER HEAD -InspectionT (Margin thickness)

Pi,
D
SEM188A

id

VALVE DIMENSIONS Check dimensions in each valve. For dimensions, refer to S.D.S. When valve head has been worn down to 0.5 mm (0.020in) in margin thickness, replace the valve. Grinding allowance for valve stem tip is 0.2 mm (0.008in) or less.

L - -

VALVE SPRING SQUARENESS Out of square: Outer in) Less than 2.2 mm (0.087 Inner in) Less than l .9mm (0.075

SEM288A

VALVE SPRING PRESSURE LOAD Refer to S.D.S.

ROCKER SHAFT AND ROCKER ARM 1. Check rocker shafts and rocker arms for scratches, seizure and wear. 2. Check outer diameter of rocker shaft. Diameter mm (in):

19.979 - 20.000 (0.7866 0.7874) -

3. Check inner diameter of rocker arm. Diameter mm (in):

20.007 - 20.028 (0.7877- 0.7885)

Rocker arm to shaft clearance:

0.007 - 0.049 (0.0003 0.0019) -

SEM762A

CYLINDER HEAD -Assemlbly-

1-

1. lnstall valve component parts. Always use new valve o i l seal. (Refer t o EM-77) Before installing valve o i l seal, install inner valve spring seat. lnstall outer valve spring (uneven pitch type) w i t h its narrow pitch side toward cylinder head side.

Install above order

SEM787A

2. lnstall camshaft. 3. Install camshaft locate plate. (n) : Locate plate b o l t 7 8 - 8 8 N.m (8.0 - 9.0 kg-m, 5 8 - 65 ft-lb) 4. Apply engine oil t o camshaft oil seal and install it i n place.
Always use new camshaft oil seal.

CYLINDER HEAD -Installation1

Head bolt

Washer

1. Install cylinder head with new gasket. Be sure to install washers between bolts and head. Do not rotate crankshaft and camshaft separately, because valves will hit piston heads.

Flat face downward. Tightening order

SEM654A

This bolt is the longest.

2. Apply oil to the thread portion and seat surface of bolts and tighten cylinder head bolts. Tightening procedure. Tighten a l l bolts to 29 N.m (3.0 kg-m, 22 ft-lb). 1st Tighten a l l bolts to 78 N-m (8.0 kg-m, 58 ft-lb). 2nd 3rd Loosen all bolts completely. Tighten a l l bolts to 29 N.m (3.0 kg-m, 22 ft-lb). 4th 5th Using an angle wrench, turn bolt @ 83 t o 88 degrees and the other bolts 75 t o 80 degrees clockwise.
SEM285B

3. Install camshaft, locating plate, rear cover and camshaft pulley (whilst holding pulley with E7 18 1A
:

Camshaft pulley: 78 - 88 N.m (8.0 - 9.0 kg-m, 58 - 65 ft-lb) Locating plate bolt: 78 - 88 N-m (8.0 - 9.0 kg-m, 58 - 65 ft-lb)

4. Confirm that No. 1 cylinder is set a t T.D.C. on i t s compression stroke as follows: (1) Check crankshaft key near to the top.

(2) Check camshaft pulley aligning mark a t the top.

SEM838A

CYLl NDER HEAD -Installation5. Install timing belt and adjust belt tension. Refer to "TIMING BELT-Installation".

Front mark is punched.

6. Install rocker shaft with rocker arms. To prevent rocker shaft springs from slipping out of rocker shafts, insert bracket bolts into shaft.

Slits

Punched mark

Intake Front Exhaust

SEM694A

7. Tighten rocker shaft bolts. Tighten bolts gradually, in two or three stages outwardly from center position. Make sure that valve clearance adjusting screws are fully loosened. Rocker shaft bolts: [q : 18 - 22 N.m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)

SEM585A

CYLINDER HEAD -Installation8. Adjust valve clearance. (1) Set No. 1 cylinder in top dead center on i t s compression 0 , and @ . @ stroke, and adjust valve clearance (2) Set No. 4 cylinder in top dead centei on i t s compression stroke, and adjust valve clearance @, @ , @ and @ .

a,

Valve clearance
Unit: m m (in)

COLD"

HOT

Intake Exhaust

0.21 (0.008) 0.23 (0.0091

0.30 (0.012) 0.30 (0.012)

*: At temperature 2 0 ' ~ (68' F )

Adjusting screw lock nuts: [a) : 18 - 22 N.m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)

9. Install intake and exhaust manifolds. (n) : lntake manifold: 20 - 25 N.m (2.0 - 2.6 kg-m, 14 - 19 ft-lb) Exhaust manifold : 20 - 29 N.m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

10. 1 nstall distributor.

a The distributor drive is keyed intothe camshaft and will only

locate in one position.

OIL PAN AND OIL PUMP Removal

1. Drain engine oil and remove oil pan. 2.' Remove timing belt.

ICA20E I

3. Remove oil pump assembly.

Inspection
Refer to LC section.

lnstallation
Always install with new oil seal. 1. Install oil pump assembly. (4) : Refer page LC-13

2. Apply sealant t o oil pan and oil pan gasket. 3. Install gasket and oil pan.
:

(CIJ :

Oil pan: 5 - 6 N.m (0.5 - 0.7 kg-m, 3.6 - 5.1 ft-lb) Drain plug: 29 -'39 N-m (3.0 - 4.0 kg-in, 22 - 29 ft-lb)

OIL SEAL REPLACEMENT

OIL SEAL INSTALLlNG DIRECTION

(CA20EI

CAMSHAFT OIL SEAL 1. Remove timing belt and camshaft sprocket. 2. Remove camshaft oil seal. Be careful not t o scratch camshaft. 3. Apply engine oil t o camshaft oil seal and install it in place.

FRONT OIL SEAL 1. Removeoil pumpassembly. . 2. Remove crankshaft oil seal. 3. Apply engine oil t o oil seal and install it in place.

REAR OIL SEAL 1. Remove flywheel and rear oil seal retainer. 2. Remove rear oil seal from the retainer. 3. Apply engine oil t o oil seal and install it in place. 4. Install rear oil seal retainer with gasket. (4) : 4 - 6 N.m (0.4 - 0.6 kg-m, 2.9 - 4.3 ft-lb)

VALVE OIL SEAL 1. Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove one spark plug. 4. Install air hose adapter into spark plug hole and apply air pressure t o hold valves in place [Apply pressure of 490 kPa (4.9 bar, 5 kg/cm2, 71 psi)]. When performing this operation piston should be set at T.D.C.
5. Remove valve spring and valve oil seal (using E7007 tool).

OIL SEAL REPLACEMENT

6. Apply engine oil to valve oil seal and install it in place using tool no. E7003.
Before installing valve oil seal, install inner valve spring seat.

Unit: mm (in)

SEM791A

ENGINE REMOVAL

1 CAPOE l

ENGINE REMOVAL

pq

WARNING: a. Situate vehicle on a flat and solid surface. b. Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself and/or fire may break out in fuel line. c. For safety during subsequent steps, the tension of wires should be slackened against the engine. d. Where possible, remove w i r i n g sub-harnesses with engine. Refer t o "Releasing Fuel Pressure" i n section ES. e. Before removing front axle from transaxle, place safety stands under designated front supporting points. Refer to GI section for lifting points and towing. f. Be sure to hoist engine and transaxle in a safe manner. g. For engines not equipped w i t h engine slingers, attach suitable slingers and bolts. CAUTION: When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake lines, and brake master cylinder. In hoisting the engine, always use engine slingers in a safe manner. In removing drive shaft, be careful not to damage grease seal of transaxle.

Removal
1. Drain coolant. 2. Disconnect adjacent wires, harness, pipes and hoses. 3. Remove the following parts: Drive belts Power steering pump A/C compressor Alternator and adjusting bar Drive shafts Front exhaust tube 4. Lift up engine slightly with engine slingers and disconnect or remove all engine mountings. 5. Support engine and transaxle assembly by placing suitable jacks under oil pan and transaxle. 6. Lower engine and transaxle assembly. 7. Remove engine from transaxle.

Installation
Use reverse order t o removal.

ENGINE OVERHAUL

Cyl~nderblock

Rear

011 seal

retainer

Rear oil seal ( ' 1

98 - 108 (10 - 11,72

and connecting rod Flywheel ( M / T )

(C1 32 - 36 (3.3 - 3.7.24 - 271

Main bearing cap

Oil pan gasket (') Front oil seal ('

[01 5 - 7 (0.5 - 0.7, 3.6 - 5.1 1

(1.0 - 1.4, 7 101

Drain Plug

R 29 - 39 (3.0 - 4.0, 22. 29)

When installing sliding parts such as bearings, be sure to apply engine oil on the sliding surfaces.
(') Always use new gaskets, oil sealsand sealing washers.

N.rn (kg-m, ft-lb)

ENGINE OVERHAUL-DisassemblyPISTON AND CRANKSHAFT 1. Place engine on suitable work stand.

( q

2. 3. 4. 5. 6.

Remove timing belt. Drain coolant and oil. Remove water pump. Remove oil pan and oil pump. Remove cylinder head. 7. Remove pistons.

8. Remove bearing cap and crankshaft. Place the bearings and caps in their proper order. Upper bearings (Cylinder block side) have oil groove.

ENGINE OVERHAUL -Inspection-

piq

PISTON AND PISTON PIN CLEARANCE Confirm piston pin is a smooth push fit by hand at room temperature. Piston pin to piston clearance: 0.008 - 0.012 mm (0.0003 - 0.0005 in) Apply engine oil to piston pin.

PISTON RING SIDE CLEARANCE Side clearance: Top ring 0.040 - 0.073 mm (0.0016 - 0.0029 in) 2nd ring 0.030 - 0.063 mm (0.0012 - 0.0025 in) Max. limit of side clearance (Top and 2nd rings): 0.1 mm (0.004 in)

PISTON RING GAP Standard ring gap mm (in): Top ring 0.25 - 0.51 (0.0098 - 0.0201) 2nd ring 0.15 - 0.31 (0.0059 - 0.0122) Oil ring (Rail ring) 0.20 - 0.76 (0.0079 - 0.0299) Max. limit of ring gap: l.0 mm (0.039 in) BEARING CLEARANCE Bearing clearance: Main bearing 0.020 - 0.047 mm (0.0008 - 0.0019 in) Limit 0.1 mm (0.004 in) Connecting rod bearing 0.010 - 0.044 mm (0.0004 - 0.0017 in) Limit 0.1 mm (0.004 in)

Method A (Using plastigage) CAUTION: Do not turn crankshaft or connecting rod while the plastigage is being inserted. When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. However, if excessive bearing clearance s t i l l exists, use thicker main bearing or undersized bearing so that the specified bearing clearance i s obtained.

ENGINE OVERHAUL -Inspection-

(C

~ O E

Method B (Using dial gauge & micrometer) MAIN BEARING 1. lnstall main bearings to cylinder block and main bearing cap. 2. Install main bearing cap to cylinder block. Tighten all bolts in correct order and in two or three stages. (0) : 44 - 54 N-m (4.5 - 5.5 kg-m, 33 - 40 ft-lb)

3. Measure inside diameter "A" of main journal.

4. Measure outside diameter "Dm" of main journal in crankshaft.

5. Calculate main bearing clearance. Main bearing clearance = A - Dm

CONNECTING ROD BEARING 1. Install connecting rod bearing to connecting rod and cap. 2. l nstall connecting rod cap to connecting rod. Apply oil to the thread portion of bolts and seating surface of nuts. : 32 - 36 N-rn (3.3 - 3.7 kg-m, 24 - 27 ft-lb)

3. Measure inside diameter "C" of bearing. 4. Measure outside diameter "Dp" of crankshaft pin journal. 5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C - Dp

ENGINE OVERHAUL --InspectionCONNECTING ROD BEND AND TORSION Bend and torsion: Limit 0.1 mm (0.004 in) per 100 mm (3.94 in) length

CRANKSHAFT 1. Check crankshaft journals for score, bias, wear or cracks.

2 Check journals with a micrometer for taper and out-of-round. . Out-of-round(X - Y 1:

Less than 0.03 mm (0.0012 in) Taper (A - B): Less than 0.03 mm (0.0012 in)

Taper: A Out-of-round: X

-B -Y
a.

Fillet roll should not be reground. L: Pin journal 2.5 mm (0.098 in) Main journal 2.0 mm (0.079 in)

b. Refer to S.D.S. for regrinding crankshaft and available service parts.

3. Check crankshaft runout. Runout [T.I.R. (Total Indicator Reading)] : Less than 0.05 mm (0.0020 in)

ENGINE OVERHAUL -Inspection-

W 1

Measur~ng po~nts

Warpage of surface: Less than 0.1 mm (0.004 in)

CYLINDER BLOCK DISTORTION AND WEAR 1. If beyond the specified limit, resurface it. Nominal cylinder block height: 223.25 - 223.35 mm (8.7894 - 8.7933 in) Resurfacing limit: The resurfacing limit of cylinder block is determined by the cylinder head resurfacing in an engine. Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing is "B" s The maximum limit is a follows: A + B = 0.2 mm (0.008 in)

SEM655A

Mov~ng bore gauge the a shown, take the s m~nimum d~ameter.

2. Using a bore gauge, measuce cylinder bore for wear, out-ofround or taper. Standard inside diameter: 84.50 - 84.55 mm (3.3268 - 3.3287 in) Refer to S.D.S. Wear limit: 0.20 mm (0.0079 in) Out-of-round(X-Y) limit: 0.02 mm (0.0008 in) Taper (A-B) limit: 0.02 mm (0.0008 in) 3. Check for scratches or seizure. If seizure is found, hone it.

xo
Un~t mm (In)
SEM792A

CYLINDER BORING When any cylinder needs boring, all other cylinders must also be bored at the same time. 1. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to S.D.S.

ENGINE OVERHAUL -Inspection-

ICA20E I

The size to which cylinders must be honed is, determined by adding piston-tocylinder clearance to the piston skirt diameter "A". Dimension "a": 45.0 mm (1.772 in) Rebored size calculation D = A + B C = A + [0.005 to 0.025 mm (0.0002 to 0.0010 in)] where, D : Honed diameter A : Skirt d,iameter as measured B : Pistotj-to-wallclearance C : Machining allowance 0.02 mm (0.0008 in)

3. Install main bearing caps in place, and tighten to the specified

torque to prevent distortion of the cylinder bores in final assembly. 4. Cut cylinder bores in the order of 2-4-1-3. a Do not cut too much out of the cylinder bore a t a time. Cut only 0.05 mm (0.0020 in) or so in diameter a t a time. 5. Hone the cylinders to the required size referring to S.D.S. 6. Measure the finished cylinder bore for out-of-round and taper. a Measurement of a just machined cylinder bore requires utmost care since it i s expanded by cutting heat.

PISTON TO CYLINDER WALL CLEARANCE Using micrometer 1. Measure piston and cylinder bore diameter. Piston diameter "A": Refer to S.D.S. Measuring point "a" (Distance from the bottom): 45.0 mm (1.772 in) 2. Check that piston clearance is within the specification. Piston clearance: 0.025 - 0.045 mm (0.0010 - 0.0018 in) Using feeler gauge Measure the extracting force by pulling feeler gauge straight upward. Feeler gauge thickness: 0.04 mm (0.0016 in) Extracting force: 2.0 - 14.7 N (0.2 - 1.5 kg, 0.4 - 3.3 Ib)

ENGINE OVERHAUL -AssemblyFLYWHEEL RUNOUT Runout (Total indicator reading): Less than 0.15 mm (0.0059 in)

I'ziq

PISTON a. Numbers stamped on the connecting rod and cap correspond to each cylinder. Care should be taken to avoid a wrong combination including bearing.

Cylinder No.
SEM590A

b. When pressing piston pin in connecting rod, apply engine oil to pin and small end of connecting rod. c. After assembling, ascertain that piston swings smoothly.

EM156

1. Install piston rings.

PI.1.d

I
CRANKSHAFT 1. Set main bearings in the proper position on cylinder block.
If either crankshaft, cylinder block or main bearing i s reused again, it i s necessary to measure main bearing clearance. Upper bearings (Cylinder block side) have oil groove.

Front

SEM617

ENGINE OVERHAUL -Assembly r

1 ~ ~ 2 0 ~

Englne front

2. Apply engine oil to main bearing surfaces on both sides of cylinder block and cap. 3. Install crankshaft and main bearing caps and tighten bolts to specified torque. (o) : Main bearing cap bolt 44 - 54 N-m (4.5 - 5.5 kg-m, 33 - 40 ft-lb) Arrange the parts so that the indicated number on bearing cap i s in a row from the front of engine. Prior to tightening bearing cap bolts, place bearing cap in proper position by shifting crankshaft in the axial direction. Tighten bearing cap bolts gradually i n t w o or three stages in the sequence shown. After s e c u r ~ n r m r ~ n g bolts, make sure that crankshaft cap turn smoothly.

SEM794A

4.

Measure crankshaft end play at center bearing. Crankshaft end play: Limit 0.30 mm (0.0118 in)

Top rlng

Set piston ring as shown.

011 rlng (Expander)

011

Second rang rtng (Lower rail)

EM725

5, Install pistons with connecting rods. (1) Install them into corresponding cylinder using Tool. Be careful not t o scratch cylinder wall with connecting rod. Apply engine oil to cylinder wall, piston and bearing. Arrange s that the front mark on piston head faces to the o front of engine.

ENGINE OVERHAUL -Assembly(2)Install connecting rod bearing caps.

[01 :
Connecting rod bearing nut 3 2 - 3 6 N-m (3.3 - 3.7 kg-m, 24 - 27 ft-lb)

6. Measure connecting rod side clearance. Connecting rod side clearance: Limit 0.30 mm (0.01 18 in)

SERVICE DATA AND SPECIFICATIONS General Specifications

Engine model Cylinder arrangement Displacement Bore X stroke Valve arrangement Firing order Number of piston rings Compression Oil Number of main bearings Compression ratio cm3 (cu in) mm (in) CA20 4, in-l~ne 1,974 (120.45) 84.5 X 88.0 (3.327 X 3.465) O.H.C. 1-34-2 Compression pressure Standard Minimum Differential limit between cylinders

(CA20E-j
Unit: kPa (bar, kg/cm2, psi)/rpm

1,196 (11.96.12.2. 17311350 902 (9.02,9.2,131)/350 98 (0.98.1 .O, 14)/350

2 1 5 8.5

Inspection and Adjustment

CYLINDER HEAD

SEM529A

Unit: mm (in)

Height (H)

*: Total amount of cylinder head resurfacing and cylinder block

resurfecing

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd)

VALVE V A L V E CLEARANCE

IEziz-1
Unit: mm (in)

* : At temperature 2 0 ' ~ (68" F)

V A L V E SPRING

i
SEM188A

Unit: mm (in) Engine model Valve head diameter ( D ) In. 40.0 - 40.2 (1.575 - 1.583) 35.0 - 35.2 (1.378 - 1.386)
-

CA20

Limit

Ex.

Valve length ( L ) In. 105.25 - 105.55 (4.1437 - 4.1555) 107.79 - 108.21 (4.2437 - 4.2602) Free height (H) Outer
-

SEM567A

Unit: mm (in)

Ex.

Valve stem diameter (d) In. 6.965 - 6.980 (0.2742 - 0.2748) 6.945 - 6.960 (0.2734 - 0.27401

t
Standard Limit

l nner Pressure height mm/N (mmlkg, inllb) Outer

Ex.

Valve face angle (a) In. 45" 15' - 45"45'

Ex.
-

Valve head margin ( T ) In. 1.l - 1.45 5 (0.0453 - 0.0571) 0.5 (0.020)
Ex.

l nner

1.35 - 1.65 (0.0531 - 0.0650)

Assembled height mm/N (mmlkg, inllb) Outer

Valve ster.1 end surface grindins limit

0.2 (0.008) lnner

Out of square (S) Outer lnner

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd)

VALVE GUIDE

p ]
Unit: mm (in) Standard

ROCKER SHAFT AND ROCKER ARM

EXHAUST

7.3- 7.5(0.287 0.295) dir.

Rocker shaft Outer diameter Rocker arm lnner diameter Clearance between rocker arm and rocker shaft
19.979 - 20.000 (0.7866 - 0.78741

INTAKE

20.007- 20.028 (0.78770.7885) 0.007- 0.049 (0.0003 0.0019) -

10.2- 10.4 (0.402 0.4091

-v
Intake

Exhaust

C
a INTAKE EXHAUST Unit: m m (in) Standard Length Service

(L)

45.0(1.772)

45.0 (1.7721

Outer diameter (D) lnner diameter (d) [Finished size] Cylinder head hole diameter (a) Interference f i t

11.023-11.034 11.223-11.234 (0.4340- 0.4344) (0.4418 0.4423) 7.000 - 7.018 (0.2756 0.2763) 10.975- 10.996 11.186- 11.196 (0.4321- 0.4329) (0.4404 0.4408) 0.027- 0.059(0.001 - 0.0023) 1
Standard In. Limit

Stem t o guide clearance Ex. Valvr deflection

0.020-0.053 (0.0008 0.0021 0'040 - 0'073 (0.0016- 0.0029)

o~l(o~OOg~ 0.1 (0.004) 0.2(0.008'

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd)

VALVE SEAT
Standard Intake Service

Exhaust

Unit: m m (in) Standard In. Cylinder head seat recess diameter (D, ) EX. In. Valve seat interference f i t EX. In. Valve seat outer diameter (D, ) EX. In. Valve seat inner diameter (D, ) EX. In. Height (H) EX. In. Face angle (8 Ex. In. Contacting width ( W ) EX. In. Face inner d~ameter(D, ) EX. Face outer diameter (D, ) In. Service*

43.000 -43.016 (1.6929 - 1.6935) 37.000 - 37.016 (1.4567 - 1.4573)

43.500 -43.516 (1.7126 - 1.7132) 37.500 - 37.516 (1.4764 - 1.4770)

0.081 - 0.1 13 (0.0032 - 0.0044) 0.064 - 0.096 (0.0025 - 0.0038) 43.097 - 43.1 13 (1.6967 - 1.69741 37.080 - 37.096 (1.4598 - 1.4605) 43.597 -43.613 (1.7164 - 1.7170) 37.580 - 37.596 (1.4795 - 1.4802)

36.85 - 37.15 (1.4508

- 1.4626)
7.0 - 7.1 (0.276 - 0.280)

752 - 1.1870) 29.85 - 30.15 (1.l 7.6 - 7.7 (0.299 - 0.303)

7.4 - 7.5 (0.291 - 0.295) 45O 45 O 1.8 - 2.1 (0.071 - 0.083) 1.4 - 1.8 (0.055 - 0.071 37.8 (1.488) 34.4 - 34.6 (1.354 - 1.3621 40.6 - 40.8 (1.598 - 1.606)
':

Valve seat surface must be corrected into specified value.

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd)

CAMSHAFT A N D CAMSHAFT BEARING
Unit: m m (in) Standard Camshaft journal t o bearing clearance Inner diameter o f camshaft bearing Max. tolerance

CYLINDER BLOCK

46.000. 46.016 (1.8110 1.81161 #l - #4 45.935 - 45.955 (1.8085 1 .E0921 #5

0.1 (0.004)

Outer diameter o f camshaft journal

45.915 - 45.935 (1.8077 1.80851

Camshaft r u n o u t [T.I.R.'] Standard Engine model

U n ~ t :m m ( i n )

CA20 223.25- 223.35 (8.7894 8.79331 -

L~mlt (*:Wear limit)

"A"

Cam height "A" Intake Exhaust Wear l i m i t o f cam height 'Total indicator reading

@
0.2 (0.0081
T.D.C.

Height (H) Surface flatness Cylinder bore Inner diameter Standard

EM671

o,2 (o,oo81.

0.03(0.00121

0.1 (0.0041

Grade N o . 1

84.50- 84.51 (3.3268 3.32721 84.51 - 84.52 (3.3272 3.3276) 84.52- 84.53 (3.3276 3.32791 84.53-84.54 (3.3279 3.3283) 84.54- 84.55 (3.3283 3.32871 -

1
o.2 (0,0081.

Grade No. 2

Grade N o . 3

Grade No. 4

Valve timing

Grade N o . 5

,
For oversize plston

0.02(0.0008)
(Standard for service)

84.52- 84.57 (3.3276 3.3295) -

Out-of-round ( X - Y )

B.D.C.
U n ~ t :degree a b
C

Less than 0.015 (0.000611 02 (00008) 0

I

Taper ( A - B ) D ~ f f e r e n c e n inner diamI eter between cylinders

Less than 0.01 (0.0004) 0.02(0.00081 Less than 0 05 (0.0020) 0 2 (0.008)

d .

240

240

12

48

14

54

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd)

PISTON, PISTON RING AND PISTON PIN Piston
Standard Engine model Side clearance To P 0.040 - 0.073 (0.0016 - 0.0029) CA20

l-GiiF)

Piston ring
Unit: mm ( ~ n )

Limit

0.1 (0.004) 2nd Ring gap To P Unit: mm (in) Engine model Piston skirt diameter ( A ) Standard Grade No. 1 Grade No. 2 Grade No. 3 Grade No. 4 Grade No. 5 Service (Oversize) 0.02 (0.001) (Standard for service) 0.5 (0.0201 1 .O (0.0391 Dimension (a1 Piston pin hole diameter Piston to cylinder bore clearance Feeler gauge extraction force with gauge thickness 0.04 mm (0.0016 in) N (kg, Ib) CA20 2nd 0.25 - 0.51 (0.0098 - 0.0201) 0.1 5 - 0.31 (0.0059 - 0.01 22) 0.20 - 0.76 (0.0079 - 0.0299)
l. (0.039) O

0.030 - 0.063 (0.0012 - 0.0025)

Oil (Rail) 84.465 - 84.475 (3.3254 - 3.3258) 84.475 - 84.485 (3.3258 - 3.32621 84.485 - 84.495 (3.3262 - 3.3266) 84.495 - 84.505 (3.3266 - 3.3270)

Piston pin
Unit: mm (in)

84.505 - 84.515 (3.3270 - 3.3274) CA20

1

Piston pin outer diameter 84.485 - 84.635 (3.3262 - 3.3281) clearance

19.995 - 20.000 (0.7872 - 0.7874)

84.965 - 85.01 5 (3.3451 - 3.3470) 85.465 - 85.51 5 (3.3648 - 3.3667) 45.0 (1.772) 20.003 - 20.012 (0.7875 - 0.7879) 0.025 - 0.045 (0.0010 - 0.0018)

(0.0001 - 0.0007) 0.01 7 - 0.038 (0.0007 - 0.001 5 )

to connecting rod

2.0 - 14.7 (0.2 - 1.5, 0.4 - 3 . 3 )

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd)

CONNECTING ROD
CRANKSHAFT

1-

Out-of-round Taper
SEM570A

X-Y A-B

Unit: mm (in) Standard L~mit Engine model CA20 149.25 149.35 (5.8760 5.8799)

Center distauce (S)

Unit: mm (in) Engine model CA20 52.951 . 52.964 (2.0847 - 2.08521 44.961 - 44.974 (1.7701 - 1.77061 ' 43.97 - 44.03 (1.7311 - 1.7335) Lim~t Taper of journal and pin (A - B ) Out-of-round of journal and pin ( X - Y) Bend Free play Runout [T.I.R.] 0.03 (0.0012)

Bend [per 100 mm (3.94 in)] Torsion [per 100 mm (3.94 in)] Piston pin bore diameter (d) Crank pin bore diameter (D) Big end play

Less than 0.05 (0.00201

0.10 (0.0039) Main journal diameter (Dm) Pin journal diameter (Dp)

Less than 0.05 (0.0020) 19.965 - 19.978 (0.7860 - 0.78651 48.000 - 48.013 (1.8898 - 1.8903) 0.2 - 0.3 (0.008 - 0.01 2)

0.10 (0.0039) Center distance ( r l

0.3 (0.012)

0.03 10.0012)

0.05 (0.0020)

0.3 (0.012) 0.05 (0.0020)

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd)

BEARING Bearing clearance
Standard Matn bear~ng clearance Connecting rod bear~ng clearance L~mit

0'020 - 0'047 (0.0008 - 0.0019) 0.010 - 0.044 (0.0004 - 0.001 71

0.1 (0.004)

0.1 (0.004)

Main bearing undersize

U n i t : m m (in) Crankshaft journal diameter Standard

52.951 - 52.964 (2.0847 - 2.0852) 52.701 - 52.714 (2.0748 - 2.0754) 52.451 - 52.464 12.0650 - 2.0655)

0.25 (0.0098)
Undersize

0.50 10.0197)
Undersize

connect;ng rod bearing undersize

I

Unit: m m (in) Crankshaft pin diameter Engine model Standard

CA20 44.961 - 44.974 (1.7701 - 1.77061 44.881 - 44.894 (1.7670 - 1.7675)

0.08 (0.0031)
Undersize

0.12 10.00471
Undersize

44.841 - 44.854 (1.7654 - 1.7659)

0.25 10.0098)
Undersize

44.71 1 - 44.724 (1.7603 - 1.7608) 44.461 - 44.474 11.7504 - 1.7509)

0.50 (0.0197)
Undersize

MISCELLANEOUS COMPONENTS
Unit: m m (in) Camshaft sprocket runout [T.I.R.] Flywheel runout [T.I.R.] Less than 0.1 (0.004)

Less than 0.15 IO.00591

ENGINE LUBRICATION &

SECTION

LC
..
.

CONTENTS

PREPARATION PRECAUTION

.... ....

.. ..

...

. . .. ...

.. .

..

..

...
,

..

.
.

....

.......

....

KA24E

/
.

....

..

..

...

..

LC- 2 LC- 3

ENGINE LUBRICATION SYSTEM . . . .. . . .... . ... ENGINE COOLING SYSTEM SERVICE D A T A AND SPECIFICATIONS (S.D.S.)

..
. . .
.

..

.. ..

1 CA2OE A/
.. ...

....

LC- 4 LC- 7 LC- 1 1

ENGINE LUBRICATION SYSTEM . .... . . . . ENGINE COOLING SYSTEM SERVICE D A T A AND SPECIFICATIONS (S.D.S.)

LC- 12 LC- 17 LC-2 1

PREPARATION
SERVICE TOOLS
Tool number Tool name Radiator cap tester adapter 8 1099 1 (Repco) Use with 8 10200 or 8 10300 (Repco tester)

Description Testing radiator leakage

COMMERCIAL TOOLS
Oil pressure gauge

Hose

Adapting oil pressure guage to cylinder block

PRECAUTION

46 ..>: :S .F

k,;,ol *
.: . * $

LIQUID GASKET APPLICATION PROCEDURE

a. Before applying liquid gasket, use a scraper to remove all traces of old liquid gasket from mating surface. b. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.) m Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177
in) wide (for oil pan).

Inner side

Groove

Bolt hole

a Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118

in) wide (in areas except oil pan).
SEM371C

c. Apply liquid gasket to inner sealing surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) d. Wait at least 30 minutes before refilling engine oil and engine coolant.

ENGINE LUBRICATION SYSTEM

Lubrication Circuit

1 ~ ~ 2 4 ~ 1

By-pass passage

, Intermittently --

Chain tensioner

Center cam bracket

SEF115I

Oil Pressure Check

WARNING: m Be careful not to burn yourself, as the engine and oil may be hot. m Oil pressure check should be done in "Neutral" gear position.

1. Check oil level. 2. Remove oil pressure switch.

ENGINE LUBRICATION SYSTEM

Oil Pressure Check (Cont'd)

p 1

3. Install pressure gauge. 4. Start engine and warm it up to normal operating temperature. 5. Check oil pressure with engine running under no-load.

More than 78 (0.8, 1 ) 1

If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.

Oil Pump
REMOVAL
1. Drain oil. 2. Remove front cover. (Refer to EM section.) 3. Remove oil pump assembly.

DISASSEMBLY AND ASSEMBLY

Always replace with new oil seal and gasket. When installing oil pump, apply engine oil to inner and outer gears. Be sure that 0-ring is properly installed.

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont'd)
INSPECTION Using a feeler gauge, check the following clearances: Standard clearance:
Body to outer gear clearance Inner gear to crescent clearance Unit: mm (in)

@ @ @

0 1 1 - 0.20 (0.0043 0.0079) . 0.22- 0.33 (0.0087 0.0130) 0.21 - 0.32 (0.0083 0.0126) 0.05- 0.09 (0.0020 0.0035) 0.05 - 01 1 (0.0020 0.0043) . -

Outer gear to crescent clearance @) Housing to inner gear clearance Housing to outer gear clearance

If any clearance exceeds the limit, replace gear set or entire oil pump assembly.

REGULATOR VALVE INSPECTION 1. Visually inspect components for wear and damage. 2. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil and check to make sure that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump assembly.

OIL PRESSURE RELIEF VALVE INSPECTION Inspect oil pressure relief valve for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove valve by prying it out with a suitable tool. Install a new valve by tapping it in place.

ENGINE COOLING SYSTEM Cooling Circuit

Thermostat: Open Thermostat: Closed

System Check
WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap and carefully remove by turning it a quarter turn to allow built-up pressure to escape. Then continue to turn the cap until it can be removed safely.

CHECKING COOLING SYSTEM HOSES

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

ENGINE COOLING SYSTEM

System Check (Cont'd)
CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 98 kPa (1.0 kg/cm2, 14 psi) CAUTION: Higher than the specified pressure may cause radiator damage.

CHECKING RADIATOR CAP

To check radiator cap, apply pressure to cap with a tester Radiator cap relief pressure: 78 98 kPa (0.8 1.0 kg/cm2, 11 14 psi)

Water Pump
REMOVAL AND INSTALLATION
Drain coolant from drain cocks on both cylinder block and radiator.

SMAOOBC

(C1 :

N.m (kg-m, ft-lb)

S L C 3 l lA

ENGINE COOLING SYSTEM

Water Pump (Cont'd)
CAUTION : When removing water pump assembly, be careful not to get coolant on timing belt. Water pump cannot be disassembled and should be replaced as a unit. To avoid damaging timing cover, make sure there is adequate clearance between it and the hose clamp. a After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester. When refilling cooling system, refer Section MA. INSPECTION 1. Check for badly rusted or corroded vanes and body assembly. 2. Check for rough operation due to excessive end play.

Thermostat
INSPECTION 1. Check valve seating condition at ordinary room temperatures. lt should seat tightly.

2. Check valve opening temperature and maximum valve lift.

-

Maximum valve lift

8/90 (0.311194)

3. Then check if valve is SC (gF) below valve opening temperature. After installation, run engine for a few minutes, and check for leaks. Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant.

Electric Cooling Fan Control System

Radiator fan and condenser fan are both controlled by E.C.C.S. control unit. For details, refer to ES section.

ENGINE COOLING SYSTEM

Radiator
REMOVAL AND INSTALLATION

3.2 - 4.2 (0.33 - 0.43, 2.4 - 3.1)

Radiator upper hose

Reservoir tank

Radiator rubber mounting Radiator lower hose

fan

Radiator shroud

: N m (kg-m, ft-lb)

3.2 - 4.2 (0.33 - 0.43, 2.4

- 3.1)
3. Dry affected tube and area with an air drier. 4. Lightly surface damaged area with suitable scraper and wipe clean with petrol. 5. Mix contents of bottle well and apply repair agent to affected area with a suitable clean, dry applicator (cut down wooden stirrer). 6. Apply repair agent sparingly. 7. Repair agent must be allowed to dry in ambient conditions for a minimum of 3 hours before re-fitting the radiator in vehicle. Do not use heat to promote drying. 8 . Refit radiator and refill cooling system (refer Section MA).

Radiator Minor Repair Procedure

(Using Agent Part No. 2 141 1-J7025) Minor radiator repairs are defined as damage to tubes in the form of holes no greater than approximately 1mm. 1. Remove radiator. 2. If necessary, carefully cut away or bend fins to expose affected area. Do not cut away what is not necessary and do not remove more than 25mm (total)finning from the radiator.

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Engine Lubrication System
Oil pressure check
Engine rpm Approximate discharge pressure kPa (kglcm' ,psi) More than 78 (0.8, 11) 412 - 481 (4.2 - 4.9.60

W
I

Oil pump

Idle speed 3,000

- 70)
OUTER GEAR

INNER GEAR

SLC673

Unit: mm (in)
"1

H 2

Height 11.5 (0.453) 17.25 (0.6791

Unit: mm (in) Body to outer gear clearance @ Inner gear to crescent clearance @ Outer gear to crescent clearance @ l Housing to inner gear side clearance @ Housing to outer gear side clearance @ 0.1 1 - 0.20 (0.0043 0.0079) 0.22 - 0.33 (0.0087 0.0130) 0.21 -0.32 (0.0083 -0.0126) 0.05 - 0.09 (0.0020 0.0035) 0.05 - 0.1 1 (0.0020 0.0043)

Engine Cooling System

Thermostat
Standard Cap relief pressure Valve opening temperature "C (OF) Maximum valve lift mmPC (inf'F) 8/90 (0.31 1194) Leakage ten pressure

Radiator
Unit: kPa (kg/cm2, psi)

78-98(0.8-1.0,11-14) 98 (1.0, 14)

ENGINE LUBRICATION SYSTEM

Lubrication Circuit
Note: : Oil gallery in cylinder block

~CAZOE~

@
*
Oil pan

4- - :

Oil passage By-pass passage

: Only for A/T model

t
Oil strainer

---C---

.-

Main bearing Connecting rod bearing

Cylinder head 011gallery

0 Ir
No. 4 cam bracket Connecting rod Camshaft

6 d5
Cam surface

z
Rocker s h a f t 1 Rocker arm

Oil Pressure Check

WARNING: Be careful not to burn yourself, as the engine and oil may be hot. Oil pressure check should be done in "Neutral" gear position.

1. Check oil level. 2. Remove oil pressure switch.

ENGINE LUBRICATION SYSTEM

Oil Pressure Check (Cont'd)

p ]

3. Install pressure gauge. 4. Start engine and warm it up to normal operating temperature. 5. Check oil pressure with engine running under no-load.
p p p

Engine rpm

Approximate discharge pressure kPa (bar, kg/cm2,psi) More than 59 (0.59,0.6,9) 333-510 (3.3-5.10.3.4-5.2,48-74)

Idle speed

3,200

If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.

Oil Pump
REMOVAL AND INSTALLATION
1 . Remove drive belts. 2. Remove timing belt covers and timing belt. (Refer EM Section). 3. Remove oil pan.

SLC651

4. Remove oil pump assembly with oil strainer.

5. Installation is in reverse of removal.

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont'd)
DISASSEMBLY AND ASSEMBLY

m-)---cover

m Jr
Regulator valve set

Gasket

Inner gear

Washer

: N m (kg-m, ft-lb)

SLC911

When installing oil pump, apply engine oil to inner and outer gear.

INSPECTION
Using a feeler gauge, check the following clearances.
Unit: m m (in) Body t o outer gear clearance

@
@

0.1 1 - 0.20 (0.0043 - 0.0079) 0.12 - 0.23 (0.0047 - 0.0091) 0.21 - 0.32 (0.0083 - 0.0126) 0.05 - 0.09 (0.0020 - 0.0035) 0.05 - 0.1 1 (0.0020 - 0.0043)

Inner gear t o crescent clearance

Outer gear t o crescent clearance @ Housing t o inner gear clearance

Housing t o outer gear clearance @

If it exceeds the limit, replace gear set or entire oil pump assembly.

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont'd)
REGULATOR VALVE INSPECTION

~CAZOE~

1. Visually inspect components for wear and damage. 2. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump assembly.

SLC295

OIL PRESSURE RELIEF VALVE INSPECTION Inspect oil pressure relief valve for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove valve by prying it out with a suitable tool. Install a new valve in place by tapping it.
011 separator

011 pressure relief valve

ENGINE LUBRICATION SYSTEM

Oil Cooler -A/T Models Only
CAUTION: Remove any dust from oil seal surface.

m 20 - 25 -

(2.0 2.5, 14 - 18)

Oil cooler cover

(C1J

29 - 34 (3.0 - 3.5, 22 - 25)

Oil cooler stud

O i l cooler

&--

011 cooler support

(C1J

: N.m (kg-m, f t - l b )

INSPECTION
1. Check oil cooler element and housing for cracks. 2. Check coolant inlet of oil cooler for clogging by blowing through it. Replace it if necessary.
011 cooler

ENGINE COOLING SYSTEM

Cooling Circuit

~CAZOE~

P-:: q ] Reservoir tank Radiator Water pump

Oil cooler

For A/T model

Water outlet

Thermostat

ENGINE COOLING SYSTEM

Water Pump
REMOVAL AND INSTALLATION
1. Drain coolant from radiator.

2. Remove cylinder block drain plug located at left rear of cylinder block and drain coolant.

40 54 ft-lb)

SLC764

CAUTION: When removing water pump assembly, be careful not to get coolant on timing belt. e Water pump cannot be disassembled and should be replaced as a unit. After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester.

INSPECTION
1. Check for badly rusted or corroded body assembly and vane. 2. Check for rough operation due to excessive end play.

ENGINE COOLING SYSTEM

Thermostat
INSPECTION

~CAZOE~

1. Check for valve seating condition at ordinary temperatures. It should seat tightly.

(4) 18 - 22 N.m (1.8 - 2.2 kg-m, 13 - l e f t - l b )

SLC30l

3. Install thermostat with arrow facing upward. After installation, run engine for a few minutes, and check for leaks. Always replace with new gasket.

2. Check valve opening temperature and maximum valve lift.

Standard Valve opening temperature
'C ("F)

Max. valve lift rnm/'C (in/'F)

SLC343

8/95 (0.311203)

3. Then check if valve at 5C (9F) below valve opening

temperature. After installation, run engine for a f e w minutes, and check for leaks.

Electric Cooling Fan Control System

Radiator fan and condenser fan are both controlled by E.C.C.S. control unit. For details, refer to ES Section.

ENGINE COOLING SYSTEM

Radiator
REMOVAL AND INSTALLATION

r-Radiator

cap

Radiator upper hose

Radiator rubber mounting Radiator lower hose-

(01 :

N m (kg-m,

3. Dry affected tube and area with an air drier. 4. Lightly surface damaged area with suitable (Using Agent Part No. 2 14 1 1-J7025) scraper and wipe clean with petrol. Minor radiator repairs are defined as damage t o tubes in the form of holes no greater than 5. Mix contents of bottle well and apply repair agent t o affected area with a suitable clean, approximately 1mm. dry applicator (cut down wooden stirrer). 1. Remove radiator. 2. If necessary, carefully cut away or bend fins 6. Apply repair agent sparingly. t o expose affected area. Do not cut away 7. Repair agent must be allowed t o dry in ambient conditions for a minimum of 3 hours what is not necessary and do not remove before re-fitting the radiator in vehicle. more than 25mm (total) finning from the Do not use heat t o promote drying. radiator. 8. Refit radiator and refill cooling system (refer Section MA).

Radiator Minor Repair Procedure

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Engine Lubrication System
Oil pressure check
Engine rpm Idle speed 3,200 Approximate discharge pressure kPa (bar, kg/cm2, psi) More than 59 (0.59,0.6,9) 333-510 (3.3-5.1.3.4-5.2,48-74)

Oil pump inspection

Unit: mm (in)
Body t o outer gear clearance Inner gear t o crescent clearance Outer gear t o crescent clearance Housing t o inner gear clearance Housing t o outer gear clearance

0.11 - 0.20(0.0043 0.0079) 0.12- 0.23(0.0047 0.0091) 0.21- 0.32(0.0083 0.01 26) 0.59- 0.09(0.00200.0035) 0.05- 0 1 (0.0020 0.0043) .1 -

Engine Cooling System

Thermostat
Standard Valve opening temDerature Max. valve lift mm/"C(in/"F) 8/95 (0.3 11203)

Water temperature sensor

l

-C ('F)

82 (180)

Resistance k B

Radiator
Unit: kPa (bar, kg/cm2, psi) Leakage test pressure 157 (1.57, 1.6.23)

ENGINE SYSTEMS

SECTION

ES
KA24E ES-2 ES-82 ES-83 ES-85 ES-9 1 ES-96 ES- 105

CONTENTS
CA20E
Preparation . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ES2 . . Precautions . . . . . . . . . . . . . . . . . . . . . . . .............................. ES-3 Component Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-4 E.C.C.S. Description . . . . . . . . . . . . . . ......... ................ ES-5 Component Parts Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ES-9 E.C.C.S. Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 1 4 . . . . . . . . .E S-20 E.C.C.S. Control Unit Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . E.C.C.S. Control Unit Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ES-22 . Idle Speed/lgnition Timinglldle Mix Ratio Inspection . . . . . . . . . . . . . .Trouble Diagnoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ES-25 . E.C.C.S. Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..ES-77 . E.C.C.S. Service Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ES-78 . E.C.C.S. System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-79

ES- 106 ES-112 e5-2 19 ES-90

e5-88

PREPARATION
Tool supplier: Litchfield Tool number Tool name

E7 1 18-2 Adapter Harness (CA20E Only)

Ignition coil adapter to connect external tachometer

E71 18-1 Adapter Harness (KA24E Only)

Ignition coil adapter to connect external tachometer

DIGITAL MULTlMlTER Commercial Supplier

10 M/fl minimum

General Fault Finding

(0-500 kpa) Commercial Supplier

VACUUM PUMP with gauge Commercial Supplier

Checking Diaphragms, etc.

The test lamp globe must

PRECAUTIONS
Do not operate the fuel pump when the fuel lines are empty. Always use a 12-volt battery as power source. Do not attempt to disconnect the battery cables while the engine is running.

p%q
When installing tranceiver equipment or a mobile phone, be sure to observe the following notes as it may adversely affect the electronic control systems depending on its installation location. 1) Keep the antenna a far as possible s away from the electronic control unit. 2) Keep the antenna feeder line more than 20 cm (7.9 in) away from the harness of electronic controls. Do not let them run parallel for a long distance. 3) Adjust the antenna and feeder line so that the standing-wave ratio can be kept smaller. 4) Be sure to ground the radio to vehicle body.

Do not disconnect the E.C.C.S. harness connectors before the battery ground cable has been disconnected. Securely connect the E.C.C.S. harness connector. A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to ICs. Keep the E.C.C.S. harness a t least 10 cm (3.9 in) away from adjacent harnesses, to prevent an E.C.C.S. system malfunction due to receiving an external noise, degraded operation of ICs, etc. Keep E.C.C.S. parts and harnesses dry. Before removing parts, turn off the ignition switch and disconnect the battery ground cable.

Do not depress the accelerator pedal when starting.

immediately after do rev U the engine unnecessarily. P DO "Of rev U the engine just prior P to shutdown.

Do not disassemble the E.C.M. (Electronic Control Module)

E.C.C.S.
COMPONENT PARTS LOCATION

/ CAZOE I

Throttle chamber Air regulator

Fuel filter

Air flow meter

Injector Distributor

Hall effect sensor Ignition coil and power transistor

E.C.C.S.
Electronic Concentrated Engine Control System (E.C.C.S.)
The E.C.C.S. system is an engine management system. It is designed to control engine fuel requirements, ignition timing, spark plug switching, radiator cooling fans, torque converter lock-up (AT only), engine idle speed, air conditioner compressor (where fitted) and an E.C.M (electronic control module) lamp. Incorporated in the system is a self-diagnostic function for fault identification. The system consists of input sensors, an electronic control module (E.C.M.) and actiuators, the functions of which are shown below.

Oxygen Sensor

Air/Fuel ratio Fuel injection 81mixture Injectors

Hall effect sensor (Distributor)

Engine Speed Ignition timing control Power transistors

Air flow meter

Spark plug switching

Power transistor

- Exhaust coil

Water temperature sensor

Engine temperature Air flow meter wire cleaning control

>I
>I

Air flow meter

I
I

Throttle position sensor

Throttle valve position Rate of throttle valve movement Electronic Engine idle speed Idle Air Control (IAC) Valve

NeutrallPark switch A/T Neutral Switch M/T

Gear position

Control Module (E.C.M.) Fault indication to driver

E.C.M. lamp

Vehicle speed sensor

lgnition switch

Start signal

Fuel pump and air regulator control

Air conditioner switch

Air conditioner request

Engine cooling fan control Battery voltage

>I

Engine cooling fans

Air conditioner compressor control (where fitted)

\ I Air conditioner
compressor clutch

Automatic transaxle lock-up function (Auto Trans only)

Idle air control valve

position sensor

xhaust gas sensor

Hall effect sensor built-in distributor'

er temperature sensor

Catalytic Converter

Air flow meter (Hot wire type)

Air conditioner compressor (where fitted)

FUEL FLOW SYSTEM DESCRIPTION

I CAZOE (

Fuel tank Fuel pump and damper

A EF-003

(3 Bar, 43.5psi)

The amount of fuel to be injected is determined by the injection pulse duration as well as by a pressure difference between fuel pressure and intake manifold vacuum pressure. The E.C.M. controls only the injection. pulse duration. For this reason, the pressure difference between the fuel pressure and intake manifiold vacuum pressure should be maintained at a constant level. Since the intake manifold vacuum pressure varies with engine operating conditions, a pressure regulator is placed in the fuel line to regulate the fuel pressure in response to changes in the intake manifold vacuum pressure.
d

AIR FLOW SYSTEM DESCRIPTION

1-

@ : Intake air flow

: Exhaust gas flow

Throttle valve

Air cleaner

t
Air flow meter
SEF606D

E.C.C.S. DESCRIPTION - E.C.C.S. Components

ELECTRONIC CONTROL MODULE (E.C.M.) The E.C.M. consists of a microcomputer, connections for signal input, output and power supply. The E.C.M. controls the amount of fuel injected, ignition timing, engine idle speed, spark plug switching, radiator cooling fans, air conditioner compressor (where fitted), fuel pump, autotrans torque converter function, air flowmeter burn off function and E.C.M. lamp operation. Additionally the control unit incorporates a diagnostic system and a failsafe system to provide substitution for certain components should they fail along with a limp processor t o provide limited operation of the system should the main processor fail. Distributor (HALL EFFECT) SENSOR The hall effect sensor is a basic signal sensor for the entire E.C.C.S. System. It monitors engine speed and sends a signal t o the E.C.M. The hall effect sensor has a rotor and stator assembly. The rotor consists of four windows and four metal tabs that rotate past the stator assembly (hall effect switch). The stator assembly consists of a hall effect device and a magnet. As the rotor rotates, alternatively a metal tab, then a window pass between the hall effect device and the magnet. The resulting changes t o magnetic flux create an ON/OFF pulse within the device, which is then sent to the E.C.M. WATER TEMPERATURE SENSOR The water temperature sensor monitors changes in cooling water temperature and transmits a signal t o the E.C.C.S. control unit. The temperature sensing unit employs a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response t o the temperature rise.

THROTTLE POSITION SENSOR (TPS) The throttle position sensor is attached to the throttle chamber and actuates in response to accelerator pedal movement. The TPS is a potentiometer which provides an output voltage that varies according to throttle valve opening. In this way the ECM can detect both the amount of throttle opening and the rate of throttle opening or closing. The E.C.M. uses the idle reading as a zero reading (0%throttle), so no T.P.S. adjustment is necessary.

E.C.C.S. DESCRIPTION - E.C.C.S. Components

1 CA2OEI

AIR FLOW METER The air flow meter measures the mass flowrate of intake air. Measurements are made in such a manner that the control circuit emits an electrical output signal in relation t o the amount of heat dissipated from the hot wire placed in the stream of intake air.

compensation resistor

: Hot wire resistance : Temperature compensation resistance

The air flowing around the hot wire removes the heat from the hot wire. The temperature of the hot wire is very sensitive t o the mass flowrate of the air. The higher the temperature of the hot wire, the higher its resistance value. The change in the temperature (or: resistance) is determined by the mass flowrate of the air. The control circuit accurately regulates current (I) in relation t o the varying resistance value (R,) so that V always equals V. The air flow meter , , transmits an output for voltage V t o the control unit where the out, put is converted into an intake air signal.

Ignition switch

- 11 7
l
OFF

' l

I I

Self-cleaning

1 3
oFi=
10 sec.
1 sec.

Self-cleaning After each 100kg of air mass flow through the air flow meter, the E.C.M. operates a self-cleaning function the next time the engine is stopped. The hot wire is heated t o approximately 1000C t o burn off any contamination which may have occurred. This is done approximately 1 0 seconds after the key is turned off and is activated for approximately 1 second.

OFF

FUEL PUMP The fuel pump assembly consists of an intake filter, a low pressure vane pump element feeding a high pressure "G-rotor" pump element motor, relief valve and check valve. This combination of low and high pressure pump elements in series minimizes fuel pulsation, therefore eliminating the need for a low pressure dampener.

E.C.C.S. DESCRIPTION - E.C.C.S. Com~onents

/ CAPOEI

FUEL INJECTOR The fuel injector is a small, precision solenoid valve. As the E.C.C.S. control unit outputs an injection signal to each fuel injector, the coil built into the injector pulls the needle valve back, and fuel is injected through the nozzle into the intake manifold. The amount of fuel injected is controlled by the E.C.C.S. control unit as an injection pulse duration.

POWER TRANSISTORS The ignition signal from the E.C.C.S. control unit are amplified by the power transistor, which connects and disconnects the coil primary circuit to induce the proper high voltage in the secondary circuit. Each coil (ie) intake and exhaust, has its own power transistor. Note: If power transistors are removed from their, mounting brackets, heat sink compound must be used on reassembly. IGNITION COILS The ignition coils are a moulded type. IDLE AIR CONTROL (IAC) VALVE The IAC valve is a stepper motor with pintle valve located in a throttle valve bypass passage: The IAC valve receives "a pulse sequence" from the E.C.M. and responds by extending or retracting the pintle. As the pintle moves in or out, it will control the amount of bypass air flow, thus controlling engine idle speed. When a load, (eg) heaterfan (electrical load), is placed on the engine, the E.C.M. can compensate for the resultant effect on engine RPM, by increasing the amount of throttle bypass air flow.

VEHICLE SPEED SENSOR The vehicle speed sensor provides a vehicle speed signal to the E.C.M. The sensor is an electronic Hall switch which provides a pulse signal. This pulse occurs 10 times per sensor revolution.

E.C.C.S. DESCRIPTION - E.C.C.S. Components

I CAZOE I

Insulation bushing

EXHAUST GAS SENSOR The exhaust gas sensor, which is located in the exhaust manifold, monitors the density of oxygen in the exhaust gas. It consists of a closed-end tube made of ceramic zirconia and'other components. Porous platinum electrodes cover the tube's inner and outer surfaces. The closed-end of the tube is exposed to the exhaust gas in the exhaust manifold. The outer surface of the tube contacts the exhaust gas while the inner surface contacts the air.

AIR REGULATOR Air regulator gives an air by-pass when the engine is cold for the purpose of afast idle during warm-up. A bimetal, heater and rotary shutter are built into the air regulator. When the bimetal temperature is low, the air by-pass port is open. As the engine starts and electric current flows through a heater, the bimetal begins to rotate the shutter to close off the by-pass port. The air passage remains closed until the engine is stopped and the bimetal temperature drops.

SEF937B

INHIBITOR SWITCH (A/T MODELS) NEUTRAL SWITCH (M/T MODELS) The inhibitor/neutral switch signals the E.C.M. when the transaxle is in park or neutral (A/T) or neutral (M/T). This input is used for I.A.C. control. IGNITION SWITCH AND A/C SWITCH (WHERE FITTED) Additional inputs to the E.C.M. are providedfrom the ignition switch (start signal) and air conditioner switch (where fitted). The start signal is used for fuel enrichment when starting, whilst the air conditioner request signal is used by the E.C.M. to command the air conditioner compressor. BATTERY VOLTAGE When the battery voltage is too low, the injector opening sp&ed is slowed, thereby reducing the amount of fuel injected. The E.C.M. will compensate for the battery voltage by extending the pulse duration accordingly.

E.C.C.S. DESCRIPTION - E.C.C.S. Components

MIXTURE RATIO FEEDBACK

I CAZOE (

This system utilizes an exhaust gas sensor located in the exhaust manifold to monitor whether the air fuel ratio is richer or leaner than the stoichiometric point (14.7: 1 air/fuel mix). The control unit then adjusts the injection pulse width according to the sensor output signal, to maintain the mixture ratio within a narrow window around the stoichiometric point.

To maintain optimum engine operation, the mixture ratio feedback system does not operate under the following conditions: when starting the engine when the exhaust gas is cold when the engine coolant is below 60C when the engine speed is above 3800 rpm when the engine speed is below 3800 rpm and engine load is above a pre-determined rate when engine is idling for more than approximately 20 seconds when throttle position changes faster than a pre-determined rate (ie)acceleration or deceleration
l

When in operation, the mixture ratio feedback control system is said to be in the closed loop condition. Conversely, when not in operation, the mixture ratio feedback control system is said to be in the open loop condition.

E.C.C.S. DESCRIPTION
Fuel Injection Control

Distributor (Hall effect sensor)

Engine speed

Air flow meter

Amount of intake air

Water temperature sensor

Temperature of engine
W

Throttle position sensor

Throttle valve position Throttle valve rate of opening/closing Density of oxygen in exhaust gas

E.C.M.
t

Injector

Exhaust gas sensor

Ignition switch

Start signal

Battery

Battery voltage
W

Vehicle speed sensor

Vehicle speed

The E.C.M. calculates basic injection pulse width by processing signals from the hall effect sensor and air flow meter. Receiving signals from each sensor which detects various engine conditions, the control unit adds various enrichments, which are pre-programmed in the control unit, to the basic injection amount. Thus, the optimum amount of fuel is injected through the injectors.

2) Fuel shut-off (during deceleration). Fuel shut-off

occurs under certain conditions defined by water temperature, engine and vehicle speed and throttle closure. Additionally fuel shut-off to all cylinders occurs at 6500 rpm to prevent the engine from overrevving. When this occurs, fuel injection resumes at 6480 rpm. 3) Simultaneous injection. The fuel is injected into all four cylinders simultaneously twice each engine cycle.
Simultaneous injection No. 1 cylinder No. 2 cylinder No. 3 cylinder No. 4 cylinder

1) Fuel enrichment In each of the following conditions, fuel is enriched: a) When starting. b) After starting. c) During warm-up. d) During acceleration. e) During heavy load and high engine rpm.

1engine cycle I ,

E.C.C.S. DESCRIPTION
Fuel Pump and Air Regulator Control
Engine speed
b

Hall effect sensor

Fuel pump

E.C.M.

Air regulator
lgnition switch

Start signal

Fuel Pump and Air Regulator Control

The fuel pump and air regulator are both controlled b y the E.C.M. via a fuel pump relay.

Fuel pump and air regulator ON-OFF control

lgnition switch position

1
L

Engine condition

I
I
l

Fuel pump/ i i r regulator o~eration Operates for 3 seconds Operates Stops in 1 second Operates

Stopped ON Running After stall START Starting

E.C.C.S. DESCRIPTION
lgnition Timing Control
Distributor (Hall effect sensor) Engine speed
b

Air flow meter

Amount of intake air

E.C.M.

Power transistors

Water temperature sensor

lgnition timing is controlled, corresponding to the engine operating conditions, by the E.C.M.: that is, as the optimum ignition timing in each driving condition has been pre-programmed in the E.C.M., the ignition timing is determined by electrical signals processed in the E.C.M. The signal from E.C.M. is transmitted to power transistor, and controls ignition timing.

Spark Plug Switching Control

Amount of intake air

Air flow meter

E.C.M. Distributor (Hall effect sensor) Engine speed

Power transistor (Exhaust Coil)

The spark plug switching control system is designed to change the ignition system from 2-plug ignition to l-plug ignition during heavy load driving in order to reduce engine noise.

E.C.C.S. DESCRIPTION
ldle Speed Control
Distributor (Hall effect sensor) Engine speed

Water temperature sensor

Engine temperature

Ignition switch

Start signal

Throttle position switch

Throttle valve idle position

b E.C.M.

Idle air control valve

Air conditioner switch (where fitted)

Air conditioner operation

Vehicle speed sensor

Vehicle speed

,
The idle speed is controlled by the E.C.M., corresponding to the engine operating conditions. Th'e E.C.C.S. control senses the engine condition and determines the best idle speed at each water temperature. The E.C.M. then sends a series of pulses, corresponding t o the difference between the best idle speed and the actual idle speed, to the I.A.C. valve.

Torque Converter Lock-Up Control

b

Water temperature sensor

E.C.M. Throttle position sensor

Lock-up Solenoid ON

Torque Converter Lock-up solenoid

Torque converter lock-up is only available in 4th gear above approximately 70-75 kph (hydraulic pressure available). Torque converter lock-up operation is then controlled by the E.C.M. turning "OFF" the lock-up solenoid to engage torque converter lock-up as follows:
Lock-up Operation (Vehicle Speed above approx. 70-75 kph) OFF OFF ON

Water Temp. Less than 50C Above 50C

Throttle Position Idle Above Idle Idle Above Idle

ON OFF

E.C.C.S. DESCRIPTION
Radiator Cooling Fan Control
Vehicle speed sensor Vehicle speed

+
+
E.C.M.
High speed Radiator cooling fans

Water temperature sensor

Engine temperature

Air conditioner switch (where fitted)

Air conditioner request

Radiator Cooling Fan Operation

The E.C.M. controls cooling fan operation from information received from vehicle speed sensor, water temperature sensor and air conditioner switch (where fitted). The fans are operated via cooling fan relays (high and low) at either low speed, high speed or off according to the conditions as shown below.

Where air conditioning is not fitted, fans will operate as for air conditioner OFF. Note: To enable high speed fan operation, both relays must be energized.

E.C.C.S. DESCRIPTION
Air Conditioner Compressor Control (Where fitted)

Air conditioner switch

C
amplifier (ie) thermostat high and low pressure switch A/C inputs E.C.M. Air conditioner compressor

Throttle position sensor

Throttle valve position Throttle valve rate of change

The E.C.M., upon receiving an A/C request signal from the A/C switch, activates the air conditioner compressor via the A/C relay. Inputs from the thermo amplifier indicating high or low pressures, or thermostat cut-out temperature has been reached will cause the E.C.M. to de-activate the air conditioner. Additionally, if the throttle is opened more than 60% and acceleration enrichment is triggered, the E.C.M. will de-activate the compressor for approximately 12 seconds or until the throttle is closed to lower than 50%.

E.C.C.S. DESCRIPTION
Control Unit Systems
Fail Safe System
The E.C.C.S. control unit incorporates a fail safe system which allows it to substitute a preprogrammedvalue or utilize other sensor information in place of the fail sensor/circuit. When this occurs, the E.C.M. lamp will illuminate.

Throttle Position Sensor If a fault occurs with the throttle sensor and/or its circuit, the control unit will substitute a value equivalent to 2% of throttle opening. Air Flow Meter If a fault occurs with the air flow meter and/or its circuit, the control unit will substitute the throttle sensor signal to indicate engine load. Water Temperature Sensor If a fault occurs with the water temperature and/or its sensor, the control unit will substitute a value equivalent to engine operation of 90C. Main Processor Failure The E.C.C.S. control unit incorporates a back-up processor (known as the limp processor) for limited operation of the engine management system should a malfunction of the main processor occur. When in the fail safe mode and operating from the limp processor, the following conditions will apply.

Air Conditioning System (where fitted) Torque converter lock-up Radiator Fans Low speed High speed

Operational Operational OFF ON Operational Operational Disabled Operational Fixed at last operating position until restart, then reset and fixed to approximately 1000 rpm Disabled

Injection system Ignition System Intake side Exhaust side

Fuel pump Idle Speed Control

Air Flow Meter Burn-Off

E.C.C.S. DESCRIPTION
Control Unit Systems (Con't)
Diagnostic System
The E.C.C.S. system incorporates a diagnostic system to aid rectification should a malfunction occur. The system utilizes an E.C.M. lamp in the instrument cluster to: Indicate to the driver that a malfunction has occurred and that it should be attended to as soon as practicable. To provide code information to the technician of recorded malfunction and indicate mixture condition under certain operating conditions. The lamp should illuminate as a bulb and system check with the ignition "ON" engine stationary. Once the engine is started, the lamp should go out. If the lamp remains on, a malfunction has been detected. If a malfunction occurs whilst driving, the lamp will illuminate and a malfunction code will be recorded in the control unit memory. If the problem goes away, (e.g. intermittent), the lamp will not come back on at the next restart. The malfunction code, however, will be retained in the control unit memory. The E.C.C.S. diagnostic system provides 3 modes of operation. They are:

1. Diagnostic Mode 2. Field Service Mode 3. Clearing Mode

The E.C.C.S. system is provided with a diagnostic terminal to activate system diagnostics. Located near the E.C.M., the connector may be accessed by removing eitherthe left or right hand side's trim in front of the console. Summary of E.C.M. lamp functions during normal operation.
Ignition Switch Position Engine Condition Stopped ON Running YES OFF System Operation OK NO/YES NO E.C.M. Lamp Operation ON ON

E.C.C.S DESCRIPTION
Control System Modes

piEl

Diagnostic Mode The diagnostic mode is activated by turning the ignition 'OFF", waiting 15 seconds for the E.C.M. t o power down, inserting service tool ESD-28079 or similar (diagnostic bridge) then turning the ignition "ON". When in the diagnostic mode, the E.C.M. lamp will flash in a sequence which can be read as a code number t o indicate that system functions are normal or that a malfunction has been recorded. A normal system operation (no malfunctions recorded) is identified by code 12. Code 12 is read as follows:

,"-1-

g*

I
Seconds

I
1.0

I
3.0

I
1.0

10.5 1

10.510.510.51

10.51

10.510.5 10.51

sZ

l?

TEMP

The number of half second flashes preceding the one second pause indicates the ten digits whilst the number of half second flashes following the one second pause indicates the unit digits. Codes are repeated after a three second pause. If no malfunctions are recorded, code 12 will continue until the diagnostic bridge is removed. If a malfunction is recorded, only that malfunction code will be displayed as in code 12 above. If multiple malfunctions are recorded each code will be displayed once in a predetermined sequence then repeated. Malfunction Codes Within the E.C.M. microcomputer, a predetermined set of conditions exists under which a malfunction code will be set. For example, if a sensor voltage does not fall within the parameters that the E.C.M. is programmed to expect under the existing conditions, a code will be set. This code will refer to the circuit within which the fault occurred (i.e.) the sensor, the wiring and connectors to it, and the E.C.M.

E.C.C.S. DESCRIPTION
Diagnostic Mode (Cont'd)

p 6 q

on automatic versions. It is set in Field Service Mode and only cleared by starting in P/N and shifting into gear while in Field Service Mode. Air flow meter (Voltage too low) Air flow meter (Voltage too high) Burn-off air flow meter Vehicle speed NOTE: This code is set in Field Service Mode and is only cleared by driving at more than 5 km/h while in Field Service Mode. Lean exhaust indication (Voltage too low) Rich exhaust indication (Voltage too high) Engine management module 32 33 34" 43

44 45

55

"NOTE: These codes do not cause the E.C.M. lamp to come on when they occur.

E.C.C.S. DESCRIPTION
Field Service Mode
The Field Service Mode is activated by initiating diagnostic mode, then starting the engine. In this mode, the following Field Service and diagnostic functions are enacted. The ignition timing reverts to the static or base setting of 5" BTDC whilst the engine speed is lower than 3000 rpm and the load is less than 250 mg of air/stroke. Note: This is the only condition under which base timing may be checked and/or adjusted. The "E.C.M." lamp will i n d i c a t e w h e t h e r t h e s y s t e m i s in o p e n or closed loop operation. Additionally, when the system is in closed loop, the lamp will indicate whether a rich, lean or normal mixture is being sensed.

Interpretation of lamp Open loop

Flashing rate of lamp On and Off approx.

2.5 times/second
Closed loop system normal Closed loop-0, sensor indicates lean exhaust Closed loop-0, sensor indicates rich exhaust On and Off approx. once per second

Off most of the time

On most of the time

Clearing Mode
Diagnostic Code Clearing To enter Diagnostic Code Clearing, the engine must be run in Field Service Mode, the ignition switched "OFF". After the engine stops, the ignition must be switched back on again within 15 seconds. The radiator fans will now operate at high speed ignition "ON" and the existing fault codes including the Vehicle Speed and Park/ Neutral fault codes (unless they were cleared while in the Field Service Mode) will be displayed. While in this mode (i.e. ignition "ON", radiator fans "ON" and the engine having been run previously) it is now possible to clear the existing diagnostic codes by fully depressing and releasing the throttle three (3) times. The E.C.M. lamp will come on to acknowledge each depression. Note: As the E.C.M. utilizes capacitor back-up for the memory, disconnecting the battery cable will not clear the memory. Forcing Burn-off After performing Diagnostic Code Clearing as described previously, a further two (2) depressions of the throttle will initiate an air flow meter burn-off. This burn-off will occur if the diagnostics bridge is removed before turning the ignition "OFF". Note: The diagnostics bridge must be removed first and then the ignition switch "OFF" or else a burn-off error will be recorded in the E.C.M. memory. A burn-off will occur after the ignition is switched "OFF". Clearing Learned Parameters After performing Diagnostics Code Clearing and initiating the Forced Burn-off, an additional one (1) depression of the throttle clears all the learned parameters in the self learn RAM memory. SUMMARY OF THROTTLE DEPRESSIONS (as indicated by the E.C.M. lamp) 3 times Diagnostic Code Clearing Plus 2 times Forced Burn-off Plus 1 time Clearing Learned Parameters
For example, depressing the throttle six or more times and removing the diagnostic plug causes all the above to occur.

TROUBLE DIAGNOSIS
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair . . . . . . . . . . . . . . . . . . . . . . . Self-diagnosis System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 1 -- ECM Lamp Won't Flash Any Code . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 2 -- Engine Cranks But Will Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 3 -- Fuel Pump Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 4 -- Fuel Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 5 -- Idle Air Control (IAC) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 6 -- Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 7 -- Radiator Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 8 -- Torque Converter Lock-Up Release Solenoid . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 9 -- Air Conditioner Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 10 -- Code l l -- Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 1 l -- Code 13 -- Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 12 -- Code 14 -- Water Temperature Sensor (Voltage Low) . . . . . . . . . . Diagnostic Procedure 13 -- Code 15 -Water Temperature Sensor (Voltage High) . . . . . . . . . Diagnostic Procedure 14 -- Code 2 -- Throttle Position Sensor (Voltage High) . . . . . . . . . . . . 1 Diagnostic Procedure 15 -Code 22 -Throttle Position Sensor (Voltage Low) . . . . . . . . . . . . Diagnostic Procedure 1 6 -- Code 23 -- No Start Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Diagnostic Procedure 17 -- Code 3 -- ParkINeutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 18 -- Code 32 -Air Flow Meter (Voltage Low) . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 19 -- Code 33 -- Air Flow Meter (Voltage High) . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 20 -- Code 34 -- Air Flow Meter Burn-Off . . . . . . . . . . . . . . . . . . . . . . . 1 Diagnostic Procedure 2 -- Code 43 -Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 22 -- Code 44 -- Lean Exhaust Indication . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 23 -- Code 45 -- Rich Exhaust Indication . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 24 -- Code 55 -- Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . Electrical Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLE DIAGNOSES

1-

Sensors
Control unit
Actuators

How to Perform Trouble Diagnoses for Quick and Accurate Repair

INTRODUCTION
The engine has an electronic control unit to control major systems such as fuel control, ignition control, idle speed control, etc. The control unit accepts input signals from sensors and instantly drives actuators. I t is essential that both kinds of signals are proper and stable. At the same time, it is important that there are no conventional problems such asvacuum leaks, fouled spark plugs, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems. A road test with a circuit tester connected to a suspected circuit should be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a driveability complaint. The customer is a very good supplier of information on such problems, especially intermittent ones. Through the talks with the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for "conventional" problems first. This is one of the best ways to troubleshoot driveability problems on an electronically controlled engine vehicle.

SEF232G

SEF234G

TROUBLE DIAGNOSES
WORK FLOW

/ CA2OE I

How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd)

CHECK I N

LISTEN TO CUSTOMER COMPLAINTS

I
r------

BASIC INSPECTIOY

2(

Do self-diagnostic results exist?*l Yes INSPECTION ON THE BASIS OF EACH MALFUNCTION

INSPECTION ON THE BASIS OF EACH SYMPTOMX2

FINAL CHECK Confirm that the trouble is completely fixed by performing Basic Inspection and Test Drive.

CHECK OUT

*l If the self-diagnosis cannot be performed, check ECM main power supply and ground circuit. : *2: If the trouble is not duplicated, see INTERMITTENT PROBLEM SIMULATION.

TROUBLE DIAGNOSES

I CA2OE I

KEY POINTS

How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd)
DIAGNOSTIC WORKSHEET
There are many kinds of operating conditions that lead to malfunctions on engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, feelings for a problem depend on each customer. It is important to fully understand the symptoms or under what conditions a customer complains.. Make good use of a diagnostic worksheet such as the one shown below in order to utilize all the complaints for trouble-shooting.

WHAT WHEN WHERE HOW

..... Vehicle & engine model ..... Date, Frequencies ..... Road conditions ..... Operating conditions,
Weather conditions, Symptoms

Worksheet sample
Customer name Engine # Incident Date M RIMS Model & Year Trans. Manuf. Date VIN Mileage In Service Date

U Startability

Impossible to start C1 No combustion U Partial combustion C1 Partial combustion affected by throttle position Partial combustion NOT affected by throttle position C1 Possible but hard to start U Others [ No fast idle

U Idling
Symptoms

U Unstable

High idle

U Low idle

.
U Driveability

U Others [

1
U Lack of power
-

Stumble U Surge U Detonation U Intake backfire U Exhaust backfire U Others [ 1

Engine s t a l l

U At the time of start C1 While accelerating

Just after stopping Just after delivery

While idling While decelerating U While loading Recently

lncident occurrence Frequency Weather conditions Weather Temperature Engine conditions

U In the morning U All the time

U Not effected
Fine

U At night

In the daytime

U Under certain conditions

U Sometimes

U Raining

U Snowing
C1 Cool
1

U Others [

1
"F

U Hot U Cold

C1 Warm

U Cold

U Humid
1

Engine speed Road conditions Driving conditions

During warm-up I 1 2,000 In suburbs

U After warm-up

I
4,000

1 6,000

1
8,000 rpm

C1 In town

U Highway

U Off road (upldown)

Not affected U At starting While idling At racing While accelerating U While cruising While decelerating While turning (RHILH) Vehiclespeed

'

'

20

'

40

'

60

'

80

'

100

'

120KPH

ECM light
4

Turned on

Not turned on

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd)
INTERMITTENT PROBLEM SIMULATION In order to duplicate an intermittent problem, it is effective t o create similar conditions for component parts, under which the problem might occur. Perform the activity listed under Service procedure and note the result.

symptom, isn't it ?

SEF235G

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Variable factor Influential part Target condition Made lean Service procedure Remove vacuum hose and apply vacuum. Remove vacuum hose and apply pressure. Rotate distributor clockwise. Rotate distributor counterclockwise. Disconnect exhaust gas sensor harness connector. Perform self-diagnosis at 2,000 rpm. Tap or wiggle. Race engine rapidly. See if the torque reaction of the engine unit causes electric breaks. Cool with an icing spray or similar device. Heat with a hair drier. [WARNING: Do not overheat the unit.] Wet. [WARNING: Do not directly pour water on components. Use a mist sprayer.] Turn on head lights, air conditioner, rear defogger, etc. Try t o flash timing light for each cylinder.
h

Mixture ratio

Pressure regulator Mad. rich Advanced

lgnition timing

Distributor Retarded Suspended Operation check Poor electric connection or faulty wiring Cooled

Mixture ratio feedback control Electric connection (Electric continuity)

Exhaust gas sensor

control unit

',4

Harness connectors and wires

Temperature

Control unit Warmed

Moisture

Electric parts

Damp

7 8

Electric loads Ignition spark

Load switches Timing light

Loaded Spark power check

TROUBLE DIAGNOSES

TROUBLE DIAGNOSES
SELF DIAGNOSIS SYSTEM CHECK
Ignition on engine stopped. Diagnostic bridge removed. Note ECM light.

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No Light

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Steady Light

1
Flashing Light

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Go to Diagnostic Procedure 1.

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Connect diagnostic bridge and note ECM light.

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Flashing code 12 or other codes.

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Erratic or at times intermittent. I Check for intermittent short to earth onAN114

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If flashing code 55. see code 55 chart first. Otherwise. Check diagnostic circuit AN114 for a short to earth. If not earthed. Check for a short to 12 volts on AN 1 14. If AN114 is ok, it is a faulty ECM.

h
Does not flash any code.

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Flashes code 12 or any malfunction code.

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Go to Diagnostic Procedure 1

Note and record any malfunction codes. Code 12 isnot a malfunction code. Perform Diagnostic Procedure 2 1 t o check Vehicle Speed Sensor. Perform Diagnostic Procedure 17 t o check ParkINeutral switch (A/T models only) Note and record any malfunction codes. Code 12 is not a malfunction code.

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No Malfunction Codes Malfunction Codes

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Diagnostic circuit check ok if engine cranks but will not run, go to Diagnostic Procedure 2.

If flashing code 55 see that chart first. Otherwise. See applicable chart. If more than one code is stored. Start with the lowest code. If engine cranks,but , not run, go to ~ l l i ,, iprocedure 2. ~

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~ ~

Enter field service mode by running engine with Diagnostic Bridge connected. Note ignition timing will stay in the "Set Timing" mode with rpm below 2000. With engine at normal operating temp. Run at 1600-1800 rpm for two minutes and note ECM liqht.
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1 per sec. confirming "Closed Loop" operation.

Light flashes at a rate of 2.5 per sec indicating "Open Loop" operation.

Light is off all or most of the time, indicating a lean exhaust.

Light is on all or most of the time, indicating a rich exhaust.

Fuel system operating normally.

Vehicle may be driven in the field service mode and evaluated at any steady speed. This can be helpful in diagnosing drive ability problems that involve the fuel control system being rich or lean too long.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 1 ECM LAMP WON'T FLASH ANY CODE (LAMP ON STEADY OR NO LIGHT)

+l 2V INSTR. CLUSTER

ECM LAMP 1 .2U BULB

p .

A -- N 100

--

INPUT

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 1 (Cont'd) ECM LAMP WON'T FLASH ANY CODE (LAMP ON STEADY OR NO LIGHT)

Disconnect all ECM connectors.

W
Light off (Please Note: Test light

Light on

Repair short to earth in circuit AN100.

With testlight connected to earth, back probe ECM connector terminals 1, 32, 2, 44. There should be no light on any of the four terminals.

4 watt).

No Light

l
Reconnect ECM connectors back probe ECM connector terminal 44 with test light to earth and note ECM light.

Repair short to voltage on circuit with light.

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No Light

- Diagnostic request circuit AN114.

or

Check for and repair open circuit in either

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Light on Steady

- Earth circuit AN115 leading to diagnostic

Connect Diagnostic Bridge.
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connector.

Flashes Codes

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Replace ECM. Recheck Codes.

U

Code 12 indicates no malfunctions have been detected. Note and record any malfunction codes, and refer to the appropriate Diagnostic Chart. If engine cranks but won't run. Go to Diagnostic Procedure 2.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 2 ENGINE CRANKS BUT WILL NOT RUN
NOTE: THIS CHART SHOULD ONLY BE CONSULTED AFTER PERFORMING "SELF DIAGNOSIS SYSTEM CHECK"

5 -

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 2 (Cont'd) ENGINE CRANKS BUT WILL NOT RUN
Note: This chart should only be consulted after performing "Self Diagnosis System Check"

Check fuel tank quantity ok. Disconnect &/injector electrical connectors ignition coil & Coil driver electrical connectors. Connect test lamp across one injector connector. "Ensure that no short to earth or across terminals occurs". Turn on ignition.

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Using a test lamp or multimeter check power on AN63 of the two ignition coil connectors and to each injector connector.

Repair short on circuit AN130.

a
Light "on" No Power

a
Power Ok Using a multirneter check each of AN01 and AN02 voltages at the coil driver module harness plugs, to engine earth. (Lead Positive to AN01 or AN02) Ignition off. After at least 10 seconds key off, check AF66 pump power line with test lamp or multirneter. Power should be on for Tat least 3 seconds after ignition key is turned on again.

Repair power circuit AN63.

a
Voltage over 0 . 8 ~

ECM faulty. (Check driver module for damage).

Ignition off. Reconnect coil connectors and coil driver connectors. Connect E7176 spark checker. (See Note) Check for spark during cranking. Check both inlet and exhaust, 2 Leads each. 'A few sparks then nothing is considered no spark".

See Diagnostic Procedure 3.

6
A

Go to

@ on the next page.

NOTE: use E7776 or equivalent. Do not use a sparkplug in open air earthed to the engine as an indication of sufficient "spark Only a few kilovolts are required to jump the gap of a spark plug outside of the engine, and that would be an inadequate test of the ignition coil output ability

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 2 (Cant'd)

No Spark
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Go to Diagnostic Procedure 6.

Reconnect all injectors and HT leads. Remove fuel pump fuse. Crank for 5 seconds to relieve fuel pressure. Ignition off and connect fuel pressure gauge. "Between fuel rail inlet and flexible hose': Reinstall fuel pump fuse. Observe fuel pressure after ignition "on''. Pressure should be 280 to 320 kPa and not continue to drop after pump stops running.
(Pump should run about 3 seconds, then shut off. It is normal for the pressure to dmp slightly afrer the pump stops running, but it should then hold steady and dmp no further).

Ok

Not Ok
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Disconnect injectors again! Connect test lamp across one injector harness plug. "Ensure that no short to earth or across terminals occurs': Have a helper crank the engine while you closely observe the lamp. The lamp should blink, indicating fuel pulses are present.

Turn ignition on and listen for fuel pump run running at fuel tank.

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Running

Not Running

Procedure 4.

Procedure 3.

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Check resistance across each injector. Should be 15.5-16.5 OHM @ 20C.

Steady Light

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Check remaining injectors. If any do not blink, repair open circuit on AN63 or AN130lAN230 circuit.

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Ignition "on". Probe each terminal of one injector harness connector with a test light to ground.

Ok

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Not Ok

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1
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No Light

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injector not within

r - - - At this point, the fuel control system, I fuel delivery system, I and ignition system are ok.
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Light "on" One

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AN130lAN230 (Check ECM

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1
*Repair circuit on AN63.

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_ _ _ _ _

Continue for further checks.

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_ _ _ _ -I

- ECM diagnostic. - Dist. ref. mark sensor diagnostic.

- Fouled spark plugs. - Proper TPS circuit operation. - Restricted exhaust. - Improper airflow meter operation.

Check for:

- Improper coolant sensor resistance.

- Water or foreign material in fuel, or incorrect fuel. - Initial ignition timing not correct, or spark plug wires ''crossed': - Camshaft timing belt slipped or stripped, causing cam to be out-of-time. - Inadequate engine compression.

TROUBLE DIAGNOSES

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 3 FUEL PUMP ELECTRICAL CIRCUIT

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 3 (Cont'd) FUEL PUMP ELECTRICAL CIRCUIT

1-1

Check fuel pump fuse. is it blown? No Probe fuel pu/p ckt AF66 with test light to earth. Ignition "off" for 10 seconds. Note light for 3 seconds after ignition "on".

,
No

Yes

Disconnect fuel pump relay. lgnition 'bff': Probe circuit A105 with a test light to the "+" battery terminal. Is test light on? Light stays "off" -or"on" steady. Yes
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Light "on" for 3 seconds. Then off.

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~ p p l y l 2 volts to fuel + pump by bridging ckt A105 to AF66 on fuel pump relay plug. Turn ignition on. Listen for fuel pump running at fuel tank. is pump running? Yes

Repair short to earth on circuit A105. Disconnect fuel pump electrical connector. Ignition off'! Probe circuit AF66 with a test light to the "+ " Battery terminal. Is the test light on? Yes

GO to on the next page.

No

I
Fuel Pump electrical circuit is ok. To complete testing of the fuel delivery pressure system. Continue to Diagnostic Procedure 4.

I
Check for: - Open in circuit AF66 - Open pump earth circuit 970 Reconnect fuel pump relay back probe circuit AF66 with test light still connected to "+" battery terminal. Is test light on? No

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Repair short to earth on Circuit AF66

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Both Ok

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Replace fuel pump

Reconnect fuel pump. Replace fuse. Ignition "on". Recheck fuse.

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Replace Relay

Ok Problem was either an intermittent short to earth in circuit AF66 or A105 -or- a defective fuse. Shorted fuel pump

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 3 (Cont'd)

0
lgnition "on".'Engine stopped. With fuel pump relay connected. backprobe relay connector circuit AF64 with a test light to ground.

l Backprobe relay connector circuit

I
A105 with testlight to earth. Testlight should light. Does it?

Yes

No

Repair open circuit AF64 to relay connector.

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Ignition "off" for 10 seconds. Backprobe relay connector circuit AF67 with testlight to earth. observe testlight as ignition is turned "on': It should light for 3 seconds. Then go out. Does it? Repair open in circuit A105.

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Ignition "off" for 10 seconds. Backprobe relay connector circuit AF66 with testlight to earth. Observe testlight as ignition is turned "on''. It should light for 3 seconds. Then go out. Does it?
I

Ignition "off". Disconnect fuel pump relay and ECM connectors. Check ckt AF67 for being open -or- shorted to earth.

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Circuit AF67

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Yes

No

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No

Fuel pump relay is operating correctly, repair open in circuit AF66.

Replace relay. will engine start?

I Check resistance acrossNay pins opposite connector circuits AF67 and AF64 should be more than 75 ohms. Is it?

If open circuit.

- repair wire and

continue back to on step previous page.
If circuit shorted to earth. - Repair short to earth and retest at step .

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Yes

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Yes

1
I
No

Continue back to step on previous Page.

I -

Continue back to Diagnostic Procedure 2.

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Replace ECM

Replace relay and retest at step .

With engine running, disconnect fuel pump relay. Engine should continue to run. Does it?

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Yes

1
No

l
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Check for "Open" in circuit AF66 or A105. If both circuits are ok.

TROUBLE DIAGNOSES

Notes:

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 4 FUEL DELIVERY SYSTEM
probe fuel pump test circuit AF66 with test light to earth. lgnition "off" for 10 seconds.

Note: Before consulting this chart ensure there is sufficient fuel in the tank.

Go to Diagnostic Procedure 3.
I

apply + l 2 volts to fuel pump by bridging ckt A105 to AF66 on fuel pump relay plug. Ignition "on". Listen for fuel pump running at fuel tank. Is pump running? Yes No

1I
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(1) - lgnition "off", remove + l 2 volts to fuel pump (Remove Bridge). (2) - Disconnect fuel pump electrical connector. Crank engine for 10 seconds to relieve any residual fuel pressure. (3) - lgnition "off'', connect fuel pressure gauge to hose between fuel rail and filter, reconnect pump electrical connector. (4) - Remove vacuum hose from pressure regulator. (5) - lgnition "on'', apply bridge to ckt A105 & AF66 on relay and allow pump to run 1 minute. This is to purge the lines of any air before pressure testing. (6) - lgnition "off" for 10 seconds. Remove bridge from fuel pump relay. (7)- Observe fuel pressure when ignition is turned "on". (8) - Pressure should be 280-320 kPa. & not continue to d r o ~ after pump stops r u n n i n ~(Pump should run about 3 seconds, then shut off.) See *Note Above. . Ok *Ilgnition ''on7', connect + l 2 volts to fuel pump (Bridge ckt A105 & AF66 on relay plug). and note fuel pressure. Connect a hand vacuum pump to the regulator vacuum fitting and apply 50 kPa (15" Hg) vacuum to the regulator. Note fuel pressure with vacuum applied to regulator. It should be S at least 15 kPa & than when no vacuum was applied. Is it?

'NOTE: It is normal for the pressure to drop slightly after the pump stops running, but should then hold steady and drop no furthe,: I If the engine is hot when this pressure test is performed. It is OK if the pressure very slowly begins to rise after the pump stops.

1I
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Pressure, but continues to drop after pump stops.

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Ignition "off" for 10 seconds. while you observe the pressure gauge, have a helper turn the ignition "on". When the pump stops running (after 3 seconds) and while the pressure is dropping, pinch shut the pressure (supply) hose at the fuel rail. Pressure now holds?? Yes
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Go to

@ on following page.
Check for: - Fuel pressure line restricted between pump and fuel rail. - Fuel supply line between tank and pump either restricted -orleaking (sucking air). - Restricted fuel filter. - Restricted in-tank fuel strainer.

No
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No trouble found. Ensure vacuum hose between regulator and intake plenum is connected, has no splits or kinks and is not restricted.

Replace Pressure regulator.

Check for leaks in the "Pressure-Side" of the fuel system. If ok, replace fuel Pump.

Ignition "off" for 10 seconds. while you observe the pressure gauge, have a helper turn the ignition "on". When the pump stops running (after 3 seconds), while the pressure is dropping, pinch shut the fuel hose. Pressure now holds??

Replace pressure regulator.

Locate and replace Leaking injectors.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 4 (Cont'd)

1
1
Fuel pressure less than 280 kPa. Make close ins~ection fuel of lines between h e l tank and fuel rail for restrictions.

Holds Pressure But/,

Less than 280 kPa more than 320 kPa -Or-

1
Fuel pressure more than 320 kPa. Disconnect fuel return line hose from "Return" fuel pipe next to fuel rail. Attach a piece of fuel hose to the "Return" fuel pipe. Insert other end of hose into an ao~roved aasoline container. .

1
I I

This includes: - Tank flexible hoses to vehicle steel lines. - Steel lines under vehicle. - Flexible hoses between steel lines and filter andlor fuel rail.

Apply +l2 volts to fuel pump (Bridge Relay) and note fuel pressure.

I
Not Ok Repair, then recheck All Ok Replace fuel filter, then Pressure still more than 320 kPa. Pressure now 280-320kPa. Locate and correct restricted fuel return line to tank.

regulator.

Less than 280 kPa.

Pressure now 280-320kPa and does not continue dropping when pump stops.

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Return to step on previous page.

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Ignition "off". Pinch shut the fuel return hose connecting to the "Return" fuel pipe behind fuel rail. Apply +l2 volts to fuel pump (Bridge Relay) and note fuel pressure.

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Replace pressure regulator and recheck pressure. If still low, replace in-tank fuel strainer.

Replace fuel pump and return to on previous step page.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 5 IDLE AIR CONTROL (IAC) SYSTEM.

r
IDLE AIR

F
l

In

- 42
41

mVUVE

16

ECM

44 .

"

-1' 1 11s

L----d

15

52 PIri CONNECTOR

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 5 IDLE AIR CONTROL (IAC) SYSTEM.

p56F-I

Ensure diagnostic bridge removed. Engine idling at normal operating temperature. A/C off. Record closed throttle idle rpm in "Park or or Neutral':

I
Ignition "off''. Disconnect IAC valve. Start engine. Note rpm in ParklNeutral.
NOTE: When performing this test. ensure that a standard low power testlight is used. Do not use a "high-wattage" testlight, as the ECM could be damaged. A high wattage testlight will either give inaccurate test results, damage the ECM, or both.

NO rpm increase.

I
Ignition "off". Reconnect IAC valve. Start engine. Note rpm in Park or Neutral.

1
T

t
No light, one or more terminals.

Disconnect IAC valve. Probe each IAC harness connector with test light to earth while switching ignition on and off continuously with engine stopped. I

I Does not return to idle Rpm listed in first step.

Returns to idle rpm recorded in first step.

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No trouble found - IAC ok.

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Steady light one or more terminals.

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Flashing light each terminal.

If idle problem exists. continue for further checks.

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1
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Check:

- - - -

Check for open or short to earth in circuit with no light.

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Check for faulty IAC terminals. If ok, replace IAC valve.

1

Disconnect ECM. Ignition "on". Check for short to voltage on circuits with steady light.

I i
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Repair and retest.

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,W 1(

For high idle sppeds check auxiliary air valve - pinch air hose to plenem. ~frpm drops: - Check for 12 volts and ground for the electric heater element. - Measure the heater resistance is in the range 30 to 50 ohms. - Remove the auxillary air valve and check that the blade is closed before the valve cools down. For vacuum leaks (causes fast idle speeds). For sticking or binding throttle shah, cables or linkages. sparkplugs for being excessively worn, or mis-gapped. Coolant sensor resistance. See Code 14. Tps operation. For dirty or loose battery cables or earth straps. ECM earth circuit terminals at the head bolts for being clean and tight. ParklNeutral switch operation. For high or low fuel pressure, or leaking injectors.

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Check resistance across IAC coils. (Shoul be more than 30 ohms between IAC terminals opposite harness connector terms. ''A" to "B" and "C" TO "D").
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1I
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al g f~ e

voltage.

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Check for faulty ECM terminals or IAC terminals. Check for 12 volts on ECM pins 25 and 50. IF all ok replace ECM.

1
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Replace IAC valve.

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NOTE: If IAC valve is removed from throttle body, then the learned offsets in the ECM must be cleared: - Ignition off, connect diagnostic bridge. - Run engine, switch ignition off and back on again when engine stops. Depress accelerator six (6)times, remove diagnostic bridge and switch ignition off.

I,

AIC relay control circuit failure. Generator output - if under 10 volts, ECM will not command the IAC to move. Throttle body - remove IAC and inspect I bore for foreign material or evidence of IAC - - - -in the bore. - valve "Dragging" I -

I I

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 6 IGNITION SYSTEM
NOTE: THIS CHART SHOULD ONLY BE CONSULTED AFTER PERFORMING DIAGNOSTIC PROCEDURE 2

5
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15 .1

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 6 IGNITION SYSTEM

Note: This chart should only be consulted after performing Diagnostic Procedure 2

lgnition key "on". Check voltage on AN63 at each coil

Check voltage on AN22, hall sensor power. (Should be battery voltage. min. 10.5~).

Check and repair circuit AN63

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Ok

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Ok

Low Voltage

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Check voltage at pin 9 of the ECM. (Should be battery voltage).

Check voltage on AN31 using a multimeter to earth (not AEO1). Do not use a test lamp.

1
Low Voltage

Approx. 5v or below lv
I

I
Check and repair open circuit on AEOl to ECM pin 34. -ordistributor defect. -orshort AN31 to AN22 or other power. Check and repair AN22.

I
Check and repair distributor defective. -orAN22 short circuit to earth. -orECM defect.

Continue monitoring voltage on AN31. Briefly crank over the engine. During or after cranking.

1
Changed voltage. No change of voltage.
.
-

I
Check voltage on AN01 and AN02 (Each in turn) during cranking. Does voltage vary during cranking.

Distributor defective or AN3 1 short circuit to earth.

I
I
Changing Voltage.

I
No Change

I
Check voltage on "OC" terminal of each driver module.
I

I
Check and repair AN01 or AN02 as applicable. -orECM defect.

- Driver module. - Ignition coil.

Check and repair

- Connection problem coil to driver module. -orCoil defect.

Check and repair

a
No Power

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 7 RADIATOR FAN CONTROL
NOTE: IF CODES 14.15 OR 55 ARE DISPLAYED, ATTEND TO THEM FIRST.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 7 RADIATOR FAN CONTROL
Note: If codes 14, 15 or 55 are displayed, attend to them first.

Ignition off. Remove temperature sender connector. Bridge the two sockets in the connector (AN17 and AN20). Both fans should come on at high speed when the ignition is turned on.

Insert the diagnostic bridge. Run the engine. Switch ignition off and back on again when engine stops. High speed fans only should be operating.

/
Remove diagnostic plug, reconnect temperature sender.

L
Repair fault in the high speed fan circuit.

Check the fan relays both high and low speed and replace if necessary. Check the wiring to 12 volts on the relays, the wiring from relays to the fans and from the fans to ground, and repair if necessary. Check AR05 and AR02 for open or short circuits and repair if necessary. Check the fans operation and replace if necessary. If all the above are ok then replace ECU.

Run the engine at 3000 rpm for 5 minutes or until the water temperature reaches greater than 95OC. The low speed fans should come on.

Check for intermittent fault.

Repair fault in the Low speed fan circuit.

TROUBLE DIAGNOSES

I CA20E I

DIAGNOSTIC PROCEDURE 8 TORQUE CONVERTER LOCK-UP RELEASE SOLENOID. (AIT MODELS ONLY).
Note: If codes 14, 21, 22 or 55 are displayed, attend to them first.

Run engine and bring to normal operating temperature. With no accelerator applied measure ECU pin 37.

I :
Less than 2 volts.
I

I
More than 2 volts.
I

Check for short circuit on AR15. Check for 12 volts supply to lock-up solenoid. Apply accelerator to run the engine at 2000 rpm. Measure the voltage at ECU pin 37.

Check AR15 for short circuit to 12 volts

l 1
I

l l

More than 8 volts.

I

I
I

Check lock-up solenoid for connection to 12 volts. Check solenoid for shorted winding and replace if faulty. If all the above ok, unplug connector. If pin 37 still measures more than 2 volts replace ECM.

Replace lock-up solenoid.

Check AR15 and repair if necessary. Check solenoid for open circuit and replace solenoid if necessary. If all above are ok then replace ECM.

LOCK UP CONVERTER SOLENOID

TROUBLE DIAGNOSES
DIAGNC STlC PROCEDURE 9 AIR CONDITIONER CLU' %H CONTROL (WHERE A/C IS FITTED).
With engine running, check ECU pin 36 while switching AIC on.

I
Less than 2 volts with AIC switch on.
I

I
More than 2 volts with AIC switch on. Check AIC fuse. Check Hi and Lo pressure switch. Check thermo amp.

Measure voltage at ECU pin 10 with AIC switched off this will be 12 volts. If not check ignition fuse. Now switch AIC on and measure ECU

More than 2 volts.

Less than 2 volts.

.
I

Check AN101 for short to 12 volts. If ok, replace ECM.

Check AIC relay. Check AIC compressor.

10

ECM

AN 141

AC REOUEST

I 7

m m M o AMP

LOW AND HIGH

PRESSURE WITCH

I- -

I -

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 10 CODE 11 ENGINE SPEED SENSOR (DISTRIBUTOR).

ECM terminals 7 and 34 are the distributor signal outputs. It is a square wave signal, and the signal must be present for the ECM, to issue spark and fuel pulses. Code 11 is set if the engine is cranked but no distributor signal is received by the ECM.

lgnition off, clear codes. Connect diagnostic plug. Crank engine. Leave key "on".

I
Code 11
I

l
No Code 1 1 I Possibly intermittent. Check for poor electrical connection.

I I

Connect a voltmeter across pins 7 and 34 of ECM. Set voltmeter to 2 volt W C " range. The voltage should read more than 0.7 volts AC whilst cranking and normally reads 1.4 volts AC.

Voltage

> 0.7 volts.

I

/I

Check connector and terminals 7,34andgatECM. If ok replace ECM.

Disconnect connector at distributor. Set voltmeter to 20 volt "DC" scale. Ignition on. Read voltage at pin 9 of ECM, it should read > 11 volts.

I
Voltage

II I I
>
11 Volts. Voltage

< 11 volts.

Supply voltage to engine speed. Sensor ok. Check circuit AN22 for open circuit, if ok replace sensor in distributor.

Check circuit AN22 for short Circuit if ok replace ECM.

DISTRIBUTOR ASSEMBLY

HALL SENSOR ENGINE SPEED

TROUBLE DIAGNOSES
DlAG UOST CODE 13 - OXYGEN SE1 ISOR
CODE 13 IS SET IF:
(1)

SOCEDURE 11 :SIGNAL INDICATES OPEN CIRCUIT).

The engine has been running for a minimum number of revolutions (ie 2000 revolutions). Equivalent to 1 minute at 2000 rpm.

AND 70 degrees. (2) The engine temperature AND (3) The engine is not operating at idle. AND The system is operating in closed loop zone (4) AND (5) The engine R P M is greater than 1300. AND (6) The oxygen sensor stays in the mid-range for more than 10 seconds

>

r---02 SENSOR

Engine at normal operating temperature. Connect diagnostic plug. Run engine at approx. - 2000 rpm for 2 minutes and note ECM light.

I DIAGNOSTICS INPUT

--J

I
Flashing open loop.

Ignition "off". Disconnect oxygen sensor and ground lead AN18 to earth. Start engine and hold rpm at 2000 while watching ECM light. It may flash "Open Loop" for up to 30 seconds. But should then go out. (Error code 44, lean could be set by this test). Does it?

Flashing closed loop. m I Stop engine Ignition on. Ensure any other codes are noted. Clear codes. Remove diagnostic plug. Run engine at approx. 2000 rpm for two minutes and note ECM light.

I
Light stays "off" Code 13 is intermittent. If no other codes were stored. Check for an intermittent fault. Light came "on"

plug. Note code and refer to applicable code chart.

l
Yes
I

Ignition off. Check for open O2 sensor earth circuit AE16 between ECM terminal 6 and engine earth. If ok, it is a faulty oxygen sensor connector. Or sensor. See below.

Ignition off. Check for open O2 sensor signal circuit AN18. Check for open 0 sensor earth circuit AE16 , between ECM terminal 6 and engine earth. Check for good continuity from engine block to battery negative. Repair if bad. If ckt's AN18 and AE16 are both ok, it,is a faulty ECM.

NOTE: Oxygen sensor contamination - If fuel containing lead or silicone is used, or engine repairs using unapproved RTV gasket sealer are performed, the sensor may be contaminated. It may send a "false" rich exhaust indication to the ECM and the ECM will attempt to drive the fuel system lean to compensate. Poor driveability or a malfunction code 13 could result. If this happens, the sensor will need to be replaced, but every affempt to locate the source of contamination should be pursued.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 12 - WATER TEMPERATURE SENSOR (VOLTAGE LOW).
Note: This chart assumes coolant level is correct.
CODE 14 I SET IF: S The WTS indicates the temp. (1)

I CA2OE I

CODE 14

> 130 degrees Celcius.

AND
(2) This condition exists for more than 25.5 seconds with the engine running.

lgnition "off", clear codes. Diagnostic bridge removed. Start warm engine and run for 1 minute, or until the ECM light comes on. lgnition "on': engine stopped bridge diagnostic test terminal and note code.

I
Code 14

I I

1
No Code 14

I
Disconnect coolant sensor connector. lgnition "on'', engine stopped. Check voltage between harness connector terminals circuits AN17 and AN20.

I
Problem is intermittent. If no other codes were stored. Look for poor electrical connection in WTS circuit.

Over 4 volts

I
I

Under 4 volts

I
Disconnect ECM connectors. Check signal circuit AN17 for short to circuit AN20 or to chassis earth.

Check resistance across coolant sensor terminals. See table for approximate temperature to sensor resistance values.

I
If circuit AN17 is ok, replace ECM.

Check for intermittent or loose terminals in sensor harness connector, or for the 2 terminals shorting together when connectedto the sensor If ok, replace ECM.

Replace Sensor.

Coolant sensor temp. to resistance values (approximate).

I
27

ENGINE COOLANT SENSOR

OHMS
146 188 247 444 1,191 1,716 2,523 5,860 9,307 15,258

ECM

"F:
43
AN 115

I DIAGNOSTICS INPUT

L _ -

Clear codes, run engine for 2 minutes and recheck for codes.

ES-54

TROUBLE DIAGNOSES

CODE 15

(1)

DIAGNOSTIC PROCEDURE 13 WATER TEMPERATURE SENSOR (VOLTAGE HIGH).

The WTS indicates the temp.

CODE 15 IS SET IF:

<

-20 degrees Celcius.

AND

(2) This condition exists for more than 25.5 seconds with the engine running.

Ignition "off': clear codes. Diagnostic bridge removed. Start warm engine and run for 2 minutes, or until ECM light comes on. lgnition "on'', engine stopped bridge diagnostic test terminal and note code.

I
Code 15

I
1 I

i
No Code 15
Problem is intermittent. If no other codes were stored. Look for poor electrical connection in WTS circuit.

1 I

Disconnect coolant sensor connector. Ignition "on': engine stopped. Check voltage between harness connector terminals circuits AN17 and AN20.

I
1

Repair short to voltage on circuit AN17.

Check resistance across coolant sensor terminals. See table for a ~ ~ r o x i m a t e temperature to sensor residance values. I

Probe coolant sensor harness connector circuit AN17 with a voltmeter to earth. Should be 4-6 volts.

Not Ok Check for intermittent or loose terminals in sensor harness connector. Terminals may not be connecting to sensor when connected.

Sensor.

Check for open Circuit AN20. If ok, check ECM connector terminals. If ok, r e ~ l a c e ECM.

Check for open circuit AN17 If ok, check ECM connector terminals. If ok, replace ECM.

If ok, replace ECM.

I
Coolant sensor temp. to resistance values (approximate).

I
27

I
ECM
-

ENGINE COOLANT SENSOR

O C 110 100 90 70 40 30 20 0 -10 -20

OHMS 146 188 247 444 1,191 1,716 2,523 5,860 9,307 15,258

1
I DIAGNOSTICS INPUT

- A

Clear codes, run engine for 2 minutes and re-check for codes.

TROUBLE DIAGNOSES

CODE 21

DIAGNOSTIC P OCEDURE 14 F THROTTLE POSITIOI' SENSOR (TPS) (VOLTAGE HIGH).

NOTE: CODE 21 IS SET IF: No airflow meter faults exist (Codes 32 or 33). AND Load is less than 200mg of airlstroke. AND Rpm is less than 1600 RPM. AND TPS voltage is greater than 2.5 volts. AND All these conditions exist for 2 seconds.

3 2
28

AN43

'A

ECM
Engine at normal operating temperature. Diagnostic bridge removed. Ignition "off". Clear codes. Start engine and idle for 1 minute, or until ECM light comes on.

AE 101

THROTTLE POSITION SENSOR

AN 114 AN 115

11
L

I DIAGNOSTICS INPUT

- 1

I
Light on

I
I
Code 21 is intermittent. Look for poor electrical connection ' in TPS circuit.
I

I
lgnition "on". Engine stopped. Bridge diagnostic terminal and note codes.

Any other code. See applicable chart. Diagnostic bridge removed. Ignition "off". Clear codes. Disconnect TPS sensor. Start engine and idle for 2 minutes, or until ECM light comes on. Ignition "on': Engine stopped. Bridge diagnostic terminal and note code.

I I

I I

I
Code 22

I l

Probe TPS harness connector circuit AN34 with test light to 12 volts.

I I

Light

I
circuit AN34.

Ignition "off". Disconnect ECM. Ignition "on". Probe harness connector circuit AN44 with a voltmeter to earth.

.
I

I
Less than 1 volt. Over 1 volt.

connector terminals. If ok, replace TPS. See note below.

Note: The TPS is not adjustable.

The reading at idle is used as "0% throttle':

between circuits AN43 and AN44. If ok, replace ECM.

Clear codes, run engine for 2 minutes and re-check for codes.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 15 CODE 22 - THROTTLE POSITION SENSOR (TPS) (VOLTAGE LOW).

NOTE: CODE 22 IS SET IF: No airflow meter faults exist (Codes 32 or 33) AND Engine is running. AN D TPS voltage is less than 0.1 volts. AND All these conditions exist for 2 seconds.

2 28

-AE 101

ECM

Diagnostic bridge removed. lgnition "off". Clear codes. Start engine and idle for 1 minute, or until ECM light comes on.

AN 115

THROTTLE POSITION SENSOR

DIAGNOSTICS INPUT

a
Light on

lgnition "on''. Engine stopped. Bridge diagnostic terminal and note code.

I
Light off Code 22 is intermittent. Look for poor electrical connections in TPS circuit.

I
Code 22
I
I

I I

Diagnostic bridge removed. lgnition "off". Clear codes. Disconnect TPS, then Start engine. With engine running, jumper AN43 and AN44. Together at TPS harness connector. Ignition "on". Engine stopped. Bridge diagnostic terminal and note codes.

I I

I
Code 22 only
I

Remove jumper from AN43 and AN44. Check voltage between harness connector AN34 and AN43 using digital voltmeter.

I
4-6 volts

I
Below 4 volts

I
Ignition off. Disconnect ECM. Check AN44 for open or short to earth.

I
Ignition "off': Disconnect ECM. Check AN43 for open or short to earth.

I
Circuit AN44 ok.

1
Circuit AN44 not ok.

I
Circuit AN43 ok.

i
Circuit AN43 not ok.

I
Check CM connector terminals. If ok, replace ECM.

I
Repair open or short in circuit AN44.

I
Check ECM connector terminals. If ok, replace ECM.

1
Repair open or short in AN43.

Note: The TPS is not adjustable. The reading at idle is used as "0% throttle".

Clear codes, run engine for 2 minutes and recheck for codes.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 16 CODE 23 - NO START SIGNAL
Note
1. This chart assumes that the engine will start.

2.

Code 23 is recorded and stored if the CM recieves distributor signals without having firstly recieved a start signal.

3. This code will be recorded if the vehicle is push started.

I
I
Code 23

Ignition off, clear codes. Bridge diagnostic plug. Start engine.

I
No Code 23

I
Connect voltmeter to connector pin 33 of ECM. Observe voltage whilst cranking.

I
Intermittent problem. Vehicle was possibly push started.

I
I
> 5 volts.
I
l

Voltage.

< 5 VOLTS.
I

Voltage

Check ECM terminals and harness terminals.

Check harness for open circuit or short circuit.

33

A N 35

44

A N 114 A N 115

-1

13

I DIAGNOSTICS INPUT
L

Clear codes, run engine for 2 minutes and re-check for codes.

ES-58

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 17 CODE 31 - PARKINEUTRAL SWITCH (AIT MODELS ONLY)
With the diagnostic plug inserted and the engine having been run an error code 31 is recorded by the ECM when the ignition is again turned on This error code 31 is cancelled as soon as the transmission is engaged into 1, 2, drive or reverse with the diagnostic plug inserted and the engine running.

C A -

Ignition off, clear codes. Bridge diagnostic plug. Run engine, switch ignition off.

I
I

Code 31
I

Disconnect connector at transmission connect a jumper between AN36 and

Possibly intermittent look for poor electrical connection in PIN switch circuit.

I
Code 31

I
Check terminals and connectors. Check parklneutral switch harness for open circuit. I

I
~arnbss and ECM ok. Replace parklneutral switch.

If ok replace ECM.

I*.

I
PARKINEUTRAL SWITCH AF 1 2 i A N 36

ECM
44
AN 114 AN 115

l DIAGNOSTICS

43

!
L

I
- J

INPUT

Clear codes, run engine for 2 minutes and re-check for codes.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 18 CODE 32 - AIR FLOW METER (VOLTAGE LOW).
Wiring Circuit shown with Code 33.
CODE 32 I SET IF: S
No TPS errors have been flagged AND 1.9 volts (2) If the air flow sensor voltage is AN D (3) Throttle is not closed while vehicle moving AND (4) The above condition occurs for more than 2 seconds
(1)

<

Clear codes. lgnition "off'', clear codes. Diagnostic bridge= inserted. Start the engine. Idle for 1 minute or till ECM light comes on. Stop engine and insert diagnostic bridge. lgnition "on", engine stopped, read code.

I
Code 32 I Leave idling engine. Check voltage on AN16 to AN15 using multimeter at AFM terminals 3 and 2. Is the voltaae-?
I

Problem is intermittent check for poor electrical connection in AFM circuit.

Check voltage across ECU terminals 32 and 30. Is the voltage-?

Stop engine. Check for short on AN16 to ground.

lgnition "on'', not running. Check voltage on AN139 to ground AN127.

Repair AN139 Fix short circuit. ECM faulty. circuit.

Continue to monitor voltage on AN16 to AN15. Rev engine to 2000-3000 rpm. Does voltage rise.

Check for: Air leaks. ECM faulty.

AFM faulty.

Clear codes, run engine for 2 minutes and recheck for codes.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 19 CODE 33 AIR FLOW METER (VOLTAGE HIGH).

CODE 33 IS SET IF: Engine is running AND (2) Air flow meter voltage 4.4 volts. AND Both these conditions exist for 5 seconds.
(1)

>

Clear codes. lgnition "off". Remove diagnostic bridge. Start engine and idle for 1 minute or until "ECM" lamp comes on. Stop engine. Connect diagnostic plug. lgnition "on". Note code.

a
Code 33 Clear codes. lgnition "off". Remove diagnostic bridge. Disconnect AFM sensor connector. Start engine and idle for 1 minute or until "ECM" lamp comes on. Stop engine. Insert diagnostic bridge. lgnition "on''. Note code. Code 33

Problem is intermittent. Look for poor electrical connection in AFM circuit.

i
Check for short to voltage in circuit AN16.

I
Check for open in earth circuit AN15.

I
If circuit AN16 is ok, replace ECM.

I
If circuit AN15 is ok, replace AFM.

AIR FLOW SENSOR

1 ;l

CENTRAL EARTHING POINT

AN114 AN 115

r - 1

I DIAGNOSTICS INPUT
- - _ I

Clear codes, run engine for 2 minutes and re-check for codes.

ES-61

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 20 CODE 34 -AIR FLOW METER BURN-OFF (VOLTAGE LOW).

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 20 (Cont'd) CODE 34 - AIR FLOW METER BURN-OFF (VOLTAGE LOW).
If burnoff is enabled,then halfway through the burnoff the voltageof the AFM sensor 2.2 volts then code 34 is set. is examined. If this voltage

<

Note: If code 32 is also displayed then attend to that chart first. Note: If battery voltage is not available at CM pin 51, burn-off will not occur. however no code 34 will be set.

To force a burn-off. Connect diagnostic plug, start engine. ECM lamp shows the state of the oxygen sensor. Switch engine off and when engine stops switch ignition back on again immediately. Depress accelerator five times. The ECM lamp will be on when the accelerator is depressed and off when the accelerator is released. Remove the diagnostic plug. After the ignition is switched off, a forced burn-off will occur under normal circumstances within ten seconds of switching the ignition off.

I
Continue measuring the air flow meter voltage (ECM pin 32) when the ignition is switched off in the last step above.

I
I

Less than 2.2 volts.

I
Repeat the force-a-burn-off procedure and measure the air flow meter burn-off control (Pin 4 of the AFM) while switching off the ignition.

for one second.

connections in AN139,

I
Less than 8 volts.

I
More than 8 volts for 1 second after ignition off. Repeat force-a-burn-off and measure ECM pin 38 while switching off ignition.

I
Disconnect airflow meter connector. Repeat the force-a-burn-off procedure and measure the voltage at connector AN38 while switching off the ignition.

Less tha;

8 volts.

Check AN38 for

More than 8 volts for 1 sec. after ignition off.

volts for one second after

Check AN04 for open or short circuits. If ok replace ECM.

If ok, replace ECM. repair loom. Repeat force-a-burn-off and measure air flow

Check air flow meter relay for faulty operation. Check for short or open circuit in AN139.

Clear codes, run engine for 2 minutes and re-check for codes.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 21 CODE 43 VEHICLE SPEED SENSOR (VSS).

piiq iii

The vehicle speed sensor provides a square wave voltage output varying from 0 to 12 volts. Code 43 is always set when the ignition key is first turned on, while in diagnostic mode, engine running. The error is cleared when the vehicle speed exceeds (approx.) 5 kmlhr. While indiagnostic mode, engine running.

Ignition off, clear codes. Connect diagnostic plug. Start engine. Drive vehicle and achieve a speed of at least 10 kmlhr. Turn off engine and when engine stops, turn key to on position.

a
Code 43 Connect a voltmeter across pins 8 and 35 of ECM. (8 is signal). Put the car in neutral and observe the voltage of the signal. Roll the car forward one metre and observe if the voltage changes. (From 0-12 volts or 12 volts -0).

a
No Code 43

Check for poor electrical

Voltage Changes.
I

Voltage does not Change. I Disconnect connector to speed sensor. Probe across pins 8 and 35 of ECM with voltmeter.

Check connector terminals 8 and 35 on ECM and connector.

Go to

@ on following page.

T
Approx. 12 V .
AF 178

Go to

@ on following page.

I
< 2 volts.

7:
,

HALL SENSOR

SIGNAL

VEHICLE SPEED

ECM

O A G N O I C S INPUT

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 21 (Cont'd) CODE 43 (CONTINUED)

1-

Disconnect ECM. Probe circuit AF178.

< 2 volts

z 5
1
Approx. 12 volts

Repair ckt. AF178.

Reconnect smallest plug to ECM. Probe across ECM pins 8 and 35.

< 2 volts
Replace ECM.

Approx. 12 volts Replace speed sensor.

Clear codes, run engine for 2 minutes and re-check for codes.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 22 CODE 44 LEAN EXHAUST INDICATION.

Code 44 is set if conditions exist as for code 13 but O2 sensor voltage remains low for more than 50 seconds.

ENGINE EARTH

ENGINE EARTH

Engine at normal operating temperature. Connect diagnostic bridge. Run engine at approx 2000 rpm for 2 minutes and note ECM light. Refer page ES-25 to read ECM light.

ECM

DIAGNOSTICS INPUT
L

- J

Light staying "off" more than "on': or flashing "open loop".

staying on and off approximately

I
Ignition "off". Remove diagnostic bridge. Disconnect oxygen sensor. Start engine and hold rpm at approx. 2000 for at least 30 seconds. What does ECM linht do? Code is intermittent. If no additional codes were stored, look for poor electrical connection and see below.

I
Flashing open loop. Check the following:

I
Light went off for at least 30 seconds. Ignition "off". Disconnect ECM connectors. Check O2signal circuit AN18 for a short to earth. If circuit AN18 is shorted to earth, repair wire. If circuit AN18 is not shorted to earth, it is a defective ECM.

- Low fuel pressure. - Contaminated fuel. - Vacuum leak on inlet system. - Exhaust manifold leaks
Ahead of O2Sensor.

- Faulty airflow sensor. - O2sensor metal vent

covered with mud, etc. - Lean injectors.

Flashing normal closed loop, light flashing approx.

I
Clear ECM learned parameters.

Code intermittent Possible past rich operation of the engine, learning factor overcompensating after prior fault removed. - High fuel pressure. - Leaking injector. - Cannister purge. - Coolant sensor. - TPS sensor. - Air flow sensor. - Failure to clear system parameter after prior repairs.

I
Reconnect O2sensor. Repeat step (1) above.

I
I
O sensor faulty. n

I I I
I

I
Clear codes, run engine for 2 minutes and reccheck for codes.

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 23 CODE 45 - RICH EXHAUST INDICATION.
Code 45 is set if condit~ons exist as for code 13 but 0 sensor voltage remains high for more than 50 seconds. 2

I
I

Engine at normal operating temperature. Connect diagnostic bridge. Run engine at approx 2000 rpm for 2 minutes and note ECM light.

I
I

Light staying "on" more than "off'', or flashing "Open Loop''.

I

Flashing closed loop, with light staying on and off approximately the same amount of time. Code is intermittent. If no additional codes were stored, look for poor electrical connection and see below.

Ignition "off". Disconnect diagnostic bridge. Disconnect oxygen sensor and ground circuit AN18. Start engine, hold rpm at approx. 2000 and note ECM light.

ECM light went off for at least 30 seconds.

Light staying '!on1' more than "off7', or flashing "Open Loop".

A rich exhaust condition exists. Check for the following: - High fuel pressure. - Leaking injector. - Air flow meter. - Canister purge. . - Coolant sensor circuit. - TPS sensor operation.
I

Ignition "off". Disconnect ECM connectors. Check 0 earth circuit AE16 for aood continuitv , . to engine earth. (Must have a clian flawless connection to the engine rear head bolt). Check for good continuity from engine earth to battery minus terminal. If either AE16 or engine to battery connections are poor, repair circuit. If both good, replace ECM.

I
I

Clear ECM learned parameters. Repeat from step (1) above.

I
I

ECM light "off" or mostly "off".

I
(

I
Faulty oxygen sensor.

Flashing normal closed loop, light flashing on and off approximately the same amount of time. Code intermittent.

* Possibly past lean operation causing learned

I I

compensation towards rich.

I I I

- Low fuel pressure. - Contaminated fuel. - Vacuum leak on inlet. - Exhaust leak ahead of 0 sensor. , - Lean injectors. - Air flow meter.

Clear codes, run engine for 2 minutes and re-check for codes.

ES-67

TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 24 CODE 55 ENGINE CONTROL MODULE (ECM)

J
lgnition off. Insert diagnostic bridge, clear codes.

ignition off.

Remove diagnostic bridge. Run engine for 1 minute or until ECM light comes on.

or code 12. Check relevant chart or code 12 indicates no fault recorded.

Note: When a Code 55 is present. 1. Air conditioner will not operate. 2. Fans will be on after the engine has been run irrespective of temperature. 3. Transmission lock-up release solenoid is disabled under all conditions.

Clear Codes, run engine for 2 minutes and re-check for codes.

TROUBLE DIAGNOSES

Notes:

TROUBLE DIAGNOSES
Electrical Components lnspection
ECM Terminal Voltage lnspection

'Data are reference values Terminal No. 1 2 Item Engine temperature sensor TPS Signal TPS Supply Not connected 02sensor signal 02sensor ground Hall sensor signal Engine running (warmed up) Ignition Switch 'ON" Remove fuel pump fuse and crank engine 8 Vehicle speed signal Drive vehicle slowly or raise vehicle and rotate both front wheels 9 Hall sensor supply Ignition 'ON" Engine running - both A/C and fan switch "ON" -either A/C or fan switch "OFF" Battery voltage Switching 0-12v -0.5 to 1 . 5 ~ Condition Engine running Ignition Switch "ON" Ignition Switch "ON" "Data 0-5v (varies with temperature) 0.3-4v 4.6-5.2~

3
4

6
7

0 volts
Switching 0-5v

10

A/C clutch relay (where fitted)

Less than 2.1 volts Battery voltage

11 12 13 14

Not connected Burn-off control Fuel pump relay Fan relay - low speed Engine running Ignition 'ON" Engine running 0 volts Battery voltage for 3 secs. only Battery voltage -fans "OFF" Less than 2.1 volts -fans 'LOW" Switching >8.5v to <l .8v

16 l5

IAC valve output

Engine running

17
18 19 20

Not connected Spark output -exhaust Spark output -inlet Not connected Not applicable Not applicable Not applicable Not applicable

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)

p%q
'Data are reference values

Terminal No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 ECM lamp Not connected Not connected ECM earth Ignition Injector drive

Item

Condition

'Data Battery voltage - lamp "OFF" Less than 1.5 volts - lamp "ON"

Engine running

Ignition "ON" Ignition "ON" Not applicable Ignition "ON"

~-

0 volts Battery voltage Not applicable 0 volts

P

Engine temperature sensor ground TPS ground ParklNeutral switch* Air flow sensor signal ground Air flow sensor shield ground Air flow sensor signal Start signal Hall sensor ground Vehicle speed sensor ground

Ignition 'ON" lgnition "ON" in NeutralJPark except NeutralJPark Ignition "ON" Ignition "ON" Ignition "ON" engine stationary engine running Engine cranking Engine running Engine running Engine running

0 volts

0 volts' Battery voltage

0 volts 0 volts 1.6 volts 2 to 4.5 volts Battery voltage 0 volts 0 volts

36

A/C request

- both A/C and fan switch 'ON" -either A/C or fan switch 'OFF"
Lock-up enable -solenoid "OFF" Lock-up disabled -solenoid "ON" Burn-off forced (refer ES-24)

. Battery voltage

0 volts Battery voltage Less than 2.5 volts Battery voltage for 1 second, 7 seconds after key 'OFF" Battery voltage -fans "OFF" Less than 2.1 volts -fan high

37

Torque converter lock-up

38

Air flow meter burn-off Fan relay - high speed Not connected

39 40

Engine running

'Note: A high voltage transient may occur when relay is switched off.

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)

W
"Data are reference values

Terminal No.

Item

Condition

"Data

41

42
43 44 45 46 47 48 49

IAC valve output

Diagnostic request ground Diagnostic request Not connected Not connected Not connected Not connected

Engine running Ignition "ON" Ignition 'ON"

Switching >8.5v to < 1 . 8 ~

0 volts
5 volts, 0 volts with bridge inserted

ECM earth
Ignition Battery input Injector driver

Engine running Ignition 'ON" Ignition 'OFF" Not applicable

0 volts
Battery voltage Battery voltage Not applicable

50

51
52

ECM and harness terminal layout

ENGINE CONTROL UNIT

EGI HARNESS

TROUBLE DIAGNOSES

F 1

Electrical Components Inspection (Cont'd)

Hall Sensor (Distributor)
With ignition "OFF", disconnect and remove distributor from vehicle and test according t o the procedure below.

1. Connect Hall sensor, voltmeter and 1.5k ohm resistor according t o wiring diagram. 2. Ensure battery is fully charged and rotor trigger vane is outside air gap. Voltmeter must register 400mV ( 0 . 4 ~or less at 20C. ) 3. Place rotor trigger vane inside air gap. Voltmeter must register at least 1 1 . 0 at 20C. ~

Air Flow Meter With ignition "OFF", disconnect and remove air flow meter from vehicle. 1. Apply battery voltage t o terminals 2 and 5. 2. Measure voltage between terminals 3 and 2. Voltage approximately 1.6 5 0 . 5 ~ . 3. Blow air through air flow meter and observe the voltage change between terminals 2 and 3. Voltage approximately 2-4v. 4. Reconnect air flow meter t o vehicle harness. Do not refit meter at this stage. 5. Activate forced burn-off as detailed on page ES-24. 6. Visually inspect hot wire t o ensure it heats t o a red glow.

TROUBLE DIAGNOSES

q
k

Electrical Components Inspection (Cont'd)

Ignition Coil and Power Transistors
With ignition "OFF", disconnect ignition coils and power transistors. Check power transistor continuity as shown.

W
L

1 2 3

-n.
/'
J

----

---

--7

\
l

HT

Check coil resistance as shown Primary winding resistance: Between - and terminal 0.58 to 0.74 ohms at 20C Secondary winding resistance: '~etween and HT terminal 8,000 to 1 1,000 ohms at 20C Note: Resistance will vary with coil temperature.

Throttle Position Sensor (T.P.S.) With ignition "OFF", disconnect TPS and check resistances as shown. Resistance between: Terminals A and C 3,7000 to 6,300 at 20C Resistance between: Terminals B and C depending on throttle position 1,000 to 6,300 ohms at 20C Note: Resistance will vary with throttle body temperature.

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
Idle Air Control (IAC) Valve

I CAPOE 1

W i t h ignition "OFF", disconnect IAC valve and check resistances as shown. Resistance between: Terminals A and D 48.5 t o 60.0 ohms at 20C Resistance between: Terminals B and C 48.5 t o 60.0 ohms at 20C Note: Resistance will vary with throttle body temperature.

Fuel lnjector With ignition "OFF", disconnect injectors and check resistance as shown.
Resistance between terminals: 15.5 t o 1 6.5 ohms at 20C Note: Resistance will vary with throttle body temperature.

Fuel Pump and lnjector System Relays With ignition "OFF", remove relay and test as shown.
Check continuity between terminals @ and Condition
12V direct current supply @ between term~nals and @ No supply

0.
Continuity

Engine Control Relay With engine "OFF", remove relay and test as shown.
Continuity Between @and
12V direct current supply between terminals @and @ No supply

Condition

Between @and

No

Yes

Yes

No

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
Water Temperature Sensor
Remove sensor and test its resistance value in response t o temperature change.

Temperature "C 100 90 70 40 30 20

Resistance Value 188 247 444 1,191 1,716 2,253

(approximate)

.
12v Supply
7 V Signal

~r&nd

Vehicle Speed Sensor (VSS) 1. Remove VSS from transaxle. 2. With sensor connected t o vehicle harness and ignition "ON", connect a voltmeter t o confirm 12v supply. 3. With a ohmmeter, check ground circuit for continuity. 4. With voltmeter connected t o signal line, rotate the pinion and confirm voltage changes from Ov t o 7 . 5 (approx.) 10 times per ~ sensor revolution. Air Regulator 1. Remove connecting hoses and visually check shutter operation. Before starting at 20C - Open. After warm up - Closed. 2. Disconnect air regulator harness connector. 3. Check regulator internal resistance as shown. 4. Connect a voltmeter across the harness plug. Turn ignition "ON", voltmeter should read 12vfor approximately 3 seconds after key "ON".

Resistance: Approximately 70R

E.C.C.S. SERVICE OPERATIONS

Release Fuel Pressure
1. Remove fuse for fuel pump.

1-

2. Start engine. 3. After engine stalls, crank engine two or three times to make sure
that fuel pressure is released. 4. Turn ignition switch off and install fuse for fuel pump.

Fuel pump fusei

\
SEF832G

Checking and/or Adjusting Ignition Timing 1. Ensure vehicle is fully warmed up, and all load (i.e.) headlights, air conditioner, etc., are turned off. 2. Enter vehicle into Field Service Mode (refer ES-24). 3. Connect timing light and inspect ignition timing. 4. If required, loosen distributor mounting boltsand rotate distributor body until timing is correct. Timing: 5"B.T.D.C. 5. Disconnect timing light. 6. Remove diagnostic bridge. Checking Idle Speed Caution: Engine idle speed is ECM controlled via the IAC valve. The throttle butterfly position is factory set. To check idle speed 1. Disconnect inlet coil harness (adjacent to coil) and connect adaptor harness (E7 1 18-2) in series. 2. Connect external tachometer to adaptor harness. 3. Ensure vehicle is fully warmed up, and all load (i.e.) headlights, air conditioner, cooling fans, etc., are turned off. 4. Check idle speed. M/T - 800 rpm A/T - 800 rpm ("P" range)/750 rpm ("D" range) 5. If idle speed is not to specification, do not adjust throttle butterfly. Refer to diagnostic procedure 5.

E.C.C.S. SYSTEM
Wiring Schematic

\c!
!&E LIR
VNYE I

m IS
Yl l W

ECU

E.C.C.S. SYSTEM
Wiring Schematic (Cont'd)

ECU

I I

NR INJECTORS

AIR R 501MR W

E.C.C.S. SYSTEM
Wiring Diagram
Engine Management System

ENGINE CONTROL UNIT

E.C.C.S. SYSTEM
Wiring Diagram (Cont'd)
Ignition System

p% i j

ENGINE CONTROL UNIT

PRECAUTIONS
E.C.U. Do not disassemble E.C.C.S. control unit. (E.C.U.) Do not turn diagnosis mode selector forcibly. If a battery terminal is disconnected, the memory will return to the ROM value. The E.C.C.S. will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a problem. Do not replace parts because of a slight variation. INJECTOR Do not disconnect injector harness connectors with engine running. m Do not apply battery power directly to injectors; otherwise Do not apply undue force to mounting bracket. Before connecting or disconnecting E.C.U. connector, make sure red LED is off after turning ignition key off. Always install the properly specified E.C.U. on car; otherwise, erroneous engine operation may result.

pq
WIRELESS EQUIPMENT When installing a C.B. ham radio or a mobile phone, be sure to observe the following, as installation location may affect the electronic control systerns. 1) Keep antenna as far as possible away from electronic control units. 2) Keep antenna feeder line more than 20 cm (7.9 in) away from harness of electronic controls. Do not let them run parallel for a long distance. 3) Adjust antenna and feeder line so that standing-wave ratio can be kept smaller. 4) Be sure to ground radio to vehicle body.

m Do not operate fuel pump

when there is no fuel in lines. uel hose clamps to the specified torque.

E.C.C.S. PARTS HANDLING m Handle air flow meter carefully to avoid damage. Do not disassemble air flow meter. Do not clean air flow meter with detergent. m Do not jolt or jar the crank angle sensor. m Even a slight leak in the air intake system can cause serious problems. m Do not disassemble auxiliary air control valve.

BAllERY m Always use a 12 volt battery as a power source. Do not disconnect battery cables while the engine is running. Do not reverse polarity of battery when connecting it. Otherwise, E.C.U. andlor injectors may be burned.

WHEN STARTING m Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. m Do not rev up engine just prior to shutdown.

E.C.C.S. HARNESS HANDLING m Securely connect E.C.C.S. harness connectors. A poor connection can cause extremely high voltage to develop in the coil and condenser, resulting in damage to ICs. Keep E.C.C.S. harness at least 10 cm (3.9 in) away from adjacent harnesses, to prevent an E.C.C.S. system malfunction due to receiving external noise, degraded operation of ICs, etc. m Keep E.C.C.S. parts and harnesses dry. m Before removing parts, turn off ignition switch and then disconnect battery ground cable.
SEF23U

E.C.C.S. DESCRIPTION - E.C.C.S. Components

E.C.C.S. Component Parts Location

[m
1

Electrical fuel pump (In-tank type)

E.C.C.S. control unit

E.C.C.S. DESCRIPTION - E.C.C.S. Components

F 1

E.C.C.S. Component Parts Location (Cont'd)

Ignition coil 8. power transistor

meter

Throttle sensor & throttle valve switch A.A.C. valve

From power

S.C.V. actuator

valve housing

L Vehicle speed sensor

E.C.C.S. DESCRIPTION
System Diagram

IKA24E /

E.C.C.S. DESCRIPTION
E.C.C.S. CONTROL SYSTEM
l

pzq

System Chart

Crank angle sensor

1-

Ignition timing control

Power transistor

LI
Exhaust gas sensor Starter switch

ldle speed control

Auxiliary air control (A.A.C.) valve

h l
ldle switch Throttle sensor
b
+

C.C.P. control

Carbon canister purge (C.C.P.) control solenoid valve.

E.C.C.S. control unit

>..-.I

Fuel pump control

Acceleration cut control

Air conditioner relay

S.C.V. (Swirl control valve) control

S.C.V. control solenoid valve

Power steering oil pressure switch

Exhaust gas sensor

ECM lamp & Inspection lamp (On the control unit)

Battery

Pressure regulator control

Pressure regulator control solenoid valve

Air temperature sensor

t
I

Radiator fan control

Radiator fan relay-?& -2

I (headlamps, etc.)

I
I

Fail-safe function

Air flow meter Throttle sensor Engine temperature sensor Air terqperature sensor

E.C.C.S. DESCRIPTION
Vacuum Hose Drawing

Swirl control vacuum tank

Fuel pressure regulator valve

Carbon canister

Piping assembly

'

Fuel pressure regulator Collector

Throttle chamber

Carbon canister diaphragm

(Green paint)

,
\

,Swlrl control valve ,

@ Swlrl control and fuel pressure regulator
vacuum supply -

From swirl control vacuum tank

Swirl control solenoid (Brown)

@ Swirl control solenold

Fuel pressure regulator solenoid (Dark green) Carbon canister purge solenoid (Black)

@ Fuel pressure regulator solenold @ Carbon canlster purge solenoid

INHIBIT R E U Y

Dw'DQ=
(1701
(1%)

(1901

(20EI

WWWW

(SEE LAST P G E I

00

START

NTROL UNIT

ENG. EARTH

E.C.C.S. DESCRIPTION - E.C.C.S. Components E.C.C.S. Control Unit (E.C.U.)

KA24E -

The E.C.U. consists of a microcomputer, inspection lamps, a diagnostic mode selector, and connectors for signal input and output and for power supply. The unit controls the engine.

SE F297 H

Crank Angle Sensor

The crank angle sensor is a basic component of the entire E.C.C.S. It monitors engine speed and piston position, and sends signals to the E.C.U. to control fuel injection, ignition timing and other functions. The crank angle sensor has a rotor plate and a wave-forming circuit. The rotor plate has 360 slits for 1" signal and 4 slits for 180" signal. Light Emitting Diodes (L.E.D.) and photo diodes are built in the wave-forming circuit. When the rotor plate passes between the L.E.D. and the photo diode, the slits in the rotor plate continually cut the light being transmitted to the photo diode from the L.E.D. This generates roug h-shaped pulses which are converted into on-off signals by the wave-forming circuit, which are then sent to the E.C.U.

180" signal slit for No. 1 cylinder

Rotor plate

SEF863B

Air Flow Meter

Battery source Air f!ow meter Output voltage Ground

E.C.C.S.
unit
109

Temperature compensation resistor

.
l ,

The air flow meter measures the mass flow rate of inrake air. Measurements are made so that the control circuit will emit an electrical output signal corresponding to the amount of heat dissipated from a hot wire placed in the stream of intake air. The airflow past the hot wire removes the heat from the hot wire. The temperature of the hot wire is very sensitive to the mass flow rate. The higher the temperature of the hot wire, the greater its resistance value. This temperature change (resistance) is determined by the mass air flow rate. The control circuit accurately regulates current (I) in relation to the varying , , . resistance value (R,) so that V always equals V The air flow meter transmits a voltage value V to the control unit where the , output is converted into an intake air signal.

RH RK RA, R B

: Hot wire reststance : Temperature compensation resistance : Constant resistance SEF617B

E.C.C.S. DESCRIPTION - E.C.C.S. Components Engine Temperature Sensor

The engine temperature sensor detects the engine temperature, which is dependent on engine coolant temperature, and transmits a signal to the E.C.U. The temperature sensing unit employs a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise.

ldle contact p i t, on-

Throttle Sensor & SoftIHard ldle Switch

The throttle sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms the throttle valve position into output voltage, and emits the voltage signal to the E.C.U. In addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal to the E.C.U. ldle position of the throttle valve is determined by the E.C.U. receiving the signal from the throttle sensor. This system is called "soft idle switch" and controls engine operation such as fuel cut. On the other hand, "hard idle switch", which is built in the throttle sensor unit, is used not for engine control but for self-diagnosis.

Full throttlecontact point

SE F9030

Not used (Full throttle

Supply voltage: 5 V (Applied between terminal No. 4 and 6)

6.0 1

1
l

Output voltage between

4.0

2.0

0 0

90 45 Throttle valve opening angle (deg)

135

Fuel Injector
The fuel injector is a small, elaborate solenoid valve. As the E.C.U. sends injection signals to the injector, the coil in the injector pulls the needle valve back and fuel is released into the intake manifold through the nozzle. The injected fuel is controlled by the E.C.U. in terms of injection pulse duration. Brass wire is used in the injector coil and thus the resistance is higher than a conventional injector.
. - Needle valve
SEF359H

E.C.C.S. DESCRIPTION - E.C.C.S. Components Pressure Regulator

/ KA24E /

The pressure regulator maintains the fuel pressure at 299.1 kPa (3.05 kg/cm2, 43.4 psi). Since the injected fuel amount depends on injection pulse duration, it is necessary to maintain the pressure at the above value.

Exhaust Gas Sensor

The exhaust gas sensor, which is placed into the exhaust manifold, monitors the amount of oxygen in the exhaust gas. The sensor has a closed-end tube made of ceramic zirconia. The outer surface of the tube is exposed to exhaust gas, and the inner surface to atmosphere. The zirconia of the tube compares the oxygen density of exhaust gas with that of atmosphere. and generates electricity. In order to improve the generating power of the zirconia, its tube is coated with platinum. The voltage is approximately 1V in a richer condition of the mixture ratio than V the ideal air-fuel ratio, while approximately O in leaner condiV tions. The radical change from 1V to O occurs at around the ideal mixture ratio. In this way, the exhaust gas sensor detects the amount of oxygen in the exhaust gas and sends the signal V of approximately 1V or O to the E.C.U.

Connector
Isolation bushing

L~ontact plate
SEC336A

'L
Ideal ratio

Rich

Lean

Mixture ratio

SEF288D

Fuel Pump
The fuel pump assembly consists of an intake filter, a low pressure vane pump element feeding a high pressure "G-rotor" pump element motor, relief valve and check valve. This combination of low and high pressure pump elements in series minimizes fuel pulsati~~rr, therefore eliminating the need for a low pressure dampener.

Power Transistor
The ignition signal from the E.C.U. is amplified by the power transistor, which turns the ignition coil primary circuit on and off, inducing the proper high voltage in the secondary circuit. The ignition coil is a small, molded type.

E.C.C.S. DESCRIPTION
(Through idle (Through A.A.C. valve) Coolant

- E.C.C.S. Components

pq

ldle Air Adjusting (I.A.A.) Unit

The I.A.A. unit is made up of the A.A.C. valve and air cut valve. It receives the signal from the E.C.U. and controls the idle speed at the preset value under various conditions. The air cut valve prevents an abnormal rise of idle rpm when A.A.C. valve operates abnormally.

ldle adjusting screw Air

C Engine coolant
L

OR=
SEF1221

Auxiliary Air Control (A.A.C.) Valve

The E.C.U. actuates the A.A.C. valve by an ONIOFF pulse. The longer that ON pulse is received, the larger the amount of air that will flow through the A.A.C. valve. This air flow also varies with the temperature of the engine coolant flowing through the A.A.C. valve. The higher the coolant temperature, the less the amount of air flow.

From power

Power Steering Oil Pressure Switch

The power steering oil pressure switch is attached to the power steering high-pressure tube and detects the power steering load, sending the load signal to the E.C.U. The E.C.U. then sends the idle-up signal to the A.A.C. valve.

7
valve housing

Vehicle Speed Sensor

The vehicle speed sensor provides a vehicle speed signal to the E.C.U.

Carbon Canister Purge (C.C.P.) Control Solenoid Valve

The C.C.P. system is controlled by the E.C.U. At both low- and highspeed engine revolutions, the solenoid valve turns "ON" to de-activate the system.

E.C.C.S. DESCRIPTION - E.C.C.S. Components S.C.V. Control Solenoid Valve

piEq

The S.C.V. control solenoid valve cuts the intake manifold vacuum signal for swirl control valve. It responds to the ONIOFF signal from the E.C.U. When the solenoid is off, the vacuum signal from the intake manifold is cut. When the control unit sends an ON signal the coil pulls the plunger and feeds the vacuum signal to the swirl control valve actuator.

Fuel Filter
The specially designed fuel filter has a metal case in order to withstand high fuel pressure.

Air Temperature Sensor

The air temperature sensor controls ignition timing when the temperature of the intake air is extremely high, in order not to cause knocking.

E.C.C.S. SYSTEM DESCRIPTION

Fuel Injection Control
INPUTIOUTPUT SIGNAL LINE
P

p /

Crank angle sensor

Engine speed and piston position

Amount of intake air

4
+

Engine temperature sensor

7 -

Engine temperature

Density of oxygen in exhaust gas Exha Throttle valve position

Idle switch

Throttle valve idle position

.I

E.C.C.S. control unit

1 41

Injector

Neutral switch ( M B ) Inhibitor switch ( A n )

Gear position

Start signal

Battery voltage Battery

BASIC FUEL INJECTION CONTROL

The amount of fuel injected from the fuel injector, or the length of time the valve remains open, is determined by the E.C.U. The basic amount of fuel injected is a programmable value mapped in the E.C.U. ROM memory. In other words, the programmable value is preset by engine operating conditions determined by input signals (for engine rpm and air intake) from both the crank angle sensor and the air flow meter.

--p. - - -p -

VARIOUS FUEL INJECTION INCREASEIDECREASE 7 COMPENSATION

,--Start e n r i h m e n t

1
LOW
Water temperature

In addition, the amount of fuel injection is compensated for to improve engine performance under various operating conditions as listed below: < Fuel increase > 1) During warm-up 2) When starting the engine 3) During acceleration 4) Hot-engine operation < Fuel decrease > 1) During deceleration

E.C.C.S. SYSTEM DESCRIPTION Fuel lnjection Control (Cont'd)

CLOSED LOOP CONTROL

pq

MIXTURE RATIO FEEDBACK CONTROL

E.CX.S. Mixture ratio feedback system is designed to precisely control the mixture ratio to the stoichiometric point so that the threeway catalyst can reduce CO, HC and NOx emissions. This system uses an exhaust gas sensor in the exhaust manifold to check the air-fuel ratio. The control unit adjusts the injection pulse width according to the sensor voltage so the mixture ratio will be within the range of the stoichiometric air-fuel ratio. This stage refers to the closed-loop control condition. The open-loop control condition refers to that under which the E.C.U. detects any of the following conditions and feedback control stops in order to maintain stabilized fuel combustion. 1) Deceleration 2) High-load, high-speed operation 3) Engine idling 4) Malfunctioning of exhaust gas sensor or its circuit 5) Insufficient activation of exhaust gas sensor at low engine temperature 6) Engine starting

,' -,
Injector

Engine
SEF639B

Injection pulse

MIXTURE RATIO SELF-LEARNING CONTROL

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the exhaust gas sensor. This feedback signal is then sent to the E.C.U. to control the amount of fuel injection to provide a basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. This is due to manufacturing errors (e.g., air flow meter hot wire) and changes during operation (injector clogging, etc.) of E.C.C.S. parts which directly affect the mixture ratio. Accordingly, a difference between the basic and theoretical mixture ratios is quantitatively monitored in this system. It is then computed in terms of "fuel injection duration" to automatically compensate for the difference between the two ratios.

FUEL INJECTION TIMING

Fuel is injected once a cycle for each cylinder in the firing order.

No. 1 cylinder
No. 2 c
y

No. 3 cylinder

A
t-----l
engine cycle

No. 4 cylinder

A
----A

SEF976E

When engine starts, fuel is injected into all four cylinders simultaneously twice a cycle.

No. 1 cylinder-

No. 2 cylinderNo. 3 cle nI yidr

I -1 engine cycle -----A -

E.C.C.S. SYSTEM DESCRIPTION Fuel Injection Control (Cont'd)

FUEL SHUT-OFF

I KA24E I

Fuel to all cylinders is cut off during deceleration or high-speed operation.

Ignition Timing Control

INPUTIOUTPUT SIGNAL LINE
Engine speed and piston position Crank angle sensor Amount of intake air
b

Engine temperature
b

Throttle valve idle position Idle switch Throttle valve opening angle

+
b

E.C.C.S. control unit

Power transistor

Neutral switch (M/T) Inhibitor switch (A/T)

Neutral position
b

Start signal
b

Intake air temperature Air temperature sensor

E.C.C.S. SYSTEM DESCRIPTION Ignition Timing Control (Cont'd)

SYSTEM DESCRIPTION
The ignition timing is controlled by the E.C.U. in order to maintain the best air-fuel ratio in response to every running condition of the engine. The ignition timing data is stored in the ROM located in the E.C.U., in the form of the map shown below. The E.C.U. detects information such as the injection pulse width and crank angle sensor signal which varies every moment. Then responding to this information, ignition signals are transmitted to the power transistor e.g.

pq

N: 1,800 rpm, Tp: 1.50 msec A "B.T.D.c. In addition to this, 1 At starting 2 During warm-up 3 At idle 4 At low battery voltage 5 During swirl control valve operates 6 During hot engine operation 7 At acceleration 8 When intake air temperature is extremely high the ignition timing is revised by the E.C.U. according to the other data stored in the ROM.

TP (msec) 1.75

1.50
Injection pulse
width

1.25

1.00.

0.75

T
600 1, W 1,400 1.800 2.200

-N

Engine speed (rpm)

SEC7SOA

E.C.C.S. SYSTEM DESCRIPTION

ldle Speed Control
INPUTIOUTPUT SIGNAL LINE
Crank angle sensor Engine speed

Start signal
b

Throttle valve idle position Idle switch Neutral switch (M/T) Inhibitor switch ( A n ) Air conditioner switch Neutral position

+
E.C.C.S. control unit
b

A.A.C. valve

Air conditioner operation

Power steering operation

Battery

Battery voitage

Vehicle speed sensor

Vehicle speed

SYSTEM DESCRIPTION
This system automatically controls engine idle s ~ e e d a s ~ e c i f i e dlevel. ldle speed is conto tiolled through fine adjustment of the amount of air which by-passes the throttle valve via A.A.C. valve. The A.A.C. valve repeats ONIOFF operation according to the signal sent from the E.C.U. The crank angle sensor detects the actual engine speed and sends a signal to the E.C.U. The E.C.U.

then controls the ONIOFF time of the A.A.C. valve SO that engine speed coincides with the target value memorized in ROM.

ES- 100

E.C.C.S. SYSTEM DESCRIPTION

Fuel Pump Control
INPUTIOUTPUT SIGNAL LINE
Engine speed

p q %

E.C.C.S.
control unit

Fuel pump relay

SYSTEM DESCRIPTION
The E.C.U. activates the fuel pump for several seconds after the ignition switch is turned on to improve engine startability. If the E.C.U. receives a 1" signal from the crank angle sensor, it knows that the engine is rotating, and causes the pump to perform. If the 1" signal is not received when the ignition switch is on, the engine stalls. The E.C.U. stops pump operation and prevents battery discharging, thereby improving safety. The E.C.U. does not directly drive the fuel pump. It controls the ONIOFF fuel pump relay, which in turn controls the fuel pump.

Condition Ignition switch is turned to ON. Engine running and cranking When engine is stopped Except as shown above

Fuel pump operation Operates for 5 seconds Operates Stops in 1 second Stops

E.C.C.S. SYSTEM DESCRIPTION C.C.P. (Carbon Canister Purge) Control

INPUT/OUTPUT SIGNAL LINE
p -

Crank angle sensor

1 Engine speed
I
I

Air flow meter

Amount of intake air

Engine temperature sensor

l control
Engine temperature unit

E.C.C.S.

C.C.P. control solenoid valve

Ignition switch

SYSTEM DESCRIPTION
The E.C.U. controls the operation of the C.C.P. system by turning "ON" or "OFF" the C.C.P. solenoid valve, thereby controlling the vacuum signal to inhibit C.C.P. operation as follows:

When starting the engine. When idling. When engine temperature is low. During heavy load operation.

C.C.P. SYSTEM OPERATION

Condition When starting Water temperature 'C Below 60 Above 1 15 Idle &heavy load conditions Other conditions C.C.P. control solenoid valve C.C.P. System

ON

Not Purging

OFF

Purging

E.C.C.S. SYSTEM DESCRIPTION

Fuel Pressure Regulator Control
INPUT/OUTPUT SIGNAL LlNE
Engine temperature sensor Engine temperature

1-

r
b

E.C.C.S. unit Engine speed

A

solenoid valve

SYSTEM DESCRIPTION
The fuel "pressure-up" control system briefly increases fuel pressure for improved starting performance of a hot engine. Under normal operating conditions, manifold vacuum is applied to the fuel pressure regulator. When starting the engine, however, the E.C.U. allows current to flow through the ONIOFF solenoid valve in the control vacuum line, opening this line to the atmosphere. As a result, atmospheric pressure is applied, throttling the fuel passage to increase fuel pressure.

above 90C (194"F)

Ignition switch

OFF

pA

START

P.R. control
solenoid valve

OFF

i l k
OFF
Approx. 3 min.
SEF741 B

Swirl Control Valve (S.C.V.) Control

INPUTIOUTPUT SIGNAL LlNE
Idle switch Ignition switch ldle signal Start signal
b

+
E.C.C.S. control unit

Engine speed Engine temperature

S.C.V. control
solenoid valve

Engine temperature sensor Vehicle speed sensor

SYSTEM DESCRIPTION
This system has a swirl control valve (S.C.V.) in the intake passage of each cylinder, While idling the S.C.V. closes. Thus the velocity of the air in the intake passage increases, promoting the vaporization of the fuel and producing a SW ir l in the combustion chamber. Because of this operation, this system tends to increase the burning speed of the gas mixture, improve fuel consumption, and increase the stability in running conditions. Also, except when idling, this system opens the S.C.V. In this condition, this system tends to increase power by improving intake efficiency via reduction of intake flow resistance. The solenoid valve controls S.C.V.'s shutlopen

condition. This solenoid valve is operated by the E.C.U.

Water temperature is above 35C (95F) with stopped and engine running
Idle switch ON Engine rpm Below 1,800'1 Below 1,500*2 Solenoid valve ON OFF S.C.V. Close Open

Except above
'1: MIT
' 2 : AIT

ES- 103

E.C.C.S. SYSTEM DESCRIPTION Acceleration Cut Control

INPUTIOUTPUT SIGNAL LlNE
AIC ON signal
Air conditioner system Throttle valve opening angle E.C.C.S. control
unit

pq

Air conditioner relay

SYSTEM DESCRIPTION
When accelerator pedal is fully depressed, air conditioner is turned off for a few seconds.

This system improves acceleration when air conditioner is used.

Radiator Fan Control

INPUTIOUTPUT SIGNAL LlNE
Vehicle speed sensor Vehicle speed

Engine temperature sensor

Engine temperature Air conditioner "ON" signal Evaporator outlet air temperature E.C.C.S. control unit

Radiator fan low speed

Air conditioner switch

Radiator fan high speed

control relay-l Radiator fan control relay-2

Thermo control amp.

The E.C.U. performs ONIOFF control and LOWIHIGH speed control of the radiator fan corresponding to the vehicle speed, engine temperature, and air conditioner ON signal.

OPERATION

Note: When vehicles are not equipped with air conditioning, radiator fan operation will assume the air conditioner switch "OFF" position.

ES- 104

E.C.C.S. SYSTEM DESCRIPTION

Fail-safe System
AIR FLOW METER MALFUNCTION
If the air flow meter output voltage is above or below the specified value, the E.C.U, senses an air flow meter malfunction. In case of a malfunction, the throttle sensor substitutes for the air flow

Operation
System
C.C.P. control svstern

Fixed condition
OFF -.
A duty ratio is fixed at the

meter.
Thouah air flow meter is malfunctionina. it is ", possible to drive the vehicle and start the engine. But engine speed will not rise more than 2,400 rpm in order to inform the driver of fail-safe system operation while driving.

Idle speed control system

preprogrammed value.

I Fuel is shut off above 2,400

Fuel injection control system rpm. (Engine speed does not exceed 2,400 rpm.)

ENGINE TEMPERATURE SENSOR MALFUNCTION

When engine temperature sensor output voltage is below or above the specified value, water temperature is fixed at the preset value as follows:

THROTTLE SENSOR MALFUNCTION

When throttle sensor output voltage is below or above the specified value, throttle sensor output is fixed at the preset value.

AIR TEMPERATURE SENSOR MALFUNCTION

When air temperature sensor is below or above the specified value, air temperature value is fixed at the preset value [20C(68"F)I.

Operation
Condition Just as ignition switch is turned ON or Start More than 6 minutes after ignition ON or Start Except as shown above Engine temperature decided 20C (68F) 80C (176F) 20 - 80C (68 176F) (Depends on the time)

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

PREPARATION
1. Make sure that the following parts are in good order. a Battery a Ignition system a Engine oil and coolant levels a Fuses a E.C.U. harness connector a Vacuum hoses a Air intake system (Oil filler cap, oil level gauge, etc.) a Fuel pressure a Engine compression C.C.P. control valve operation a Throttle valve and idle switch
2. On air conditioner equipped models, checks should be carried out while the air condi-

tioner is "OFF". 3. On automatic transaxle equipped models, when checking idle rpm, ignition timing and mixture ratio, checks should be carried out while shift lever is in "NW position. 4. When measuring "CO" percentage, insert probe more than 40 cm (15.7 in) into tail pipe. WARNING: a. When checking or adjustment, move selector lever to "N" position, set parking brake and chock rear wheels. b. After the adjustment has been made, remove wheel chocks.

Overall lnspectlon sequence

INSPECTION START

Perform self-diagnosis.

Repair or replace.

ignition timing.

L
'.G Check exhaust gas sensor function by using E.C.U. inspection lamp.

Check exhaust gas sensor harness. N.G. O.K.

O.K.

4
Check base idle CO. N.G. O.K. Replace exhaust gas sensor.

Check emission control parts and repair or replace if necessary.

Check exhaust gas sensor function. O.K.

L*O
A1

v
INSPECTION END

Check E.C.U. function* by substituting another known good E.C.U.

*: E.C.U. may be the cause of a

problem, but this is rarely the case.

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

/K

A ~ ~ E

INSPECTION START

--

Visually check the following: Air cleaner clogging Hoses and ducts for leaks C.C.P. control valve operation Electrical connectors Gaskets Throttle valve and throttle sensor operation

SE F457C

Start engine and warm it up until water temperature indicator points to the middle of qauqe.

+
Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load.

4
Perform E.C.C.S. self-diagnosis.

p ]
Yes
4

Check, correct or replace malfunctioning parts.

Does engine run smoothly? No Check and clean injectors, and replace injectors if necessary.

Race engine two or three times under no-load, then run engine at idle speed.

4
Check idle speed. M/T: 850t-50 rpm

AIT: 850 k50 rpm

O.K.

N.G.

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

IK

A ~ ~ E

15"+2" B.T.D.C.

O.K.

1N.G.

I I I

Disconnect throttle sensor harness connector.

)Am I

\\

I
l I
L

1
Ensure that engine speed is below 800 rpm.
A

U.K.

4 N.G.

1 1

I
4

Adjust idle speed to less than 800 rpm by turning idle speed adjusting screw.

1
Check ignition timing with a timing light.

15"+2" B.T.D.C. o.K.~

I N.G.

Adjust idle speed by turning idle speed adjusting

MIT: 650f50 rpm

l
Connect throttle sensor harness connector.
SEF4778

Run engine a t about 2,000 rpm for about 2 minutes under no-load. ,<>\,,-AL'6).J

l
v

I
N.G.

@
SEF3621

Set diagnosis mode of E.C.U. to Mode 11. Make sure that inspection lamp on E.C.U. goes on and off more than 5 times during 10 seconds a t 2,000

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

p z q

Exhaust gas sensor

m I T

CRlaxon

SEF353H

Check exhaust gas sensor harness: 1) Turn off engine and disconnect battery ground cable. 2) Disconnect harness connector from E.C.U. 3) Disconnect exhaust gas sensor harness connector and connect terminal for exhaust gas sensor harness connector to ground with a jumping wire. 4) Check for continuity between terminal No. 19 of E.C.U. harness connector and ground metal on vehicle body. Continuity exists. Continuity does not exist

................................. O.K. .....................N.G.

N.G.

O.K.

Repair or replace E.C.C.S. harness and connect battery ground cable.

Connect harness connector t o E.C.U. and I I disconnect jumping wire from exhaust gas sensor. I

I Note: Do not reconnect exhaust gas sensor at this

stage.

I
Disconnect enaine temperature sensor harness connector. Connect a resistor (2.5 k ) between terminals of engine temperature sensor harness connector. Connect battery ground cable. I
SEF351H

Start engine and warm it up until water temperature indicator points to the middle of gauge. (Wait more than 5 minutes after starting.)

4
Race engine two or three times under no-load then run engine at idle speed.
I

After checking CO% 1) Turn off engine. 2) Disconnect the resistor (2.5 kR)from terminals o engine temperature sensor harness connector. 3) Connect engine temperature sensor harness connector t o engine temperature sensor.

l N.G.

IDLE SPEED/IGNITION TIMINGIIDLE MIXTURE RATIO INSPECTION

1K

A ~ ~ E

4
Connect exhaust gas sensor harness to exhaust gas sensor.

+
Replace exhaust gas sensor. Set diagnosis mode of E.C.U. to Mode 11. Make sure that inspection lamp on E.C.U. goes on and off more than 5 times during 10 seconds a t 2,000 rpm under no-load.

+
Check fuel pressure regulator.

I O.K.

Check air flow meter. (See page 174)

Check injector (See page 192) Clean or replace if necessary.

- - temperature sensor. Check engine

(See page 176)

.c
Check E.C.U. function* by substituting another known good E.C.U.

*: E.C.U. may be the cause of a problem, but this

is rarely the case.

IDLE SPEED/IGNITION TIMINGIIDLE MIXTURE RATIO INSPECTION

I KA24EI

Notes:

TROUBLE DIAGNOSES
Contents
How t o Perform Trouble Diagnoses for Quick and Accurate Repair . . . . . . . . : . . . . . . . . . . . . . ES-1 14 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-118 ES- 120 Self-diagnosis-Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 120 Self-diagnosis -- Mode II (Self-diagnostic results) Self-diagnosis -- Mode II (Exhaust gas sensor monitor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 123 . Consult . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 124 Basiclnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 129 Diagnostic Procedure 1 -- High Idling after Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 132 Diagnostic Procedure 2 -- Hunting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 133 Diagnostic Procedure 3 -- Unstable Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 13 4 Diagnostic Procedure 4 . to start or lmpossible to Start when Hard the Engine is Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 138 Diagnostic Procedure 5 . to start or lmpossible t o Start when Hard theEngineisHot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 140 Diagnostic Procedure 6 . t o start or lmpossible t o Start under Hard Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 142 Diagnostic Procedure 7 -- Hesitation when the Engine is Hot . . . . . . . . . . . . . . . . . . . . . . . . . ES- 144 Diagnostic Procedure 8 -- Hesitation when the Engine is Cold . . . . . . . . . . . . . . . . . . . . . . . . . ES- 145 Diagnostic Procedure 9 -- Hesitation under Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . ES- 146 Diagnostic Procedure 10 -- Engine Stalls when turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 148 Diagnostic Procedure 11 -- Engine Stalls when the Engine is Hot . . . . . . . . . . . . . . . . . . . . . . . ES- 150 Diagnostic Procedure 12 -- Engine Stalls when the Engine is Cold . . . . . . . . . . . . . . . . . . . . . . . ES- 152 Diagnostic Procedure 13 . Engine Stalls when Stepping on the Accelerator Momentarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 15 4 Diagnostic Procedure 14 -- Engine Stalls after Decelerating . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 156 Diagnostic Procedure 15 . Engine Stalls when Accelerating or when Driving at Constant Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 16 0 Diagnostic Procedure 16 -- Engine Stalls when the Electrical Load is Heavy . . . . . . . . . . . . . . ES- 163 Diagnostic Procedure 17 -- Lack of Power and Stumble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 165 Diagnostic Procedure 18 -- Detonation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 166 Diagnostic Procedure 19 -- Surge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 167 Diagnostic Procedure 20 -- Backfire through the Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 16 8 Diagnostic Procedure 21 -- Backfire through the Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 169 Diagnostic Procedure 22 MAIN POWER SUPPLY AND GROUND CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 17 0 Diagnostic Procedure 23 CRANKANGLESENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 172 Diagnostic Procedure 24 AIRFLOWMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 17 4 Diagnostic Procedure 25 ENGINE TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 176 Diagnostic Procedure 26 VEHICLESPEEDSENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 178 Diagnostic Procedure 27 IGNITION SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 179 Diagnostic Procedure 28 C.C.P. FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLE DIAGNOSES
Contents (Cont'd)
Diagnostic Procedure 2 9 EXHAUSTGASSENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 182 Diagnostic Procedure 30 AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 183 Diagnostic Procedure 3 1 THROTTLESENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 185 Diagnostic Procedure 3 2 THROTTLEVALVESWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 187 Diagnostic Procedure 3 3 STARTSIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 188 Diagnostic Procedure 3 4 P.R.V.R. CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 189 Diagnostic Procedure 3 5 INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 192 Diagnostic Procedure 36 FUELPUMP ES- 1 93 Diagnostic Procedure 3 7 S.C.V.CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 194 Diagnostic Procedure 3 8 A.A.C.VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 196 Diagnostic Procedure 3 9 RADIATORFANCONROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES- 1 98 Diagnostic Procedure 40 POWER STEERING OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-203 Diagnostic Procedure 41 NEUTRAL/INHIBITORSWlTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLE DIAGNOSES

1 KA24E I

Senwrs Control unit

Actuators

How to Perform Trouble Diagnoses for Quick and Accurate Repair

@*&
SEF232G

INTRODUCTION
The engine has an electronic control unit to control major systems such as fuel control, ignition control, idle speed control, etc. The control unit accepts input signals from sensors and instantly drives actuators. It is essential that both kinds of signals are proper and stable. At the same time, it is important that there are no conventional problems such as vacuum leaks, fouled spark plugs, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems. A road test with a circuit tester connected to a suspected circuit should be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a driveability complaint. The customer is a very good supplier of information on such problems, especially intermittent ones. Through the talks with the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for "conventional" problems first. This is one of the best ways to troubleshoot driveability problems on an electronically controlled engine vehicle.

TROUBLE DIAGNOSES
WORK FLOW

1 KA24E I
SERVJCE MANUAL REFERENCE ITEM & PAGES

How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd)

C
(

CHECK I N

1
1

LISTEN TO CUSTOMER COMPLAINTS

I
2(

BASIC INSPECTION

t ------1

Do self-diagnostic results exist?*l

INSPECTION ON THE FUNCTION

INSPECTION ON THE BASIS OF EACH SYMPTOM*:!

---

- - - - --

1
N.G.

REPAI R/REPLACE

-Basis Inspection

DIAGNOSTIC WORKSHEET

Diagnostic Procedures

Diagnostic Procedures

FINAL CHECK performing Basic lnspection and Test Drive.

Basic Inspection

TROUBLE DIAGNOSES

/ KA24EI

How to Perform Trouble Diagnoses for Quick and Accurale Repair (Cont'd)
KEY POINTS

WHAT ..... Vehicle& engine model WHEN ..... Date, Frequencies WHERE ..... Road conditions H W Operating conditions,

.....

Weather conditions, Symptoms

DIAGNOSTIC WORKSHEET There are many kinds of operating conditions that lead to malfunctions on engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, feelings for a problem depend on each customer. It is important to fully understand the symptoms or under what conditions a customer complains. Make good use of a diagnostic worksheet such as the one shown below in order to utilize all the complaints for troubleshooting. Worksheet sample

Customer name Engine # p i d e n t Date

MRlMS

Model & Year Trans. Manuf. Date I

VIN Mileage

1
Startability Idling Symptoms

In Service Date I Cl Partial combustion No combustion lmpossible to start Partial combustion affected by throttle position Cl Partial combustion NOT affected by throttle position Cl Possible but hard to start Others [ No fast idle Others [

L+p1

U Unstable

High idle

D Low idle

1
Lack of power

Driveability

Stumble Surge C l Detonation Intake backfire, Exhaust backfire Others [

I I

Engine stall

At the time of start While accelerating Just after stopping

While idling While decelerating While loading

Incident occurrence

Recently Just after delivery Cl In the morning D At night In the daytime All the time Under certain conditions Sometimes

Frequency

Weather conditions

D Note effected
Fine Hot

Weather

Raining

Snowing Cool

Others [

l
"F

Temperature

Warm

U Cold

U Humid

Engine conditions

Cl Cold

During warm-up

D After warm-up
I 2 .OOO

Engine speed Road conditions Driving conditions In town

,
0

1 4.000

I
I

6,000

8,000 rom

Oln suburbs

5 Highway

Cl Off road (upldown)

Not affected Cl At starting U While idling O At racing While accelerating ' U While cruising While decelerating ! l While turning (RHILH) Vehiclespeedj

0
P -

20

40

60

80

100

120KPH

ECM light

Turned on

Not turned on

TROUBLE DIAGNOSES
INTERMITTENT PROBLEM SIMULATION

pz']

How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd)
In order to duplicate an intermittent problem, it is effective to create similar conditions for component parts, under which the problem might occur. Perform the activity listed under Service procedure and note the result.

Variable factor
1

Influential part Pressure regulator

Target condition Made lean Made rich Advanced Retarded Suspended Operation check Raised Lowered Poor electric Connection or faulty widng

Service procedure Remove vacuum hose and apply vacuum. Remove vacuum hose and apply pressure. Rotate distributor clockwise. Rotate distributor counterclockwise. Disconnect exhaust gas sensor harness connector. Perform self-diagnosis (Mode IIJI) at 2,000 rpm.' Turn idle adjusting screw counterclockwise. Turn idle adjusting screw clockwise. Tap or wiggle.

Mixture ratio

Ignition timing

Distributor Exhaust gas sensor Control unit I.A.A. unit

Mixture ratio feedback control

Idle speed

Electric connection (Electric continuity)

Harness Connectors and wires

Race engine rapidly. See if the torque reaction of the engine unit causes electric breaks. Cool with an icing spray or similar device. Heat with a hair drier. [WARNING: Do not overheat the unit.] Wet. [WARNING: Do not directly pour water on components. Use a mist sprayer.] Turn on headlights, air conditioner, rear defogger, etc. Try to flash timing light for each cylinder.

Cooled

Temperature

Control unit

Warmed

Moisture

Electric parts

Damp

8 9

Electric loads Ignition spark

Load switches Timing light

Loaded Spark power check

TROUBLE DIAGNOSES
Self-diagnosis
C -1) 1 2
H

l< )$

-L

rZ

O h

0
D

E.C.M. LIGHT This light blinks simultaneously with the RED L.E.D. on the E.C.U.

TEMP

Fully counterclockwise

E.C.U. L.E.D.
In the E.C.U., the Green and Red L.E.D.'s have now been permanently changed to one RED L.E.D.

mode selector
SEC2396

SELF-DIAGNOSTIC FUNCTION
Mode I Engine stopped Ignition switch in "ON" position Engine running Mode 1 1

BULB CHECK

SELF-DIAGNOSTIC RESULTS

LAMP STAYS OFF

EXHAUST GAS SENSOR MONITOR

TROUBLE DIAGNOSES Self-diagnosis (Cont'd)

HOW TO SWITCH MODES
Turn ignition switch "ON".

1~

~ 2 4 ~ 1

---+

Mode I- BULB CHECK Start engine.

Mode I- LAMP GOES

OFF

(Turn diagnostic mode selector on E.C.U. fully clockwisel

Wait at least 2 seconds.

(Turn diagnostic mode selector fully counterclockwise.)

Mode I1 - SELF-DIAGNOSTIC RESU LTS

Mode I1 - EXHAUST GAS Start engine. SENSOR MONITOR

I
TO ERASE E.C.U. MEMORY Change control unit from Mode II to Mode I

(Turn diaanostic mode selector on E.C.U:~UII~ clockwise)

I

I
I

Wait at least 2 seconds.

Do not change control unit modes unnecessarily as E.C.U. memory may be cleared accidentally. Switching the modes is not possible when the engine Is running. When the ignition switch is turned off during diagnosis in each mode, and then turned back on again after power to the E.C.U. has dropped off completely, the diagnosis will automatically return to Mode L

TROUBLE DIAGNOSES
Self-diagnosis

Mode I - BULB CHECK

-Mode I

In this mode, the RED L.E.D. in the E.C.U. and the E.C.M. LIGHT in the instrument panel stay "ON". If either remain "OFF", check the bulb in the E.C.M. LIGHT o r the RED L.E.D.

Self-diagnosis - Mode II. (Self-diagnostic results)

DESCRIPTION
In this mode, a malfunction code is indicated by the number of flashes from the RED L.E.D. or the E.C.M. LIGHT as shown below:
Example: Code No. 12 and Code No. 41 3

06 .
4
l-

. -

03 .

06 .
7

0.3'
&-c
F

ON

--4
Un~t:second

OFF

09 03
Code No. 12

d a u +a
2.1

I
09 .

06 .

2.1

Code No. 41

Long (0.6 second) blinking indicates the number of ten digits and short (0.3 second) blinking indicates the number of single digits. For example, the red L.E.D. flashes once for 0.6 seconds and then it flashes twice for 0.3 seconds. This indicates the number "12" and refers to a malfunction in the air flow meter. In this way, all the problems are classified by their code numbers.

Display code table

L

<

Code No. 11 12 13 21 41 55

Detected Items Crank angle sensor circuit Air flow meter circuit Engine temperature sensor circuit Ignition signal circuit Air temperature sensor circu~t No malfunction in the above circu~t

D~agnost~c Procedure Page No ES- 172 ES- 174 ES- 176 ES-179 ES- 183 N/A

TROUBLE DIAGNOSES Self-diagnosis

Code No. Detected items Crank angle sensor circuit

- Mode II (Self-diagnostic results) (Cont'd)

Check item (remedy) Harness and connector (If harness and connector are normal, replace crank angle sensor.)

Malfunction is detected when ... Either ' or 1 0 signal is not entered for 1 8' the first few seconds during engine cranking. Either ' or 1 0 signal is not input often 1 8' enough while the engine speed is higher than the specified rpm. The air flow meter circuit is open or shorted. (An abnormally high or low voltage is entered.) The engine temperature sensor circuit is open or shorted. (An abnormally high or low output voltage is entered.) The ignition signal in the primary circuit is not entered during engine cranking or running. The air temperature sensor circuit is open or shorted. (An abnormally high or low voltage is entered.)

1 1 '

12

Air flow meter circuit

Harness and connector (If harness and connector are normal, replace air flow meter.) Harness and connector Engine temperature sensor

13

Engine temperature sensor circuit

'1 2

Ignition signal circuit

Harness and connector power transistor unit Harness and connector Air temperature sensor

4 1

Air temperature sensor circuit

': Check items causing a malfunction of crank angle sensor circuit first, if both code No. 1 1 and 2 come out at the same time. 1

TROUBLE DIAGNOSES I KA24E Self-diagnosis - Mode I1 (Self-diagnostic results) (Cont'd)

RETENTION OF DIAGNOSTIC RESULTS
The diagnostic results will remain in E.C.U. memory until the starter is operated fifty times after a diagnostic item has been judged to be malfunctioning. The diagnostic result will then be canceled automatically. If a diagnostic item which has been judged to be malfunctioning and stored in memory is again judged to be malfunctioning before the starter is operated fifty times, the second result will replace the previous one. It will be stored in E.C.U. memory until the starter is operated fifty times more.
RETENTION TERM CHART (Example)
Code No.

STARTER OPERATING TIMES 50 50 t i m r

100

150

200

CRANK ANGLE SENSOR

/////////////h A Y/////// / 4 - - -- - - - - - - - - -- - - - - - - - 11

ENGINE TEMPERATURE SENSOR

A
13

50 t i m r

'-----j
50 timr

--

- --

- - - - - - -- - - - -

----

- -.

W/////,/////

: Retention term

If the same diagnostic item is judged to be malfunctioning before the starter is operated f ifty times. it will be stored in E.C.U. memory until the starter is operated fifty times from this point in time.

: Malfunction detecting point

SEF793D

HOW TO ERASE SELF-DIAGNOSTIC RESULTS

The malfunction code is erased from the backup memory on the E.C.U. when the diagnostic mode is changed from Mode II to Mode I. (Refer to "HOW TO SWITCH MODES".) When the battery terminal is disconnected, the malfunction code will be lost from the backup memory within 24 hours. m Before starting self-diagnosis, do not erase the stored memory before beginning self-diagnosis.

ES- 122

TROUBLE DIAGNOSES Self-diagnosis monitor)

DESCRIPTION

piEiq

- Mode I1 (Exhaust gas sensor

In this mode, the E.C.M. LIGHT and RED L.E.D. display the condition of the fuel mixture (lean o r rich) w h i c h i s monitored by the exhaust qas sensor.

I
I

E.C.M. LIGHT and RED L.E.D.

ON
OFF "Remains ON or OFF

Fuel mixture condition in the exhaust gas Lean Rich Any condition

Air fuel ratio feedback control condition Closed loop control Open loop control

I
I

*: Maintains conditions just before switching to open loop.

HOW TO CHECK EXHAUST GAS SENSOR

1. 2.
3.
4.

Set Mode II. (Refer to "HOW TO SWITCH MODES".) Start engine and warm it up until engine coolant temperature indicator points to the middle of the gauge. Run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Make sure RED L.E.D. or E.C.M. LIGHT goes ON and OFF more than 5 times every 10 seconds; nleasured at 2,000 rpm under no-load.

TROUBLE DIAGNOSES
Consult
CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch. 2. Connect "CONSULT" to diagnostic connector.

1-

(Diagnostic connector is located behind left dash side panel.)

3. 4.

Turn on ignition switch. Touch "START".

5.

Touch "ENGINE"

Perform each diagnostic mode according to the inspection sheet as follows: For further information, read the CONSULT Operation Manual.
6.

TROUBLE DIAGNOSES Consult (Cont'd)

E.C.C.S. COMPONENT PARTS APPLICATION
WORK SUPPORT
Crank angle sensor A I flow meter ~ Engine temperature sensor Exhaust gas sensors

I KA24E I

SELF-DIAGNOSTIC RESULTS

DATA
X
X

ACTIVE TEST

X X
X

X X X

X X
X

+ 2 z -

Vehicle speed sensors Throttle sensor lgnitton swttch (start s~gnal) Atr cond~tloner swltch Neutral switch oll Power steer~ng pressure switch Battery Atr temperature sensor Injectors Power transistor (ignition slgnal)

X X X
X

X
X X X X X (Ignltlon tlming) X X

X
X

l-

A A C valve S w ~ rcontrol solenold valve l

X
X X

X
X

a
l-

P R V R control solenoid valve

relay Air cond~tioner Fuel pump relay Radtator fan relay

X
X X X

X X

': The E.C.C.S. component part marked ' is applicable to vehicles for Cal~fornia only. X: Applicable

CAUTION: a. When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off Ignition key with CONSULT set in "Work Support" mode. b. Be sure to set gears to "Neutral" before conducting "Active Test" on idle adjustment or A.A.C. valve.

TROUBLE DIAGNOSES Consult (Cont'd)

FUNCTION
Diagnostic mode Work support Self-diagnostic results Data monitor Active test E.C.U. part numbers Function This mode enables a technician to adjust some devices faster and more accurately by following the indications on the CONSULT unit. Self-diagnostic results can be read and erased quickly. Input/Output data in the control unit can be read. Mode in which CONSULT drives some actuators apart from the control units and also shifts some parameters in a specified range. E.C.U. part numbers can be read.

WORK SUPPORT MODE

WORK ITEM THROTTLE SENSOR ADJUSTMENT CONDITION CHECK THE THROTTLE SENSOR SIGNAL. ADJUST IT TO THE SPECIFIED VALUE BY ROTATING THE SENSOR BODY UNDER THE FOLLOWING CONDITIONS. l IGN SW "ON" l ENG NOT RUNNING ACCPEDALNOTPRESSED
l IGNITION TIMING

USAGE When adjusting throttle sensor initial position,

IGNITION TIMING ADJUSTMENT*

FEEDBACK CONTROL WILL BE HELD BY TOUCHING "START". AFTER DOING SO, ADJUST IGNITION TIMING WITH A TIMING LIGHT BY TURNING THE CRANK ANGLE SENSOR.

When adjusting initial ignition timing,

AAC VALVE ADJUSTMENT

SET ENGINE RPM AT THE SPECIFIED VALUE UNDER THE FOLLOWING CONDITIONS. l ENGINE WARMED UP l NO-LOAD
l FUEL

When adjusting idle speed,

FUEL PRESSURE RELEASE

PUMP WlLL STOP BY TOUCHING "START" WHEN IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure from fuel line,

SELF-DIAGNOSTIC RESULTS MODE

DIAGNOSTIC ITEM CRANK ANGLE SENSOR*
l Either

DIAGNOSTIC ITEM IS DETECTED WHEN

...
0

CHECK ITEM (REMEDY) Harness and connector (If harness and connector are normal, replace crank angle sensor.) and connector (If harness and connector are normal, replace air flow meter.) and connector temperature sensor

1" or 180' signal is not entered for the first few seconds during engine cranking. l Either 1" or 180" signal is not input often enough w h ~ l e the engine speed is higher than the specified rpm.
l The

AIR FLOW METER

air flow meter circuit is open or shorted. (An abnormally high or low voltage is entered.)

l Harness

ENGINE TEMP SENSOR

l The

engine temperature sensor circuit is oRen or shorted. (An abnormally high or low output voltage is entered.) air temperature sensor circuit is open or shorted. (An abnormally high or low voltage is entered.)

l Harness l Engine

AIR TEMP SENSOR

l The

l Harness l Air

and connector temperature sensor

' : Check items causing a malfuction of crank angle senser circuit first, if both "CRANK ANGLE SENSOR" and "IGN
SIGNAL-PRIMARY" come out at the same time.

ES-126

TROUBLE DIAGNOSES
Consult (Cont'd)
DATA MONITOR MODE
MONITOR ITEM CAS RPM (REF) CONDITION Tachometer: Connect Run engine and compare tachometer indication with the CONSULT value. Engine: After warming up, idle the engine AIC switch "OFF" Shift lever "N" No load Engine: After warming up Idle 2,000 rpm SPECIFICATION Almost the same speed as the CONSULT value.

[ q
CHECK ITEM WHEN OUTSIDE SPEC. Harness and connector Crank angle sensor

1.3 1.8V
1.8 2.2V Harness and connector Engine temperature sensor Harness and connector Exhaust gas sensor Intake leaks air Injectors Harness and connector Vehicle speed sensor Battery E.C.U. power supply circuit Harness and connector Throttle sensor Throttle sensor adjustment Harness and connector Fuel temp. sensor Harness and connector Starter switch Harness and connector Throttle sensor Throttle sensor adjustment Harness and connector Air conditioner switch Harness and connector Neutral switch Harness and connector Power steering oil pressure switch Harness and connector Injector Air flow meter Harness and connector Crank angle sensor Harness and connector AAC valve

AIR FLOW MTR

Harness and connector Air flow meter

ENG TEMP SEN EXH GAS SEN MIR FIC MNT

More than 70C (158'F)

O - O.SV

0.6

- l.OV

Engine: After warming U P

Maintaining engine speed at 2.000 rpm

LEAN +-B RICH Changes more than 5 times during 10 seconds. Almost the same speed as the CONSULT value 11 - 14V

CARSPEEDSEN

Turn drive wheels and compare speedometer indication with the CONSULT value Ignition switch: ON (Engine stopped) Throttle valve fully closed Throttle valve fully opened

BATTERY VOLT

THROlTLE SEN

Ignition switch: ON (Engine stopped)

0.4'- 0.5V
Approx. 4.OV 20 60'C ("

AIR TEMP SEN START SIGNAL

Engine: After warming up Ignition switch: ON + START Throttle valve: Idle position Throttle valve: Slightly open
switch "OFF"

- 140"F)

OFF + ON ON OFF OFF ON ON OFF OFF ON 2.9 - 3.6 msec. 2.6 - 3.3 msec. 15 deg. More than 25 deg. 15" - 40"

IDLE POSITION

Ignition switch: ON (Engine stopped)

AIR COND SIG

Engine: After warming up, idle the engine Ignition switch: ON

AIC switch "ON" Shift lever "P" or "NW

NEUTRAL SW

Except above Engine: After warming up, idle the engine Steering wheel in neutral (forward direction) The steering wheel is turned

PWlST SIGNAL

Idle INJ PULSE 2,000 rpm Idle IGN TIMING 2,000 rpm Idle AAC VALVE 2,000 rpm

TROUBLE DIAGNOSES Consult (Cont'd)

ACTIVE TEST MODE
TEST ITEM CONDITION a Engine: Return to the original trouble condition a Change the amount of fuel injection with the CONSULT. a Engine: After warming up, idle the engine. a Change the AAC valve opening percent with the CONSULT. a Engine: Return to the original trouble condition a Change the engine coolant temperature with the CONSULT. a Engine: Return to the original trouble condition Timing light: Set a Retard the ignition timing with the CONSULT. a Engine: After warming up, idle the engine. a AIC switch "OFF" Shift lever a Cut off each injector signal one at a time with the CONSULT.
a lgnition switch: ON a Turn the radiator fan "ON" and

I KA24E I
CHECK ITEM (REMEDY) a Harness and connector a Fuel injectors Exhaust gas sensors

JUDGEMENT If trouble symptom disappears, see CHECK ITEM.

FUEL INJECTION TEST

OPENIN' TEST

Engine speed changes according to the opening percent.

a Harness and connector

m AAC valve

ENGINE TEMP TEST

If trouble symptom disappears, see CHECK ITEM.

a Harness and connector a Engine temperature sensor a Fuel injectors

ION TIMING TEST

If trouble symptom disappears, see CHECK ITEM.

Adjust initial ignition timing

POWER BALANCE TEST

Engine runs rough or dies.

a a a a a a

Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils

RADIATOR FAN TEST

Radiator fan moves and stops.

"OFF" with the CONSULT. a lgnition switch: ON (Engine stopped) a Turn the fuel pump relay "ON" and "OFF" with the CONSULT and listen to operating sound. a lgnition switch: ON a Turn solenoid valve "ON" and "OFF" with the CONSULT and listen to operating sound. Fuel pump relay makes the operating sound.

a Harness and connector a Radiator fan motor

FUEL PUMP RLY TEST

a Harness and connector a Fuel pump relay

PRVR CONT

TEST

SWIRL CONT S O W TEST SELF-LEARN CONT TEST

Each solenoid valve makes an operating sound.

a Harness and connector a Solenoid valve

a In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching on the screen.

TROUBLE DIAGNOSES
'

pq

Basic Inspection

BEFORE STARTING 1. Check service records for any recent repairs that may indicate a related problem, or the current need for scheduled maintenance. 2. Open engine hood and check the following: Harness connectors for proper connections Vacuum hoses for splits, kinks, and proper connections Wiring for proper connections, pinches, and cuts

H
CONNECT CONSULT TO THE VEHICLE. Connect "CONSULT" to the diagnostic connector and select "ENGINE" from the menu. (Refer to page ES-124)

El

'
m
Timing light
SEF284G

DOES ENGINE ST

CHECK IGNITION TIMING. Warm up engine sufficiently and check ignition timing at idle using timing light. (Refer to page ES-107) lgnltion timing: 15"f2" B.T.D.C.

Adjust timing by 5turningignitionangle sencrack sor.

(Go to

G next page.)

TROUBLE DIAGNOSES Basic Inspection (Cont'd)

AAC UALVE ADJ I SET Et.IGINE RPM AT THE SPEC I I F ED I,IALiJE Ut.jfiER THE FOLLOW It.#; C:OI.jp 1T 1Obj
= ENG

H
CHECK IDLE ADJ. SCREW INITIAL SET RPM. 1. Select "A.A.C. VALVE ADJ" in 2. When touching "START", does engine rpm fall to the following values? MIT: 650f 50 rpm AIT: 650f50 rpm ("N" position) OR When disconnecting throttle sensor harness connector, does engine rpm fall to the following values? MIT: 650f 50 rpm AIT: 650f 50 rpm ("NWposltlon)

WARMED UP

LI3A[>

Adjust engine rpm by turning idle adjusting screw.

CAUTION Be sure to set gears to "Neutral".

S T,*:'', E T ..
SEF3721

Throttle sensor

'
SEF408J

Yes
CHECK THROTTLE SENSOR IDLE POSITION. 1. Perform "THROTTLE SEN.

-0
ITHROTTLE 5Et.I AC:tJ 1 0
*:+:+X+:+

ADJ

1TOR

:+***:+

5l . Adjust output voltage by rotating throttle sensor body.

THROTTLE SEt.4

I11.4EsU

2. Disconnect throttle
mode. 2. Check that output voltage of throttle sensor is 0.4 to 0.5V. (Throttle valve fully closes.) and "IDLE POSITION" stays "ON". O -R Measure output voltage of throttle sensor using voltmeter, and check that it is 0.4 to 0.5V. (Throttle valve fully closed.) sensor harness connector for a few seconds and then reconnect it. 3. Confirm that "IDLE POSITION" stays "ON".

-------

CM. (POS :> RPM

ITOR =======
~ I ~PmI ~ I ~ I

IDLE F ) ~ C ; I T I I ~ ~ . ~1 4 .

SEF147l

(Go to

on next page.)

SEF1481

TROUBLE DIAGNOSES Basic Inspection (Cont'dl

I KA24EI

I CHECK SWITCH INPUT SIGNAL.

Select the following switches in
"DATA MONITOR" mode,

N.G.

Repair or replace the malfunctioning switch or

its circuit.

a) Start signal, b) Idle position, c) Air conditioner signal, d) Neutral (Parking) switch, and check the switches' ON-OFF operation.

@
Switch Start i n

Remove E.C.U. from front floor panel and check the above switches' ON-OFF operation using voltmeter at each E.C.U. terminal.

Condition

Voltage (V) O vo,tage

Id. wsition

Neutral. (Parking) switch

Shift lever is "N" or "P" position Except "N" and

o-,

,,p##

F A I L U R E DETEC:TED

TIPlE
Ci

E$Il;IE;E

TEMP SENSciR

SELF-DIAGNOSTIC RESULTS. 1. Perform "SELF-DIAG RESULTS" mode. 2. Read out self-diagnostic results. 3. Is a failure detected?
1. Set "Self-diagnostic results

mode" in Mode II. (Refer to page ES- 120) 2. Count the number of RED L.E.D. flashes and read out the codes. 3. Are the codes being output?

0
INSPECTION END

I b","-Em I I - I

8.0 -9.0

5 Go to the relevant inspection procedure.

TROUBLE DIAGNOSES

pq

(ilI:TII.IE

TEST

Diagnostic Procedure 1 - High Idling after Warm-up

CHECK INTAKE AIR LEAK. 1. Select "SELF-LEARNING mode. 2. Clear the self-learning control coefficient by touching "CLEAR". 3. Does the engine speed drop? OR 1. Disconnect exhaust gas sensor harness connectors. 2. After racing engine at 1,500 rpm under no load for about 30 seconds, does the engine speed drop? No CHECK THROTTLE LINKAGE. 1. Check that throttle linkage moves smoothly. 2. Confirm that throttle valve both fully opens and fully closes.

!jELF-LEkFll
and repair.

SEF294.J

Exhrrrst gas

0 '
SEF3751

sticking of throttle valve.

. .
INSPECTION END

TROUBLE DIAGNOSES
Diagnostic Procedure 2 - Hunting

When disconnecting exhaust gas sensor harness connector, is the hunting

Check exhaust gas sensor. (See page ES-182)

1. Perform "POWER BALANCE" 2. Is there any cylinder which does not produce a momentary engine speed drop? OR When disconnecting each spark plug cap one at a time, is there any cylinder which does not produce a momentary engine speed

CHECK SPARK PLU.GS. Remove the spark plugs and check for

Repair or replace spark Plug(S).

CHECK FOR INTAKE AIR LEAK. When pinching blow-by hose (lowering the blow-by air supply), does the engine speed rise?

Discover air leak location and repair.

INSPECTJON END

TROUBLE DIAGNOSES
Diagnostic Procedure 3 U i B

I KA24E /
-Unstable Idle

1. Perform "POWER BALANCE"

2. Is there any cylinder which does not produce a momentary engine speed drop? OR When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop?

Yes

CHECK INJECTOR. 1. Remove crank angle sensor from engine. (Harness connector should remain connected.) 2. Disconnect each ignition wire. 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound? Yes

Check injector(s) and circuit(s).

L

I
I

El

l
Check ignition coil, power transistor unit and their circuits. (See page ES-179)

CHECK IGNITION SPARK. 1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark.

. .
(Go to

on next page.)

TROUBLE DIAGNOSES Diagnostic Procedure 3 - Unstable Idle (Cont'd)

CHECKSPARKPLUGS. Remove the spark plugs and, check for

N.G.

Repair or replace spark PlUg(s).

@
FI_lE; Pljp;P !!!;~i :i;T;>p E#.?/ T6l-liC:HIifi :i:T(iRT 1t.i 1 [ i ~ - ! !::E(i j TEE i#.EkiGIIiEFE:!! TIpiES kFSTHLL.
(i

CHECK FUEL PRESSURE. 1. Perform "FUEL PRESSURE RELEASE7'in "WORK SUPPORT" mode in order to release fuel pressure to zero. 2. Install fuel pressure gauge and check fuel pressure. At idle: Approx. 226 kPa (2.3 kglcm2, 33 psi) OR 1. Release fuel pressure to zero. (Refer to page ES-219) 2, Install fuel pressure gauge and check fuel pressure.

fuel pump and cir-

(Go to

next page.)

CAUTION: When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key wlth CONSULT set in "Work Support" mode.

TROUBLE DIAGNOSES Diagnostic Procedure 3

I KA24E /

- Unstable Idle (Cont'd)

CHECK EXHAUST GAS SENSOR. 1. See "M/R FIC MNT" in "Data monitor" mode. 2. Maintaining engine at 2,000 rpm under no-load (engine is warmed up sufficiently.), check that the monitor fluctuates between "LEAN" and "RICH" more than 5 times during 10 seconds. RICH+LEAN+R($H+ 1 time 2 times LEAN+RICH OR 1. Set "Exhaust gas sensor monitor" in the self-diagnostic Mode II. (See page ES- 123) 2. Maintaining engine at 2,000 rpm under no-load, check t o make sure that ECM lamp or RED L.E.D. on the E.C.U. goes ON and OFF more than 5 times during 10 seconds.

.......

CHECK FOR INTAKE AIR LEAK. When pinching blow-by hose (lowering the blow-by air supply), does the engine speed rise?
No

and repair.

(Go to

a on next page.)

TROUBLE DIAGNOSES Diagnostic Procedure 3

li]
I691::
!,illi~!;i~ AC~..T

- Unstable Idle (~ont'd)

Check clogging No throttlefor IASclogging. or valve

aC ]
l] i
CHECK IDLE ADJ. SCREW CLOGGING. 1. Perform "AAC VALVE ADJ" in "WORK SUPPORTs'mode. 2. Can you set engine rpm as follows by turning idle adjusting screw? MIT: 850 f 50 rpm AIT: 650 f 50 rpm ("NW position) OR 1. Disconnect throttle sensor harness connector. 2. Can you set engine rpm as follows by turning idle adjusting screw? MIT: 650 f 50 rpm AIT: 650 f 50 rpm ("N" position)

:+:t::t::+:+ AD.1 Mfit.i l TlziF :+::+:+::+::+: C:$i::;.R'pi(Pg!;) 71zrpri,

-- l;fit.j[:i 1T1fit.j SETT I I.jG -~AI: I,.!AL!,IE F I XED ------Mgt.4 I Tf'iR E t . 4 ~ ~ ~ t . 12~1.4 p IDLE F'Ci!3ITIl)it.{ A I lI:Cit.4fi ;:! I3 R 1
6 1 4 . I~FF

======= i77" F

SEF1451

2,,\11'

3
1

,?

*C

1 0 '

1 ;

SEF408J

m
CHECK COMPRESSION PRESSURE. Check compression pressure. Standard: kPa (kglcm2, psi)lrpm 1,206 (12.3, 175)1250 Minimum: kPa (kglcm2, ps1)lrpm 1,010 (10.3, 146)1250 Difference between each cylinder: kPa (kglcm2, psi)lrpm 98 (1.0, 14)1250

5 Check pistons, piston

rings, valves, valve seats and cylinder head gaskets.

SEF309G

. .

m
CHECK E.C.U. HARNESS CONNECTOR. Check the E.C.U. pin terminals for damage or poor connection of E.C.U. harness connector.
Repair or replace.

. .
TRY A KNOWN GOOD E.C.U.

. .
INSPECTION END

TROUBLE DIAGNOSES

Diagnostic Procedure 4 - Hard to Start or Impossible to Start when the Engine is Cold

@ % @>
+---p--

Repair or replace.

CHECKto EL section.) STARTER. Check battery and AND (Refer BATTERY starter condition.

. .

CHECK FUEL PRESSURE. 1. Pinch fuel feed hose with fingers. 2. When cranking the engine, is there any pressure on the fuel feed hose?

No

Check fuel pump and circuit. (See page ES-193)

CHECK A.A.C. VALVE. When pressing accelerator pedal fully, can you start the engine?

circuits. (See page ES-196)

CHECK INJECTOR. 1. Remove crank angle sensor from engine. (Harness connector should remain connected.) 2. Disconnect each ignition wire. 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound?

circuit(s).

Yes

& Check ignition coil, power

1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark. transistor unit and their circuits. (See page ES-179)
L

(Go to

v
on next page.)

SEF282G

TROUBLE DIAGNOSES Diagnostic Procedure 4 - Hard to Start or Impossible to Start when the Engine is cold (Cont'd)
H
CHECKSPARKPLUGS. Remove the spark plugs and check for fouling, etc.

. .

u
CHECK E.C.U. HARNESS CONNECTOR. Check the E.C.U. pin terminals for damage or poor connection of E.C.U. harness connector.

Repair or replace.

Repair or replace.
GROUND CIRCUIT. Refer to page ES- 170

. .

El
TRY A KNOWN GOOD E.C.U.

INSPECTION END

TROUBLE DIAGNOSES

I KA24E I

Diagnostic Procedure 5 - Hard to Start or Impossible to Start when the Engine is Hot
CHECK FUEL PRESSURE. 1. Pinch fuel feed hose with fingers. 2. When cranking the engine, is there any pressure on the fuel feed hose? Check fuel pump and circuit. (See page ES- 193)

Check fuel properties.

1. Select "PRVR CONT SOL

------- - . . - z -------l ----- - --- --l, t- - - , :-K F t i I . r-:

I

'4

8E:,; -E!,F
t

.,-- :E,, l'sc= 1 -. A

l$t,?

Fl.,L.:E

***I ' 1L E 11
I

-r, -i;.,---i

:G-

@
SEF266-J

mode. 2. After touching "ON", can you start the engine? OR 1. Disconnect fuel pressure regulator vacuum hose and plug hose 2. Can you start engine? No

CHECK INJECTOR. 1 Remove crank angle sensor from englne. (Harness connector should remain connected.) 2. Disconnect each ignition wire 3. Turn Ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound?

No

Check injector(s) and circuit(s).

m
CHECK IGNITION SPARK. 1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against.a suitable ground and crank engine. 4 Check for spark. Check ignitlon coil, power transistor unit and circuits (See page ES-179)

. .

El

(Go to

on next page )

SEF282G

Diagnostic Procedure 5

TROUBLE DIAGNOSES Hard to Start or Impossible to Start when the Engine is

U - b
/f\

pq

nut ~ ~ U I I LUI

lfi--b9A\

4
Repair or replace.

CHECK E.C.U. HARNESS CONNECTOR. Check the E.C.U. pin terminals for damage or poor connection of E.C.U. harness connector.

Repair or replace.
GROUND CIRCUIT. Refer to page

TRY A KNOWN GOOD E.C.U.

I INSPECTION END

TROUBLE DIAGNOSES Diagnostic Procedure 6 - Hard to Start or Impossible to Start under Normal Conditions

@ )

+------

qh
/c, '/'
SEF3801

CHECK BATTERY AND STARTER. Check battery and starter operation. (Refer to EL section.)
Repair or replace.

CHECK FUEL PRESSURE. 1. Pinch fuel feed hose with fingers. 2. When cranking the engine, is there any pressure on the fuel feed hose?

Check fuel pump and circuit. (See page ES-193)

El
CHECK INJECTOR FOR LEAKAGE. When pressing accelerator pedal fully, can you start the engine?

Yes Check injector(s) for leakage.

B
CHECK INJECTOR. 1. Remove crank angle sensor from engine. (Harness connector should remain connected.) 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound?
Check injectors and circuits.

CHECK IGNITION SPARK. 1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark.

5Check ignition coil, power

transistor unit and circuits. (see page ES-179)

(Go to

on next page.)

SEF282G

TROUBLE DIAGNOSES stic Procedure 6

1 KA24E I

- Hard to

Start or Impossible to Start uncler Normal Conditions (ContY)

CHECK SPARK PLUGS. Remove the spark plugs and check for fouling, etc.

NG, Repair or . .

realace soark , -r-. .-

PIU~(~).

. .

CHECK E.C.U. HARNESS CONNECTOR. Check the E.C.U. pin terminals for damage or poor connection of E.C.U. harness connector.

Repair or replace.

Repair or replace GROUND CIRCUIT. Refer to page ES- 170

. .

H
TRY A KNOWN GO

INSPECTION END

Replace E.C.U.

ES- 143

TROUBLE DIAGNOSES
Diagnostic Procedure 7 - Hesitation when the Engine is Hot

I HC.TI,.!E T E Z ~ T1 ,;.X

p ~ ~ i, :;* :o,

1:'F F
[I. 921: - . ,

,/E::#

-------

:lplt.rITbg ======= -c. ,1-s3m Prp .-,,-It- F

'HGC

GA$ 5Et.I Ik4.J F'CiL!:;E

I i q j l IE

1E,:;

SEF266.J

CHECK FUEL VAPOR. @ l . Select "PRVR CONT SOL VALVE" in "ACTIVE TEST" mode. 2. After touching "ON", perform cruise test. 3. Does the hesitation disappear? OR 1. Disconnect fuel pressure regulator vacuum hose and plug hose. 2. Perform cruise test. 3. Does the hesitation disappear?

Check fuel properties.

CHECK CANISTER PURGE. 1. Disconnect canister purge line hose, and plug hose. 2. Perform cruise test. 3. Does the hesitation disappear?
No

orifice into the purge line hose.

INSPECTION END

ES- 144

TROUBLE DIAGNOSES

1-

Diagnostic Procedure 8 - Hesitation when the Engine is Cold

U
CHECKSPARKPLUGS. Remove spark plugs and check for fouling, etc.

. .

R
CHECK FOR INTAKE AIR LEAK. When pinching blow-by hose (lowering the blow-by air supply), does the engine speed rise?

and repair.

No

El
TRY A KNOWN GOOD AIR FLOW METER.

Trouble is fixed. Replace air flow meter.

Trouble

IS

not flxed.

El
CHECK FOR INTAKE VALVE DEPOSITS. If there are deposits on intake valves, remove them.

INSPECTION END

ES- 145

TROUBLE DIAGNOSES

pq

Diagnostic Procedure 9 - Hesitation under Normal Conditions

CHECK SPARK PLUGS. Remove spark plugs and check for fouling, etc.
.N.G.

Repair or replace spark

~lug(s).

i;>l.tBt.iITBP
i
!
F,

liTr;:i9 1 - C
,<

I;&$. RpM,:pBS /El,..zFF..'[ HEiT

.::-!:~;v

- - --

~fi,

LEilj

l
P,t i.-.

l
.;-)

i
l

C,ri
! . X

-i

L"

SEF265.J

CHECKEXHAUSTGASSENSOR. 1. See "MIR FIC MNT" in "DATA MONITOR" mode. 2. Maintaining engine at 2,000 rpm under no-load (with engine warmed up sufficiently.), check to make sure that the monitor fluctuates between "LEAN" and "RICH" more than 5 times during 10 seconds. RlCH+LEAN-+RlFH-+ l time 2 times LEAN+RICH I OR 1. Set "Exhaust gas sensor monitor" in the self-diagnostic Mode D. (See page ES- 123)

Replace exhaust gas senSOT.

.......

2. Maintaining engine at 2,000

rpm under no load, check that RED L.E.D. on the E.C.U. goes ON and OFF more than 5 times during 10 seconds.

SEF1521

H
CHECK CANISTER PURGE. 1. Disconnect canister purge line hose and plug hose. 2. Perform cruise test. 3. Does the hesitation disappear?
No Install small size orifice into the purge line hose.

(GO to

on next page.)

ES- 146

TROUBLE DIAGNOSES Diagnostic Procedure 9 - Hesitation under Normal Conditions (Cont'd)

p
Discover air leak location and repair.

CHECK FOR INTAKE AIR LEAK. When pinching blow-by hose (lowering the blow-by air supply), does the engine speed rise? No

INSPECTION END

TROUBLE DIAGNOSES Diagnostic Procedure 10 - Engine Stalls when Turning

CHECK FUEL LEVEL. Check to see that there is enough fuel Fill fuel tank with fuel.

l
GO

PERFORM POWER BALANCE TEST. 1. Perform "POWER BALANCE" in "ACTIVE TEST" mode. 2. Is there any cylinder which does not produce a momentary engine speed drop? When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop?

to

]Yes

CHECK INJECTOR. 1. Remove crank angle sensor from engine. (Harness connector should remain connected.) 2. Disconnect each ignition wire. 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound?
I

Yes

4
Check ignition coil, power transistor unit and circuits. (See page ES- 179)

CHECK IGNITION SPARK. 1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark.

.
(GOto

on next page.)

ES- 148

TROUBLE DIAGNOSES Diagnostic Procedure 10 - Engine Stalls when Turning (Cont'd)

1. Perform "FUEL PRESSURE

5 Check fuel pressure regulator diaphragm.

II

SUPPORT" mode in order to release fuel pressure to zero. 2. Install fuel pressure gauge and check fuel pressure. At Idle: Approx. 226 kPa (2.3 kglcm2,33 psi) The moment throttle valve Is fully open: Approx. 294 kPa (3.0 kglcm2,43 psi) OR 1. Release fuel pressure to zero. (Refer to page ES-2 19) 2. Install fuel pressure gauge and check fuel pressure.

. .

a I CHECK E.C.U. HA I Check the E.C.U. pin,terminals for dam- I I age or poor connection of E.C.U. har- I I ness connector. I

Repair or replace.

l
CHECK E.C.U. POWER SUPPLY AND GROUND CIRCUIT. Refer to page ES- 170

Repair or replace.

. .

B
TRY A KNOWN GOOD E.C.U.

INSPECTION END

CAUTION: When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key with CONSULT set in "Work Support" mode.

KA24E TROUBLE DIAGNOSES Diagnostic Procedure 11 - Engine Stalls when the Engine is Hot (Cont'd)

B
Ignition wire

Spark plug

CHECK IGNITION SPARK. 1. Disconnect each all spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark.

transistor unit and their circuits. (See page ES- 179)

. .
CHECK FUEL PRESSURE. 1. Perform "FUEL PRESSURE SUPPORT" mode in order to release fuel pressure to zero. 2. Install fuel pressure gauge and check fuel pressure. At idle: Approx. 226 kPa (2.3 kglcm2, 33 psi) The moment throttle valve is fully open: Approx. 294 kPa (3.0 kglcm2, 43 psi)

Aj S 1 ulator diaphragm.

1. Release fuel pressure to zero. (Refer to page ES-2 19) 2. Install fuel pressure gauge and check fuel pressure.

1
Repair or replace.

CHECK E.C.U. HARNESS CONNECTOR. Check the E.C.U. pin terminals for damage or poor connection of E.C.U. harness connector.

I
Repair or replace.

1
CHECK E.C.U. POWER SUPPLY AND GROUND CIRCUIT. Refer to page ES- 170

1
TRY A KNOWN GOOD E.C.U. Trouble
IS

Trouble is fixed. Replace E.C.U. not f~xed.

INSPECTION END

CAUTION: When servicing fuel system a b r performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key with CONSULT set in "Work Support" mode.

TROUBLE DIAGNOSES
Diagnostic Procedure 12 - Engine Stalls when the Engine is Cold
CHECK A.A.C. VALVE. When the engine is cold, can you start the engine when pressing accelerator

piq

circuits. (See page ES-196)

1. Perform "POWER BALANCE"

2. Is there any cylinder which does not produce a momentary engine speed drop?

SEF1571

When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop?

CHECK INJECTOR.

Check injector(s) and

I 1. Remove crank angle sensor from

engine. (Harness connector should remain connected.) 2. Disconnect each ignition wire. 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound?

I
1

II circuit(s).

II

1I
Check ignition coil, power transistor unit and circuits. (See page ES-179)

El

CHECK IGNITION SPARK. 1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark.

. .
(Go to

on next page.)

( KA24E TROUBLE DIAGNOSES Diagnostic Procedure 12 - Engine Stalls when the Engine is Cold (Cont'd)

CHECK SPARK PLUGS. Remove the spark plugs and check for

& Repair or replace spark

plug(s)
L

CHECKFUELPRESSURE. 1. Perform "FUEL PRESSURE

p

Check fuel pressure regulator diaphragm.

I U F-iEL F c E i

1 FYEL F'JI~F '*l1 !'*-IF E'" I ~ ~ ; ~ ~ IT~ ;:TI : J ~ ~111 I[ L:~ H

CFwtJt H F E TEP EtlliIt4E ~

~HLL.

'Ir4Ef

HF-l

'_TLFT

SUPPORT" mode in order to release fuel pressure to zero. 2. Install fuel pressure gauge and check fuel pressure. At idle: Approx. 226 kPa (2.3 kglcm2, 33 psi) The moment throttle valve is fully open: Approx. 294 kPa (3.0 kglcm2,43 psi) OR 1. Release fuel pressure to zero. (Refer to page ES-2 19) 2. Install fuel pressure gauge and check fuel pressure.

Repair or replace.
SEF3791

Check the E.C U. pin terminals for damage or poor connection of E C.U harness connector.

Repair or replace.
GROUND CIRCUIT. Refer to page ES- 170

El

TRY A KNOWN GOOD E.C.U.

1
I

I INSPECTION END

CAUTION: When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key with CONSULT set in "Work Support" mode.

TROUBLE DIAGNOSES

IAC:TI!.!E TEST I
AAI: /!,! uPEt.11t.lrj

50:.:

Diagnostic Procedure 13 Engine Stalls when Stepping on the Accelerator Momentarily

U
CHECK A.A.C. VALVE. 1. Select "A.A.C. VALVE

-------

Mut.jITBR ======= CAS. HPM<PO!S) 550rPri, A I R FLlliW PITH 1.24l.,J Et.IG TEMP SEt.1 179F

circuit. (Seepage ES-196)

SEF1621

mode. 2. When touching "Qu" and "Qd", does the engine speed change according to the percent of A.A.C. valve opening? OR When disconnecting throttle sensor harness connector, does the engine speed drop? Yes PERFORM POWER BALANCE TEST. 1. Perform "POWER BALANCE" in "ACTIVE TEST" mode. 2. Is there any cylinder which does not produce a momentary engine speed drop?

CAUTION: Be sure to set gears to "Neutral".

:t::t::+:t: POI$EE

------CA!;.

@ALAt.II::E :+:r:t::t: Ilot.lITfiR ======= :i:5l1lr P m RPpl r: PCi!; )

=R When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop?

SEF'571A

CHECKINJECTOR. 1. Remove crank angle sensor from engine. (Harness connector should remain connected.) 2. Disconnect each ignition wire. 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound? Yes (Go to

Check injector(s) and their circuit(s).

: 0

next page.)

KA24E TROUBLE DIAGNOSES Diagnostic Procedure 13 - Engine Stalls when Stepping on the Accelerator El Momentarily (Cont'd)
Ignition wire

I --l :

a
CHECK IGNITION SPARK. 1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark.

Check ignition coil, power transistor unit and their circuits. (See page ES-179)

sEF282G

mEf'EG.liE
l
FEi

:--: - - K
;ii
Z c ,

,l!

CHECK FUEL PRESSURE. 1. Perform "FUEL PRESSURE

Check fuel pressure reg-

:ItiG. 5 ,;pHt;I ;TEF E.IU;}rE

ulator diaphragm.

-i*?E: -=-l 1

'M-!..

_I-FT

l I

SUPPORT" mode ln order to release fuel pressure to zero 2 Install fuel pressure gauge and check fuel pressure At idle: Approx. 226 kPa (2.3 kglcm2, 33 psi) The moment throttle valve is
fully open: Approx. 294 kPa (3.0 kglcm2, 43 psi) 1. Release fuel pressure to zero.

(Refer to page ES-2 19) 2. Install fuel pressure gauge and check fuel pressure.

(i]

C
Repair or replace.

CHECK E.C.U. HARNESS CONNECTOR. Check the E.C.U. pin terminals for darnage or poor connection of E.C.U. harness connector.

. .

I CHECK E.C.U. POWER SUPPLY AND

GROUND CIRCUIT. Refer to page ES- 170.

Repair or replace.
I

1
I

TRY A KNOWN GOOD E.C.U.

I INSPECTION END

CAUTION: When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key with CONSULT set in "Work Support" mode.

TROUBLE DIAGNOSES Diagnostic Procedure 14 - Engine Stalls after Decelerating

a
CHECK A.A.C. VALVE. 1. Select "A.A.C. VALVE

circuit. (See page ES-196)

mode. 2. When touching "Qu" and "Qd", does the engine speed change according to the percent of A.A.C. valve opening? I O R I When disconnecting throttle sensor harness connector, does the engine speed drop?

CAUTION: Be sure to set gears to "Neutral".

CHECK IDLE ADJ. SCREW CLOGGING.

Check for IAS clogging or throttle chamber clogging.

2. Can you set engine rpm as follows by turning idle adjusting screw? MIT: 650 f 50 rpm A m 650 f 50 rpm ("NW position)

OR
1. Disconnect throttle sensor harness connectors. 2. Can you set engine rpm as fpllows by turning idle adjusting screw? MIT: 650 f 50 rpm A m 650 f 50 rpm ("NW position) lYes

(Go to

@ on next page.)

KA24E) 3OUBLE DIAGNOSES Diagnostic Procec lure 14 - Engine Stalls after Decelerating (Cont'd)

El
PERFORM POWER BALANCE TEST. 1. Perform "POWER BALANCE" in "ACTIVE TEST" mode. 2. Is there any cylinder which does not produce a momentary engine speed drop?

N Go to o

When disconnecting each injector coil harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop? Yes

B
CHECK INJECTOR. 1. Remove crank angle sensor from engine. (Harness connector should remain connected.) 2. Disconnect each ignition wire. 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound?

circuit(s).

lYes

CHECK IGNITION SPARK. 1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end.of spark plug against a suitable ground and crank engine. 4. Check for spark.

I N.G.I.

Check ignition coil, power transistor unit and circuit.

(See page ES- 179)

(Go to

on next page.)

TROUBLE DIAGNOSES
p

KA24E

Diagnostic Procedure 14
FllEL PIJlP IjJILL STBF E'; :. TnlJl::H 1t.413 S T W T IN I D L ING. 12Rilt.IK C FEld T I i llES WTER El.4EiINE STHLL.

- Engine Stalls after Decelerating (Cont'd)

fuel pressure 5Check diaphragm. regulator

CHECK FUEL PRESSURE. 1. Perform "FUEL PRESSURE

SUPPORT" mode in order to release fuel pressure to zero. 2. Install fuel pressure gauge and check fuel pressure. At idle: Approx. 226 kPa (2.3

l
l

kglcm2, 33 psi) The moment throttle valve is fully open: Approx. 294 kPa (3.0 kglcm2, 43 psi) OR 1. Release fuel pressure to zero. (Refer to page ES-2 19) 2. Install fuel pressure gauge and check fuel pressure.

,::~c;.F.'F'M(F'g~~,:' t.l..>'i;l F..'!:: !.liiT

~:;!:~~r-p,(!

LEH!~

l
i

CHECK EXHAUST GAS SENSOR. 1. See "MIR FIC MNT" in "DATA MONITOR" mode. 2. Maintaining engine at 2,000 rpm under no-load (with engine warmed up sufficiently.), check to make sure that the monitor fluctuates between "LEAN" and "RICH" more than 5 times during 10 seconds. RI$H-LEAN +MC& 1 time 2 times LEAN-RICH OR 1. Set "Exhaust gas sensor monitor" in the self-diagnostic Mode IT. (See page ES- 123)

Replace exhaust gas sensor.

.......

2. Maintaining engine at 2,000 rpm under no load, check that RED L.E.D. on the E.C.U. goes ON and OFF more than 5 times during 10 seconds.

. .
(Go to

a on next page.)

CAUTION: When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key with CONSULT set in "Work Support" mode.

TROUBLE DIAGNOSES Diagnostic Procedure 14 Engine Stalls after Decelerating (Cont'd)

l j

Repair or replace. Check the E.C.U. pin terminals for damage or poor connection of E.C.U. har-

Repair or replace.
GROUND CIRCUIT. Refer to page ES- 170.

m
INSPECTION END

TRY A KNOWN GOOD E.C.U.

TROUBLE DIAGNOSES

I KA24E I

IAC:TI!.!E
:*:**:+: F'l'jl>lER
----W--

TE!>T I

&iiiAt.jCE :*:*:h:+: p1ot.I I T o R ======= 85111y p m CAS. RPM ( pl3!5) A I R F 1 i. PlTR L Zld l,l~~..~

-------

Diagnostic Procedure 15 - Engine Stalls when Accelerating or when Driving at Constant Speed
PERFORM POWER BALANCE TEST. 1. Perform "POWER BALANCE" in "ACTIVE TEST" mode. 2. Is there any cylinder which does not produce a momentary engine speed drop? OR Go to

fific i.,JfiLI.,!E

Z??.;

SEFI~~I

When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop? Yes

i 1. Remove crank angle sensor from engine. (Harness connector should remain connected.) 2. Disconnect each ignition wire. 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound?

circuit(s).

CHECK IGNITION SPARK. 1. ~ischnnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark.

Check ignition coil, power 5transistor unit and their circuits. (See page ES-179)

.
(Go to SEF282G

on next page.)

TROUBLE DIAGNOSES
Diagnostic Procedure 15 - Engine Stalls when Accelerating or when Driving at Constant Speed (Cont'd)

El

H FUEL PF:ES F:ELEQ!$E H

I FIG. I CHUNK A FE1j.i TI$Em!; AF-' TER ENGINE STHLL.

8
CHECK FUEL PRESSURE. 1. Perform "FUEL PRESSURE

"_l

N.G.

Check fuel pump, circuit

~ ~ ~ 3 7 9 1

SUPPORT" mode in order to release fuel pressure to zero. 2. Install fuel pressure gauge and check fuel pressure. At Idle: Approx. 226 kPa (2.3 kglcm2, 33 psi) The moment throttle valve Is fully open: Approx. 294 kPa (3.0 kglcm2, 43 psi) OR 1. Release fuel pressure to zero. (Refer to page ES-2 19) 2. Install fuel pressure gauge and check fuel pressure.

CHECK FOR INTAKE AIR LEAK. When pinching blow-by hose (lowering the blow-by air supply), does the engine speed rise?

and repair.

N O

(Go to I
I

on next page.)

CAUTION: When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key with CONSULT set in ''Work Support" mode.

TROUBLE DIAGNOSES
Diagnostic Procedure 15

- Engine Stalls when Accelerating or when Driving at

H

pq

Constant Speed (Cont'd)

&%+
Repair or replace.

CHECK E.C.U. HARNESS CONNECTOR. Check the E.C.U. pin terminals for damage or poor connection of E.C.U. harness connector.

.
Repair or replace.

GROUND CIRCUIT.
Refer to page ES- 170.

No

I TRY A KNOWN GOOD E.C.U.

I
I

I INSPECTION END

TROUBLE DIAGNOSES Diagnostic Procedure 16 Engine Stalls when the Electrical Load is Heavy

piiq
-

Check battery and alternator condition.

PERFORM POWER BALANCE TEST. 1. Perform "POWER BALANCE"

-.- --E

. .

SEF1571

2. Is there any cylinder w h ~ c h does not produce a momentary engine speed drop? OR When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop?

El
CHECK INJECTOR. 1. Remove crank angle sensor from engine. (Harness connector should remain connected.) 2. Disconnect each ignition wire. 3. Turn ignition switch ON. (Do not start engine.) 4. When rotating crank angle sensor shaft, does each injector make an operating sound?
Yes circuit(s).

El
CHECK IGNITION SPARK. 1. Disconnect each spark plug cap. 2. Connect a known good spark plug to each spark plug cap. 3. Place end of spark plug against a suitable ground and crank engine. 4. Check for spark.
transistor unit and circuits. (See page ES-179)

(GO to

on next page.)

0.K

SEFZBZG

Diagnostic Procedure 16
FUEL PUMP WILL STOP B',? TnlJCHIPIG START I N I D L I NG !:RANK A FECi TIME!; AFTER ENGINE STALL.

TROUBLE DIAGNOSES Engine Stalls when the Electrical Load is Heavy

1
ulator diaphragm.

CHECK FUEL PRESSURE. 1. Perform "FUEL PRESSURE

SUPPORT" mode in order to release fuel pressure to zero. 2. Install fuel pressure gauge and check fuel pressure. At idle: Approx. 226 kPa (2.3 kg/cm2,33 psi) The moment throttle valve Is fully open: Approx. 294 kPa (3.0 kg/cm2,43 psi) OR 1. Release fuel pressure to zero. (Refer to page ES-2 19) 2. Install fuel pressure gauge and check fuel pressure.

(i]

1
-!& !! +
Repair or replace.

CHECK E.C.U. HARNESS CONNECTOR. Check the E.C.U. pin terminals for damage or poor connection of E.C.U. harness connector.

. .
Repair or replace.
GROUND CIRCUIT. Refer to page

H
TRY A KNOWN GOOD E.C.U.

I INSPECTION END

CAUTION: When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key with CONSULT set in "Work Support" mode.

TROUBLE DIAGNOSES

I KA24E /

,
i
i
i

.;,-!EL

-F?.-

v'-:==

r.-.

7&;~:::5
.:--,C' , ! :-,,
S $

!=!!F; p:-:pp i : : I - - --

p,: I

l
l

Diagnostic Procedure 17 - Lack of Power and Stumble

U
CHECK FUEL PRESSURE. 1. Perform "FUEL PRESSURE

I tiG. i-,pk~.:t: A FE!:; T",iE.=:- G- - ! A l . ,v TEF: Et.lij It-iE 'JTHLL. 1

ulator diaphragm.

3.1:

T:A, p T ,

SUPPORT" mode in order to release fuel pressure to zero. 2. Install fuel pressure gauge and check fuel pressure. At idle: Approx. 226 kPa (2.3 kglcm2,33 psi) The moment throttle valve is fully open: Approx. 294 kPa (3.0 kglcm2,43 psi) OR 1. Release fuel pressure to zero. (Referto ES-2 19) ~ ~ ~ 3 7 9 1 2. Install fuel pressure gauge and check fuel pressure.
! I

CHECK FOR INTAKE AIR LEAK. When pinching blow-by hose (lowering the blow-by air supply), does the engine speed rise?

Yes,

I
Discover air leak location and repair.

INSPECTION END

CAUTION: When servicing fuel system after performing "Fuel Pressure Release" in "Work Support" mode, turn off ignition key with CONSULT set in "Work Support" mode.

TROUBLE DIAGNOSES

I KA24E I
Yes

Diagnostic Procedure 18 - Detonation

CHECK FOR INTAKE AIR LEAK. When pinching blow-by hose (lowering the blow-by air supply), does the engine rpm rise?
No Discover air leak location ' and repair.

--

--

CHECK VACUUM HOSES. Check the following vacuum hoses for clogging, cracks and poor connection. a) Vacuum hose between E.G.R. control valve and E.G.R. control solenoid valve. b) Vacuum hose between E.G.R. control solenoid valve and throttle chamber port. c) Vacuum hose between E.G.R. control solenoid valve and air duct.

-! + !&

Repair or replace.

CHECK FOR OIL LEAK TO COMBUSTION CHAMBER. Remove spark plugs and check for fouling with oil.
No

Check pistons, piston rings, valves, valve seats, valve oil seal, engine oil level, etc.

INSPECTION END

TROUBLE DIAGNOSES
U

I KA24E I

/
I

iiGE ~
8..

~fii.l::i

1-I i ~i

Diagnostic Procedure 19 - Surge ~

CHECKEXHAUSTGASSENSOR. a;? c: e l 1. See "MIR FIC MNT" in "DATA MONITOR" mode. 2. Maintaining engine at 2,000 rpm under no-load (with engine warmed up sufficiently,), check to make sure that the monitor fluctuates between "LEAN" and "RICH" more than 5 times during 10 seconds. RIFH-+LEAN-tRIe 1 time 2 times LEAN-+ RICH I exhaust gas sen-

ICkl;,-F.'Fw F".S1:.. .-,.! l,1 1jpl..;p F....!:: Ili.iT ;p1..;p F.'!: Plt.IT-F.

Il '
i !l
I
l

?;-!:S F- prc -- c LEA14 F.I!I.H

--

'

"

@
I

p 7

,-..

C-.

:,-. i.-)

F;' fI!

I
I

.......

1. Set "Exhaust gas sensor monitor'' in the self-diagnostic Mode I (See page ES- 123) L 2. Maintaining engine at 2,000 rpm under no load, check that RED L.E.D. on the E.C.U. goes ON and OFF more than 5 times during 10 seconds.

TRY A KNOWN GOOD E.C.U.

INSPECTION END

TROUBLE DIAGNOSES
Diagnostic Procedure zu the Intake

/ KA24E I
- BacKtlre rnrougn

CHECK INTAKE AIR LEAK. When pinching blow-by hose (lowering the blow-by air supply), does the engine speed rise?

and repair.

El
CHECK FOR INTAKE VALVE DEPOSITS. If there are deposits on intake valves, remove them.

INSPECTION END

TROUBLE DIAGNOSES Diagnostic Procedure 21 the Exhaust

CHECK ENGINE TEMPERATURE SENSOR. Check engine temperature sensor and its circuit. (See page ES-176)

- Backfire through
Replace or repair.

INSPECTION END

TROUBLE DIAGNOSES
-~

Diagnostic Procedure 22
MAIN POWER SUPPLY AND GROUND CIRCUIT (Not self-diagnostic item)
C

onwIT

11 0

-m

+
38.47'109

m a F

INSPECTION START

1
@,'a

CHECK POWER SUPPLY. 1) Turn ignition switch "ON". 2) Check voltage between E.C.U. terminals ,@and Voltage: Battery voltage ground. . .

5 CHECK GROUND CIRCUIT.

@l D SEF9041

1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check harness continuity between E.C.U. terminals @, @ @,@and engine ground.

,m

I
IT

101

caMEcTaR

6~13~107~108~116

~ W S

Continuity should exist. If N.G., repair harness or connectors.

. .
Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

SEF9051

@T c
38-47.109

WIT

--m 1 . 1 ..

N.G. CHECK HARNESS CONTINUITY BETWEEN E.C.C.S. RELAY AND E.C.U. 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Disconnect E.C.C.S. relay. 4) Check harness continuity between E.C.U. terminals @. @, and E.C.C.S. relay terminal@ Continuity should exist.

Check the following: Harness connectors Harness continuity between E.C.U. and E.C.C.S. relay If N.G., repair harness or connectors.

P"
. .
N.G.

El

CHECK VOLTAGE BETWEEN E.C.C.S. RELAY AND GROUND. 1) Check voltage between terminals @ @ a n d ground. Voltage: Battery voltage

+ -

. .

Check the following: connector fusible link Harness continuity between E.C.C.S. relay and battery If N.G., repair harness or connectors.

TROUBLE DIAGNOSES
Diagnostic Procedure 22 (Cont'd)
7

pq
,Repair harness or connectors.

c a r r 101 cawmm ]
39.48

I3

P
. .

%
A

CHECK GROUND CIRCUIT. 1) Check harness continuity between E.C.U. terminals @, @ and engine ground. Continuity should exist.

N.G.

CHECK OUTPUT SIGNAL CIRCUIT. 1) Check harness continuity between E.C.U. terminal @and
Contlnuity should exld.

Check the following: Harness connectors Harness continuity between E.C.U. and E.C.C.S. relay If N.G., repair harness or con-

@
I
-IT

101
w c ~ o t t

N.G.

E
&

3f

1
,
I

,Check the following:

Harness connectors Harness continuity between ignition switch and E.C.U. If N.G., repair harness or connectors.

1) Turn ignition switch "ON". 2) Check voltage between E.C.U. terminal @ and ground. Voltage: Battery voltage
I

SEF9091

CHECK COMPONENT (E.C.C.S. relay). Refer to "Electrical Com~onents 1 Inspection". (See page ES-2 14)

damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 23
CRANK ANGLE SENSOR (Code No. 11)

pq

P
CHECK POWER SUPPLY. 1) Disconnect crank angle sensor harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Voltage: Battery voltage

5Check the

following:

[VI
-0

SEF9121

Harness connectors Harness continuity between crank angle sensor and E.C.C.S. relay If N.G., repair harness or connectors.

-a

. .
NG, Repair harness or connectors. . .~

CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Check harness continuity between terminal @ and engine ground. Continuity should exist.

m
S F I

. .
Repair harness or connectors.

@
c:~:;.
1;:~:';.

F:~M ,:PG:; 3 ~ p l j. ~:F'EF

g:g,2r-pnl
~ , ~ ~ y p r i I

CHECK INPUT SIGNAL CIRCUIT. 1) Reconnect crank angle sensor harness connector. 2) Start engine. 3) Read crank angle sensor signals in "DATA MONITOR" mode with CONSULT. rpm: MIT 850f50 AK 850f 50

[
-IT

101

WMSCT~

OR 1) Disconnect E.C.U. harness connector. 2) Check harness continuity between terminal @ and E.C.U. terminals 0 ,@ ( l 0 signal), terminal @ and E.C.U. terminals @ , @ (180" signal). Continuity should exist.

. .

TROUBLE DIAGNOSES Diagnostic Procedure 23 (Cont'd)

--rF]
"Z
r \
i

+
CHECK COMPONENT I (Crank angle sensor). Refer to "Electrical Components Inspection".
(See page ES-2 13)

Replace crank angle sensor.

I

damage or the connection of E.C.U. harness connector.

Perform FINAL CHECK by the following procedure after repair is completed.

FINAL CHECK

0 0
Erase the self-diagnosis mem-

I Perform driving test.

1
Recheck E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

t
INSPECTION END

TROUBLE DIAGNOSES
Diagnostic Procedure 24
AIR FLOW METER (Code No. 1 2 )
INSPECTION START

1 KA24E I

-IT
11 CONNECTOR 0

7A-T
@ B ,.
1
SEF9181

-F
CHECK POWER SUPPLY. 1) Disconnect air flow meter harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Voltage: Battery voltage

5Check the following; Harness connectors

Harness continuity between E.C.C.S. relay and air flow meter If N.G., repair harness or connectors.

. .

CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Disconnect E C . U harness connector. 3) Check harness continuity between terminal @ and E.C.U. terminal @. Continuity should exist.

. N.G.

,Repair harness or connectors.

. .
CHECK INPUT SIGNAL CIRCUIT. 1) Reconnect air flow meter harness connector and E.C.U. harness connector. 2) Start engine and warm it up sufficiently. 3) Read air flow meter signal in "DATA MONITOR" mode with CONSULT. v0ltagc;: 0.8 1.SV OR 1) Check harness continuity between terminal @ and E.C.U. terminal

-!&+l

Repair harness or connectors.

1
I

WfiKITUF

fi~jii

FAIL

a/
i

A I R ~ ~ f i 1 h .i 1. 1 ~ ~ :

l.~i:~i..i

1 i

F. ~ .~ - . ; - . ! p r1, -. . ..
L

SEF5851

ME
-IT

@
I
SEF91g1

G.
Contlnulty should exist.

101

COIWECT~

. .
CHECK COMPONENT (Air flow meter). Refer to "Electrical Components Inspection". (See page ES-2 13)

NG, Replace air flow . .

meter.

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES Diagnostic Procedure 24 (Cont'd)

FINAL CHECK

I KA24E 1

Perform FINAL CHECK by the following procedure after repair Is completed.

Erase the self-diagnosis memory.

Perform driving test.

damage or the connection of E.C.U. harness connector.

INSPECTION END

TROUBLE DIAGNOSES
Diagnostic Procedure 25
ENGINE TEMPERATURE SENSOR (Code No. 13)
\

1 ~ t I T l~ ~ R~ $<1-4!3 Fh I L

0 1

1 7
INSPECTION START

- -

CHECK POWER SUPPLY. 1) Start engine. 2) Read engine temperature sensor signal in "DATA MONITOR" mode with CONSULT. Engine temperature should gradually rise and reach more than 70C (158F) after engine warmUP. OR l ) Disconnect engine temperature sensor harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Voltage: Approximately 5V

Repair harness or connectors.

. .

I Turn ignition switch "OFF".

Disconnect engine temconnector.

l3

CHECK GROUND CIRCUIT. 1) Check harness continuity between terminal @ and engine ground. Continuity should exist.

(NGI Repair harness or connectors.

(Engine temperature sensor). Refer to "Electrical Components Inspection". (See page ES-2 13)

sensor.

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES Diagnostic Procedure 25 (Cont'd)

IKA24E 1

Perform FINAL CHECK by the following procedure after repair is completed.

FINAL CHECK

Erase the self-diagnosis memOrY.

Perform driving test.

damage or the connection of E.C.U. harness connector.

+
INSPECTION END

TROUBLE DIAGNOSES Diagnostic Procedure 26

VEHICLE SPEED SENSOR (Not self-diagnostic item)

I KA24E I

1
I
I

II

CHECK SPEEDOMETER FUNCTION. Make sure that speedometer

I I functions properly.

I
I

I
l

Check vehicle speed sensor and its circuit. (Refer to EL section.)

I
I

1) Read vehicle speed sensor signal in "DATA MONITOR" mode with CONSULT. CONSULT value should be the same as the speedometer indication

Check the following: Harness connectors Harness continuity between E.C.U. and combination meter. If N.G., repair harness or connectors.

1) Turn ignition switch

2) Disconnect E.C.U. harness connector and combination meter harness connector. 3) Check harness continuity between E.C.U. terminal @and terminal @ on instrument cluster.

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES Diagnostic Procedure 27

IGNITION SIGNAL (Code No. 21)

pq

INSPECTION START

m
CHECK POWER SUPPLY. 1) Disconnect ignition coil harness connector. 2) Turn ignit~on switch "ON". 3) Check voltage between terminal @and ground. SEC~~OB Voltage: Battery voltage N.G.

,Check the following:

Harness connectors Harness continuity between ignition switch and ignition coil If N.G., repair harness or connectors.

~ CHECK GROUND CIRCUIT ij

1) Turn ignition switch "OFF". 2) Disconnect power transistor harness connector and resistor and condenser harness connector. 3) Check harness continuity between terminal @and power transistor terminal $nd resistor terminal
Continuity should exist. 4) Check harness continu~ty between ower transistor terminal h a n d engine ground. Continuity should exist.

N.G.

,Repair harness or connectors.

~ ~ ~ 9 2 8 1

SEF~Z~I

CHECK E.C.U. INPUT SIGNAL CIRCUIT 1) Disconnect E.C.U. harness connector. 2) Check harness continuity between E.C.U. terminal @ and resistor terminal @. Continuity should exist.

N.G.

Repair harness or connectors.

D/UNIT

- CONNECTOR
11 0

SEF9301

TROUBLE DIAGNOSES Diagnostic Procedure 27 (Cont'd)

I KA24E I

CHECK E.C.U. OUTPUT SIGNAL CIRCUIT 1) Check harness continuity between E.C.U. terminal @ and power transistor terminal @ Continuity should exist.

5 Repair harness or connectors. I 1

C
CHECK COMPONENTS (Ignition coil, power transistor, resistor and condenser) Refer to "Electrical Components Inspection". (See page ES-2 14) N.G.

,Replace malfunctioning component(~).

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

Perform FINAL CHECK by the following procedure after repair is completed.

71
Erase the self-diagnosis mem-

FINAL CHECK

Perform driving test.

N.G.

I
INSPECTION END

,Recheck E.C.U. pin terminals for damage or the connection of I E.C.U. harness connector. I

TROUBLE DIAGNOSES
Diagnostic Procedure 28 C.C.P. Function: (not self-diagnostic item)
INSPECTION START Warm up engine sufficiently to ensure engine water temperature is in the range 60-1 15'C.

I KA24E I

I
% Check the following:
Harness connectors 10A fuse fuse and continuity between Harness C.C.P. control solenoid valve If N.G., repair harness or connectors.

E !

H-l

m E M n
-

7
SEF9361

a c*.clawEalsuPPL.
1) Stop engine. 2) Disconnect C.C.P. control solenoid valve harness connector. 3) Turn ignition switch "ON". 4) Check voltage between terminal @ and ground. Voltage: Battery voltage

m ,-

. .
.N CUIT. .= 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check harness continuity between E.C.U. t e r m i n a i m a n d terminal 0 . Continuity should exist.

. I

Repair harness or connectors.

CHECK CONTROL FUNCTION. 1) Check voltage between E.C.U. t e r m i n a l o a n d ground under the following conditions. Voltage: At idle Approximately O V Engine speed Is about 2,000 rpm Battery voltage
I

"i
I

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

la

O.K. v CHECK VACUUM HOSE. 1) Check vacuum hose for clogging, cracks and proper connection.

~rn-

connection
SEF816F

TROUBLE DIAGNOSES
Diagnostic Procedure 29 EXHAUST GAS SENSOR (Not self-diagnostic item)

I KA24E I

~ ~ A : RPPl(PaS) ~;. t.liF.: F..,.'Iz Plt,]T

21:187rpm LEkt.4
CHECK INPUT SIGNAL CIRCUIT. 1) Start engine and warm it up sufficiently. 2) Make sure that "MIR FIC MNT" in "DATA MONITOR" mode indicates "RICH" and "LEAN" periodically more than 5 times during 10 seconds at 2,000 rpm. Check the following: Harness connectors Harness continuity between E.C.U. and exhaust gas sensor If N.G., repair harness or connectors.

RECORD
SEF41O.l

m
1
WIT

101 romcm 1

1) Disconnect E.C.U. harexhaust gas sensor harness connector. 2) Check harness continuity between terminal @ and E.C.U. terminal

@.

damage or the connection of E.C.U. harness connector.

Timing/ldle Mixture Ratio Inspection. (See page ES- 106)

TROUBLE DIAGNOSES
Diagnostic Procedure 30
AIR TEMPERATURE SENSOR (Code No. 41)

piiq

I;.jT;...ATEplF I D L E p13E;ITIat.j A I H <:ON[:i E;IG t.{ElJTRAL Z;i.;! p!,,i..:.ST S 1GNAL l LEAD I g~&?.

24"i:: fi EFF
j

I
i

1
'

1
i

fiFF

CHECK POWER SUPPLY. Read intake air temperature sensor signal in "DATA MONITOR" mode with CONSULT after engine warm-up. intake air temperature: 20 60C

Repair harness or connectors.

connector. 2) Turn ignition switch "ON". 3) Check voltage between air temDerature sensor terminal @and ground. Voltage: Approximately 5v

l +
-

Turn ignition switch "OFF".

Disconnect air temperature sensor harness connector.

CHECK GROUND CIRCUIT.

~ ~ ~ 9 4 9 1) Check harness continuity 1

N.G.

Repair harness or connectors.

between air temperature sensor terminal @and engine ground. Continuity should exist.

CHECK COMPONENT (Air temperature sensor). Refer to "Electrical Components Inspection". (See page ES-215)

Replace air temperature sensor.

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 30 (Cont'd)
Perform FINAL CHECK by the following procedure after repair is completed.

I FINAL CHECK
ory.

.
I
Erase the self-diagnosis memPerform driving test.

N.G.

Recheck E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

INSPECTION END

TROUBLE DIAGNOSES
Diagnostic Procedure 31
THROTTLE SENSOR (Not self-diagnostic item)

1 KA24E I

CHECK POWER SUPPLY. 1) Disconnect throttle sensor harness connector. 2) Turn ignit~on switch "ON". 3) Check voltage between throttle sensor terminal @and Voltage: Approximately 5 V
SEC4596

. . . N.G.
CHECK GROUND CIRCUIT. 1) Turn ignition switch 'OFF". 2) Check harness continuity between throttle sensor terminal @and engine ground. Continuity should exist. Repair harness or connectors.

B -

l3

. .
Repair harness or connectors.
SEC4616

I !

I TYF.;:,T'LE
.+.:+.:+::+.+

:EL!

i . : -

1) Reconnect throttle sensor harness connector. 2) Turn ignition switch "ON".

fi~it.4 -]?F

.+:.+,:+:i..+,

,i

II

3) Read throttle sensor

output voltage in "WORK SUPPORT" mode with CONSULT. Voltage: Throttle valve fully closed 0.4 0.5V Throttle valve fully

1) Reconnect throttle sensor harness connector. 2) Turn ignition switch "ON". 3) Make sure that voltage

between E.C.U. terminal @ and ground changes when accelerator pedal is depressed. Voltage: Throttle valve fully closed 0.4 0.5V Throttle valve fully open Approx. 4.OV

TROUBLE DIAGNOSES
Diagnostic Procedure 31 (Cont'd)
CHECK COMPONENT (Throttle sensor). Refer to "Electrical Components Inspection".
(See page ES-2 16)

Replace throttle sensor.

. .

( E.C.U. harness connector.

I damage or the connection of

Check E.C.U. pin terminals for

TROUBLE DIAGNOSES
Diagnostic Procedure 33
START SIGNAL (Not self-diagnostic item)
INSPECTION START

CHECK OVERALL FUNCTION. 1) Turn ignition switch 2) Check start signal in "DATA MONITOR" mode with CONSULT.
IGN "ON" IGN "START"
W.

INSPECTION END

1) Turn ignition switch to "START". 2) Check voltage between E.C.U. terminal @ and ground. Voltage: Ignition switch "START" Battery voltage Except above Approximately O V

CHECK SIGNAL CIRCUIT. 1) Turn ignition switch 'OFF". 2) Disconnect E.C.U. harness connector and ignition switch harness connector. 3) Check harness continuity between E.C.U. terminal @ and the start terminal on the ignition switch. Continuity should exist.

5Check the following: m Harness connectors

10A fuse m Harness continuitv between E.C.U. and ignition switch If N.G., repair harness or connectors.
l

. .
Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 34
P.R.V.R. (Not self-diagnostic item)

c 4

Fuel pressure gauge

INSPECTION START

lNSpECTlON END
1) Install fuel pressure gauge in fuel feed hose. (See page ES-2 19) 2) Start engine and warm it up until engine temperature exceeds 90'C or see NOTE at procedure end. 3) Stop engine. 4) After a few seconds, restart engine and check fuel pressure.

After a few minutes

SEF9671

Fuel pressure: Approximately 294 kPa (3.0 kg/cm2, 43 psi) 5) Make sure that fuel pressure decreases after a few minutes (approximately 3). Fuel pressure: Approximately 226 kPa (2.3 kg/cm2, 33 psi)

m
1
-17

-B
lol
106

. .
FUEL PRESSURE REGULATOR.
1) Stop engine. 2) Disconnect vacuum hose connected to fuel pressure regulator. 3) Restart engine. 4) Make sure that vacuum exists.

MCTOR

11

(Fuel pressure regulator). Refer to "Fuel Pressure Check". (See page ES-2 19)

m
CHECK CONTROL FUNCTION. 1) Stop engine and reconnect vacuum hose to fuel pressure regulator. 2) Restart engine. 3) Check voltage between E.C.U. terminal @and ground. Voltage: Approximately O V 4) In 3 minutes, recheck voltage between E.C.U. terminal @ and ground. Voltage: Battery voltage

m
1) Check vacuum hose for clogging, cracks and proper connections.

. .

TROUBLE DIAGNOSES
Diagnostic Procedure 34 (Cont'd)

1 KA24E I
Check the following: m Harness connectors m 10A fuse Harness continuity between fuse and pressure regulator control solenoid valve If N.G., repair harness or connectors.
l

1) Stop engine. 2) Disconnect pressure regulator control solenoid valve harness connector. 3) Turn ignition switch "ON". 4) Check voltage between terminal @ and ground. Voltage: Battery voltage
I

-'

. .

CHECK OUTPUT SIGNAL CIR-

Repair harness or connectors.

CUIT. 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check harness continuity between E.C.U. t e r m i n a l m a n d Solenoid terminal @. Continuity should exist.
SEF9701

I &i:.iIi.!E

TE:i;T

i
/

pF:l,iF

I-:A:~;, ~ t . 1 ; ~ ..Fc::, ; -F Et.41; T E ~ ~~P ~ 1 41-,3' F EjlH 5 ~ 5 5Et4 ; !Is,'%zl,,! ~ k j . . PULSE ~ Ih~c: I.,!GLI,!E

--------- - ---

~ : r 8 ~ ~ ~ l : , ~ F l- i ~ ~ i'v~, l
i.,c,l.., -p-'?. :!,_l.' -------i !

-_I

a/
~ ~

CHECK COMPONENT (Pressure regulator control solenoid valve). 1) Reconnect E.C.U. harness connector and pressure regulator control solenoid valve harness connector. 2) Start engine. 3) Perform "P.R.V.R. CONTROL SOLENOID VALVE TEST" in "ACTIVE TEST" mode with CONSULT.

trol solenoid valve.

:n:@;l

(See page ES-2 15)

F; 1

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 34 (Cont'd)

1-

'NOTE If englne cannot be warmed up sufflclently for some reason (Extreme cold, etc.), disconnect englne temperature sensor harness connector, and connect a resistor (0.1 kSZ) to engine temperature sensor harness connector. 1) Do not perform this test for a long time. 2) Perform self-diagnosis after this test. If code No. l 3 Is displayed, erase it.

a
0.1 kS1

-Engine temperature sensor harness connector

SEF9711

TROUBLE DIAGNOSES
Diagnostic Procedure 35
INJECTOR (Not self-diagnostic item)

p q

I INSPECTION START

1
1O.K.

1 CHECK CONTROL FUNCTION.

: No. 1 cylinder : No. 2 cylinder

, INSPECTION END I

m : No. 3 cylinder
( 3 : No. 4 cylinder
SEF9741

1) Start engine. 2) Check voltage between E.C.U. terminals @,@, and ground.

@ a

Voltage: Battery voltage

CHECK POWER SUPPLY. 1) Stop engine. . 2) Disconnect injector harness connector and E.C.U. harness connector. 3) Check voltage between injector terminal @ and sound, E.C.U. terminal @ and ground.

Check the following: Harness connectors a Fusible link Harness continuity between battery and injector a Harness continuity between battery and E.C.U. If N.G., repair harness or connectors.

I
1

Voltage: Battery voltage.

I

CHECK OUTPUT SIGNAL CIRCUIT. 1) Check harness continuity

Repair harness or connectors.

between injector terminals @ and E.C.U. terminals

Continuity should exist.

@hm@@3
+

: No. 1 cylinder . No. 2 cylinder

a : No.

@ : No. 3 cylinder J
4 cylinder
SEF9761

CHECK COMPONENT (Injector). Refer to "Electrical Components Inspection". (See page ES-2 17)

1 N.G. A Replace injector.

I
I

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 36
FUEL PUMP (Not self-diagnostic item)
INSPECTION START

l
CHECK OVERALL FUNCTION. 1) Turn ignition switch "ON". 2) Listen to fuel pump operating sound. Fuel p u m p should operate for 5 seconds after ignition s w i t c h i s turned "ON". Engine stationary.

0.K.

,INSPECTION END

SEF9801

-0

. 1"".

(VI
@

CHECK POWER SUPPLY. 1) Turn ignition switch "OFFsr. 2) Disconnect fuel pump relay. 3) Turn ignition switch "ON". 4) Check voltage between terminals @, @ and ground. Voltage: Battery voltage

N.G.

,Check the following:

Harness Connectors 10A fuse Harness continuity between fuse and fuel pump relay If N.G., repair harness or connectors.

'

.
N.G.

m
[RI
\
P .

CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Disconnect fuel pump harness connector. 3) Check harness continuity between Fuel Pump terminal @and body ground, Fuel Pump terminal @ and Fuel Pump Relay terminal @ . Continuity should exist.

,Check the following:

S.M.J. connectors Harness connectors fuel pump and body ground Harness continuity between fuel pump and fuel pump relay If N.G., repair harness or connectors.

. .
CHECK OUTPUT SIGNAL CIRCUIT. 1) Disconnect E.C.V. harness connector. 2) Check harness continuity between E.C.U. terminal and Fuel Pump Relay terminal N.G. Check the following: Harness connectors Harness continuity between E.C.U. and fuel pump relay If N.G., repair harness or connectors.

0. should exist. Continuity

L

El
a

.
J

.
nent(s).

CHECK COMPONENTS (Fuel pump and fuel pump relay). Refer to "Electrical Components Inspection". (See page ES-2 1412 16)

I6
104

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 37
S.C.V. CONTROL (Not self-diagnostic item)
INSPECTION START

t3
c

s o uo

SEF986'

H
I
WUMl T
12
11 CONNECTOR 0

II

SWIRL CONTROL VALVE. 1) Start engine and warm it up sufficiently. 2) Stop engine. 3) After a few seconds, disconnect vacuum hose to swirl control valve and restart engine. 4) Make sure that vacuum exists under the following conditions. Engine speed is less than 1,800 rpm (MIT) or 1,500 rpm

Clogging

WIT): Vacuum should exist. Englne speed Is more than 1,800 rpm (MIT) or 1,500 rpm
SEF9871

(AIT)

1) Check voltage between E.C.U. terminal @ and ground. Voltage:

SEFBlBF

Engine speed is less than 1,800 rpm (MIT) or 1,500 rpm (AIT): Approximately O V Englne speed Is more than 1,800 rpm (MIT) or 1,500 rpm (AIT) Battery voltage

SWIRL CONTROL VALVE. 1) Check vacuum hose and swirl control valve for clogging, cracks and proper connection.
I t

CHECK POWER SUPPLY.

1) Stop Engine. 2) Disconnect S.C.V. control solenoid valve harness connector. 3) Turn ignition switch 'ON". 4) Check voltage between S.C.V. solenoid terminal @ and ground. Continuity should exist.

Check the following: Harness connectors 10A fuse Harness continuity between fuse and S.C.V. control solenoid valve If N.G., repair harness or connectors.

TROUBLE DIAGNOSES
Diagnostic Procedure 37 (Cont'd)
7

CUIT.
m I T
1 1 CONNECTOR 0

OuTpuFm-.l
B.

Repair harness or connectors.

S EF988,

1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check harness continuity between E.C.U. terminal @ and terminal Continuity should exid.

N.6

,Replace S.C.V. control solenoid

valve.

(S.C.V. control solenoid valve). Refer to "Electrical Components (See page ES-2 15)

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 38
A.A.C. VALVE (Not self-diagnostic item)

1 KA24E I

CHECK OVERALL FUNCTION 1) Start engine and warm it up sufficiently. 2) Check idle speed. MD: 850 50 rpm

INSPECTION END

+ A D : 850 + 50 rpm

If N.G., adjust idle speed. 3) Disconnect throttle sensor harness connector. 4) Make sure that idle speed drops. Does not drop

Ivl
@

0.

FSEF9221

CHECK COMPONENT (Throttle sensor). Refer to "Electrical Components Inspection". (See page ES-2 16)

Replace throttle sensor.

E
---l .IH,_ 1

R
I
m

CHECK POWER SUPPLY.

5 Check the following:

1) stop engine. 2) Disconnect A.A.C. valve harness connector. 3) Turn ignition switch "ON". 4) Check voltage between terminal b) and ground Voltage: Battery voltage

Harness connectors e 10A fuse 8 Harness continuity between A.A.C. valve and fuse If N.G., repair harness or connectors.

SEF9921

. .
CHECK OUTPUT SIGNAL CIRCUIT. 1) Turn ignition switch "OFF" 2) Disconnect E.C.U. harness connector. 3) Check harness continuity between E.C.U. t e r m i n a l m a n d terminal @. Continuity should exist.

5Repair harness or connectors.

m
'

W:-- t

- -z : --

m ,

:FE..:,.;
1,- ,--.A -

C-,.

--.

I - -- - - - -

-------

jCHi.FFtt:

F':.:

H I F FLI-I~,11-F ~ ~ j TE:~; i j ;E-.

i - --- --- - - L-, , :r-,, :, 4

--:D;

3; ----I, - i
I

'1-12 l>

. .

SEF1621

TROUBLE DIAGNOSES
Diagnostic Procedure 38 (Cont'd)

1 KA24E I
I
Replace A.A.C. valve.
I

I (A.A.c. valve).

CHECK COMPONENT 1) Reconnect E.C.U. harness connector and A.A.C. valve harness connector. 2) Start engine. 3) Perform "AAC VALVE OPENING TEST" in "ACTIVE TEST" mode with CONSULT.

R Refer to "Electrical Components Inspection".

(See page ES-2 17)

. .
Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure
RADIATOR FAN CONTROL (Not self-diagnostic item)

1 KA24E I

With air conditioner

Radiator fan

I INSPECTION START
SPEED OPERATION. ith air conditioner 1) Start engine. 2) Set temperature lever at full cold position. 3) Turn air conditioner switch "ON". 4) Turn blower fan switch "ON". 5) Run engine at idle for a few minutes with air conditioner operating. 6) Make sure that radiator fan operates at low speed. Without air conditioner 1) Start engine. 2) Keep engine speed at about 2,000 rpm until engine is warmed up sufficiently. 3) Make sure that radiator fan begins to operate at low speed during warm-up.

1
Without air conditioner
r Radiator fan

I 1

rRadiator fan

Engine temperature sensor harness

SEC1676

CHECK RADIATOR FAN HIGH SPEED OPERATION. 1) Turn air conditioner switch "OFF". 2) Turn blower fan switch "OFF". (Step 1) and 2) are only performed for model with air conditioner.) 3) Stop engine. 4) Disconnect engine temperature sensor harness connector. 5) Restart engine and make sure that radiator fan operates at high speed.
I
I

INSPECTION END

N.G.

c 9

TROUBLE DIAGNOSES
Diagnostic Procedure 39 (Cont'd)

I KA24E I
N.G. Check the following: Harness connectors Fusible link 10A Fuse Harness continuity between battery and radiator fan relay- l, -2 Harness continuity between fuse and radiator fan relay- l, -2 If N.G., repair harness or connectors.

-------m

CHECK POWER SUPPLY. 1) Stop engine. 2) Disconnect radiator fan relay-l and -2. 3) Turn ignition "ON". 4) Check relay-l voltage between terminals @, @and ground. 5) Check rela 2 voltage between @and ground. terminals Voltage: Battery voltage.

6,

0.K-

relay-2

@l
3)

v
i

fan motor-2

@
fan motor-l

IRI
4

CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Disconnect both radiator fan motor harness connectors. 3) Check harness continuity between fan motor 2 terminal @and ground. 4) Check harness continuity between fan motor 1 terminal B a n d ground. 5) Check harness continuity between Relay 2 terminal @and fan motor 1 terminal@. Continuity should exist. O.K.

Check the following: Harness connectors Ground connection If N.G., repair harness or connectors.

@
5)
relay -2.

m
fan motor-l

TROUBLE DIAGNOSES

R
3)

relay-lA
\

l CHECK HARNESS

@
CONTINUITY. 1) Turn ignition switch "OFF". 2) Disconnect radiator fan motors 1 and 2 and relays 1 and 2. 3) Check continuity from radiator fan relay-l terminal @with fan motor 2 terminal D and fan motor 1 terminal H . 4) Check continuity from relay 2 terminal 7 with fan motor 2 terminal B and fan motor 1 terminal F . 5) Check continuity from relay 2 terminal 3 to fan motor 2 terminal C and fan motor 1 terminal G . Continuity should exist.

Diagnostic Procedure 39 (Cont'd)

+I

Repair harness or connectors.

fan motor9

C -

fan motor-l

4)

B B

relay-2)

[TZ
fan motor4

p,'
I I

fan motor-l

@ fan motor-.

I
j

f ao t o

TROUBLE DIAGNOSES
Diagnostic Procedure 39 (Cont'd)
N.G.

I KA24E I

CHECK OUTPUT SIGNAL CIRCUIT. 1) Reconnect radiator fan relay- l and -2, radiator fan motor- l harness connector and radiator fan motor-2 harness connector. 2) Start Engine. 3) Turn radiator fan OFF in "ACTIVE TEST" mode with CONSULT. 4) Check voltage between relay 1 terminal 1 and relay 2 terminal 2 and ground. Voltage: Battery voltage 5) Turn radiator fans HI in "ACTIVE TEST" mode with CONSULT. 6) Check voltage between relay 1 terminal 1 and relay 2 terminal 2 and ground. Voltage: Approximately OV.

Check the following: Harness connectors Harness continuity between E.C.U. and radiator fan relays 1 and 2. If N.G., repair harness or connectors. CHECK COMPONENTS (Radiator fan relay-l and -2). Perform "RADIATOR FAN TEST" in "ACTIVE TEST" mode with CONSULT. If N.G., replace malfunctioning component(s).

@
relay-l

1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check harness continuity between E.C.U. terminal 9 with relay 1 terminal 1 and E.C.U. terminal @ with relay 2 terminal @ .

Continuity should exist 4) Reconnect all components. 5) Disconnect water temperature sensor. 6) Start engine. 7) Check voltage between relay 1 terminal @ and relay 2 terminal @ with ground. Voltage: Approximately OV. If N.G. check E.C.U.

TROUBLE DIAGNOSES
Diagnostic Procedure 39 (Cont'd)

CHECK COMPONENTS (Radiator fan relay-l ,-2, radiator fan motor- l,and -2) Refer to 'Electrical Components Inspection". (See page ES-2 14)

Replace malfunctioning com-

Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 40 POWER STEERING OIL PRESSURE SWITCH (Not self-diagnostic item)
. -_'-T

_ _ _- .-.
.. .

II
I
I

INSPECTION START

El

I
I

- -- - a - - - - -

S E F ~ ~ I

lm r n
CAN1T
11 CONNECTOR 0

CHECK CONTROL FUNCTION. 1) Start engine and warm it up sufficiently. 2) Check power steering oil pressure switch signal in "DATA I MONITOR" mode with CONSULT. Steering is neutral: OFF Steering is turned: ON

5 INSPECTION END

l3

2) Check voltage between E.C.U. terminal @ and ground. Voltage: When steering wheel is turned quickly Approximately O V Except above Approximately 8 9v

. .
CHECK GROUND CIRCUIT. 1) Stop engine. 2) Disconnect power steering oil pressure switch harness connector. 3) Check harness continuity between terminal @ and body ground. Continuity should exist.

SEC5046

1
Check the following. Harness connectors Harness continuity between E.C.U. and power steering oil pressure switch If N.G., repair harness or connectors.

CHECK INPUT SIGNAL CIRCUIT. 1) Disconnect E.C.U. harness connector. 2) Check harness continuity between E.C.U. terminal @ and terminal 0. Continuity should exist.

TROUBLE DIAGNOSES
Diagnostic Procedure 40 (Cont'd)

1 KA24E I

+
CHECK COMPONENT (Power steering oil pressure switch). Refer to "Electrical Components Inspection".
(See page ES-2 15)

Replace power steering oil pressure switch.

. .

I damage or the connection of

E.C.U. harness connector.

Check E.C.U. pin terminals for

TROUBLE DIAGNOSES
Diagnostic Procedure 41
NEUTRAL/INHIBITOR SWITCH (Not self-diagnostic item)
Neutral s w i t c h M/T

I KA24E I

1
I
INSPECTION END

I I INSPECTION START
@ l )
CHECK OVERALL FUNCTION. T,y io ;nn t switch

2) Check neutral switch

signal in "DATA MONITOR" mode with CONSULT. Neutral position: ON Except above: OFF

OR Set shift lever to the neutral position. Disconnect E.C.U. harness connector. 3) Check harness continuity between E.C.U. terminal @ and body ground. Continuity should exist.

. .
Turn ignition switch "OFF".

CHECK GROUND CIRCUIT. 1) Disconnect neutral switch harness connector. 2) Check harness continuity between terminal @ and body ground. Continuity should exist.

Check the following: a Harness connectors a Harness continuity between neutral switch and body ground If N.G., repair harness or connectors.

Disconnect E.C.U. harness connector.

S I G N A L C ~ R C U ~the ~ check T following:

1)Check harness continuity between E.C.U. terminal @ and
terminal Continuity should exist.

B.

. .

a Harness connectors a Harness continuity between E.C.U. and neutral switch If N.G., repair harness or connectors.

TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Cont'd)
N.G.

pq

CHECK COMPONENT (Neutral switch). Refer to "Electrical Components Inspection". (See page ES-2 18)

Replace neutral switch.

. .
Check E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Cont'd)
- - -

- 7

- 7

1
L

.?

dIF l I

, . - L-

l -

1 - 3
&:

L-;:-;.l

-- * -

INSPECTION START

INSPECTION END

:-I

m
-

1
2) Check neutral swltch s ~ g n a In "DATA l MONITOR" mode wlth CONSULT ''NU or ''p,,: ON Except above: OFF OR Shlft selector lever to "P" range Disconnect E C U harness connector 3) Turn ignltlon swltch "ON"

CHECK OVERALL FUNCTION. 1) Turn lgnltlon swltch

--- ------ - - - - F

0K

--

i - E - .

SEF1491

la

SEFO~~J

4) Check harness continu~ty between E C U t e r m nal @ and body ground Continuity should exist. 5) Shlft selector lever to "N" range 6) Check harness contlnu~ty between E C U terminal @ and body ground Continuity should exist. NG

0 I3

c%d $ ?7 T$

IVI
-0
0 SEFOIGJ

El

CHECK POWER SUPPLY 1) Turn lgnltlon swltch "OFF" 2) Dlsconnect lnhlbltor relay 3) Make sure that selector lever IS In "NW range 4) Turn lgnltlon swltch "ON" 5) Check voltage between termlnal @ and ground Voltage: Battery voltage 6) Shlft selector lever Into "P" range 7) Check voltage between termlnal and ground Voltage: Battery voltage 0K

NG

Check the following CHECK HARNESS CONTINUITY BETWEEN INHIBITOR SWITCH AND BATTERY 1) Turn ignltlon swltch "OFF" 2) Dlscorlnect inh~bltor switch harness connector 3) Turn lgnitlon swltch "ON" 4) Check voltage between t e r m l n a l a and ground Voltage: Battery voltage If N G , check the followIng 10A fuse S M J connectors Harness connectors Harness contlnulty between fuse and lnhlbltor swltch If N G , repair harness or connectors CHECK HARNESS CONTINUITY BETWEEN INHIBITOR SWITCH AND INHIBITOR RELAY 1) Turn lgnltlon swltch "OFF" 2) Check harness contlnulty between t e r m ~ n a l s a @ , and termlnal @ "P' range: terminal @ and terminal @ "N" range: terminal a a n d terminal @ Continuity should exist. If N G , check the following Harness connectors Harness contlnulty between lnhlbltor swltch and lnhlbltor relay If N G , repalr harness or connectors CHECK COMPONENT (Inhlbltor swltch) Refer to "Electrical Components Inspect~on" (See page ES-2 18)

8
SEF017J

TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Cont'd)

piq

13
CHECK GROUND CIRCUIT. 1) TURN IGNITION SWITCH "OFF". 2) Check harness continuit and between terminals body ground. Continuity should exist. Repair harness or connectors.

a, 0

" SEFOlW

Disconnect E.C.U. harness connector.

1
35

CHECK INPUT SIGNAL CIRCUIT. 1) Check harness continuity between E.C.U. terminal @ and

%Check the following:

a Harness connectors a Harness continuity between E.C.U. and inhibitor relay If N.G., repair harness or connectors.

E
SEFO19.I

terminal Continuity should exist.

a.

CHECK COMPONENT (Inhibitor relay). Refer to "Electrical Components Inspection". (See page ES-218)

Replace inhibitor relay.

. .
Check E.C.U. pin terminals for damage or the connection of E.C.U.. harness connector.

TROUBLE DIAGNOSES Electrical Components Inspection

E.C.U. INPUTIOUTPUT SIGNAL INSPECTION E.C.U. inspection table
'Date are reference values. TERM lNAL NO. ITEM CONDITION *DATA

0.3 1 lgnition signal ldle speed IEngine is running.]

- 0.6V

Approximately 1.OV Engine speed is 2,000 rpm 3 Ignition check ldle speed
9 - 12V

0 - 1v 4 E.C.C.S. relay (Main relay) Within approximately 1 second after turning ignition switch "OFF"

For approximately 1 second after turning ignition switch "OFF" IEngine is running.) Both AIC switch and blower switch are "ON".

BATTERY VOLTAGE (11 14V)

0 - 1.ov

11

Air conditioner relay

BATTERY VOLTAGE (11 - 14V) AIC switch is "OFF". 0 - 1.ov 12 S.C.V. control solenoid valve ldle speed BATTERY VOLTAGE (11 - 14V) Engine speed is 2,000 rpm. 16 Air flow meter /Engine is running.1 1.0 - 3.0V Output voltage varies with engine revolution.

TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd)

'Date are reference values.

TERMINAL NO.
18

ITEM

CONDITION

'DATA 1.0 - 5.0V Output voltage varies with engine water temperature. 0 - Approximately 1.OV

Engine temperature sensor

IEngine is running.\

19

Exhaust gas sensor After warming up sufficiently. Throttle sensor llgnition switch "0N"I Fngine is running.]

20

0.4 - Approximately 4V Output voltage varies with the throttle valve opening angle.

22 30

Crank angle sensor (Reference signal)

Do not run engine at high speed under no-load.

0.2

- 0.5V

Temperature of intake air is 20C (68F) 26 Air temperature sensor

Approximately 1.0 - 1.5V

Temperature of intake air is 80C (176F) IEngine is running.]

Approximately 0.3V

31 40

Crank angle sensor (Position signal)

Do not run engine at high speed under no-load.

2.0 - 3.0V

Approximately 9 Throttle valve: idle posion 33 Idle switch ( O s i d e ) Throttle valve: Any position except idle position

10V

ov
8 - 12V

34

Start signal

Cranking NeutrallParking

ov
Approximately 6V

35

Neutral switch & Inhibitor switch Except the above gear position llgnition switch "OFF']

ov
BATTERY VOLTAGE (11 - 14V) Approximately 5V BATTERY VOLTAGE (11 - 14V)

36

lgnition switch

llgnition switch "ON"] pgnition switch "ON"]

37

Throttle sensor power supply Power supply for E.C.U.

38 47

[Ignition switch "ON"]

TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd)

'Date are reference values. MlNAL NO. ITEM ngine CONDITION 'DATA

F IS

runnlng.

Air conditioner switch

L ~ o t air conditioner switch and h blower switch are "ON". BATTERY VOLTAGE (11 - 14V)

7
Engine is running. tngine
I

L ~ i conditioner switch is "OFF" r

IS

runnlng.

k t e e r i n g wheel is being turned. Power steering oil pressure switch LSteering wheel is not being turned.

1
18-9V

Approximately 9 - 10V Throttle valve: idle position Idle switch ( @ side) [Ignition switch "ON"/ L h r o t t l e valve: BATTERY VOLTAGE (11

- 14V)

Except idle position l ~ n g i n e running is ir conditioner is 0~erating.1

1I
Approximately 8 - 9V

I
45 Thermo control amp.

L ~ v a ~ o r a toutlet air temperature or is between 3.0 - 8.O"C (37 - 46F) l ~ n ~ i is e n running. ir conditioner is operating. L ~ v a p o r a t o outlet air temperature r is over 8C (46F) (Ignition switch " O l - t ' l

1
Power supply (Back-up) 101 103 110 112

Approximately. O V

BATTERY VOLTAGE (11

- 14V)

1 Injector No. 1
lnjector No. 3 lnjector No. 2 lnjector No. 4

I
Engine is running BATTERY VOLTAGE (11 - 14V)

TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd)

*Date are reference values. TERMINAL NO. ITEM CONDITION 'DATA

104

Fuel pump relay

For 5 seconds after turning ignition switch "ON" IEngine is running.1

0.7

- 0.9V

Within 5 seconds after turning ignition switch "ON"

BATTERY VOLTAGE (11 - 14V)

FIS

ngine

running. 0.7 - 0.9V

105

C.C.P. control solenoid valve

Engine is cold. Water temperature is below 60C (140F).

1
BATTERY VOLTAGE (11 - 14V) 0 - 1.ov (for 3 minutes after ignition switch is turned off.)

After warning up Water temperature is between 60'C (140'F) and 105C (221F)

1
BATTERY VOLTAGE (After 3 minutes)

Pressure regulator control solenoid lo6 valve

Water temperature is above 90C (194F)

BATTERY VOLTAGE (11 - 14V) Water temperature is below 90C (194'F) 7 - 1ov Idle speed 113 A.A.C. valve Steering wheel is being turned. Air conditioner is operating Rear defogger is "ON". Headlamp are in high position. 4 - 7v

E.C.U. HARNESS CONNECTOR TERMINAL LAYOUT

TROUBLE DIAGNOSES KA24EI Electrical Components Inspection (Cont'd)

E.C.C.S. RELAY
Check continuity between terminals @ and 0.
Condition 12V direct current supply between terminals @ and @ No supply Continuity

CRANK ANGLE SENSOR

Remove distributor from engine. (crank angle sensor harness connector is connected.) 2. Turn ignition switch "ON". 3. Rotate crank angle sensor shaft slowly and check voltage between terminals@, @ and ground. Voltage fluctuates between 5V and OV.
1.

4.

Visually check rotor plate for damage or dust.

AIR FLOW METER

m
Visually check hot wire air passage for dust.

ENGINE TEMPERATURE SENSOR

Check engine temperature sensor resistance.
Temperature "C ("F) 20 (68) 80 (176) Resistance kR 2.1 2.9 0.30 - 0.33

TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd)

IGNITION COIL
Check ignition coil resistance.
Terminal Resistance Approximately 0.7Q

@- 0

POWER TRANSISTOR
Check continuity between power transistor terminals.
Terminal No. Tester polarity Continuity No

02
@

0 0
0 0 0 0 0 0

Yes

0
@

0
@

No

Yes

FUEL PUMP RELAY, RADIATOR FAN RELAYS 1 & 2 Check continuity between terminals @ and @

Condition

Continuity Yes

12V direct current supply between terminals @ and @

No supply

No

Check continuity between terminals @ and @, and @ and

Condition
12V direct current supply between terminals @ and @

Continuity Yes No

No supply

KA24E TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd)

C.C.P. CONTROL SOLENOID VALVE, A.I.V. CONTROL SOLENOID VALVE, P.R. CONTROL SOLENOID VALVE AND S.C.V. CONTROL SOLENOID VALVE

Check air passages continuity

Air passage continuity between 12V direct current supply between terminals @ and @ No supply Air passage continuity between

Condition

@ and @
Yes No

@ and
No
Yes

EXHAUST GAS SENSOR

Refer to "Diagnostic Procedure 29". (See page ES-182).

AIR TEMPERATURE SENSOR

Check air temperature sensor resistance.
Temperature "C ("F) 20 (68) 80 (176) Resistance kQ

- 2.9 0.27 - 0.38

2.1

POWER STEERING OIL PRESSURE SWITCH

1. 2.

Disconnect power steering oil pressure switch harness connector. Check resistance between terminals. Resistance: Approximately 2 3R

KA24E TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd)

THROTTLE SENSOR
1.

Disconnect throttle sensor harness connector. changes when opening throttle valve manually.
Accelerator pq++conditions Completely released Partially released Completely depressed Resistance kR Approximately 1 1-9 Approximately 9

2. Make sure that resistance between terminals @ and @

If N.G., replace throttle sensor.

Adjustment
If throttle sensor is replaced or removed, it is necessary to install it in the proper position, by following the procedure as shown below:

1.
2. 3.

Install throttle sensor body in throttle chamber. Do not tighten bolts. Connect throttle sensor and idle switch harness connector. Start engine and warm it up sufficiently. Perform "THROTTLE SEN. ADJ." in "WORK SUPPORT" mode. Measure output voltage of throttle sensor using voltmeter.

5.

6. 7.

Adjust by rotating throttle sensor body so that output voltage is 0.4 to 0.5V. Tighten mounting bolts. Disconnect throttle sensor harness connector for a few seconds and then reconnect it.

FUEL PUMP
Check continuity between terminals @I and @ . Continuity should exist.

TROUBLE DIAGNOSES
Electrical Components_lxlspection (Cont'd)
INJECTORS
a
A

Check injector resistance. Resistance: Approximately 10 15R Remove injector and check nozzle for clogging.

SWIRL CONTROL VALVE

Supply vacuum to actuator and check swirl control valve operation.
Condition Supply vacuum to actuator No supply Swirl control valve Close Open

A.A.C. VALVE
a

Check A.A.C. valve resistance. Resistance: Approximately 10R [at 20C (68"F)I

Check plunger for seizure or sticking. Check spring for broken.

TROUBLE DIAGNOSES

Electrical Components Inspection (cont'd)

THROTTLE VALVE SWITCH (Idle position) Unit check
Check continuity between terminals @ and ing throttle valve.
Throttle valve condition Fully closed Open

--.

O while mov-

Continuity Yes No

NEUTRAL SWITCH
Check continuity between terminals @ and @.
Conditions Shift to Neutral Shift to other position Continuity Yes No

INHIBITOR SWITCH
Check continuity between terminals @ and@.
Conditions Shift to "P" position Shift to "N" position Shift to positions other than "P" and "NW Continuity Yes Yes No

INHIBITOR RELAY

Check continuity between terminals @ with @, and @ with Condition

@ with @
No Yes

continuity @ with Yes No

a a

12V direct current supply between terminals @ and @

No supply

-' FUEL INJECTION CONTROL SYSTEM INSPECTION :

Releasing Fuel Pressure

pq

Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.

@
@

Perform "FUEL PRESSURE RELEASE" in "WORK SUPPORT" mode with CONSULT. 1. Remove fuel pump fuse. 2. Start engine. 3. After engine stalls, crank it two or three times to release all fuel pressure. 4. Turn ignition switch off and reconnect fuel pump fuse.

Fuel Pressure Check

When reconnecting fuel line, always use new clamps. Make sure that clamp screw does not contact adjacent parts. Use a torque driver to tighten clamps. Use Pressure Gauge to check fuel pressure. Do not perform fuel pressure check while fuel pressure regulator control system is operating; otherwise, fuel pressure gauge might indicate incorrect readings. Release fuel pressure to zero. Remove air duct. Disconnect fuel hose between fuel filter and fuel tube (engine side). lnstall pressure gauge between fuel filter and fuel tube. Install air duct. Start engine and check for fuel leakage. Read the fuel pressure gauge indication. At idllng: When fuel pressure regulator valve vacuum hose is connected More than 226 kPa (2.3 kg/cm2, 33 psi) When fuel pressure regulator valve vacuum hose is disconnected Approximately 294 kPa (3.0 kg/cm2, 43 psi) Stop engine and disconnect vacuum hose from fuel pressure regulator. Plug vacuum hose.

Fuel pump and damper

SE F892D

Fuel tank

Vacuum

Fuel pressure

10. Connect variable vacuum source to fuel pressure regulator. 11. Start engine and read fuel pressure gauge indication as vacuum changes. Fuel pressure should decrease as vacuum increases. If results are unsatisfactory, replace fuel pressure regulator.

SEF718B

FUEL INJECTION CONTROL SYSTEM INSPECTION Injector Removal and Installation

p i q

REMOVAL
1. 2. m m m m m 3.

Release fuel pressure to zero. Remove or disconnect the following: Air duct Fuel hoses Fuel pressure regulator. Accelerator wire bracket Fuel injector harness connectors Remove fuel tube securing bolts.

4.

Move fuel tube as shown and take out injectors from #4 injector.

FUEL INJECTION CONTROL SYSTEM INSPECTION

Injector Removal and Installation (Cont'd) INSTALLATION

/ KA24E I
- Y'4

1. Clean exterior of injector tail piece. 2. Replace 0-rings and insulators with new ones. 3. lnstall injectors. 4. Install any parts removed. CAUTION: After properly connecting injectors to fuel tube, check connections for fuel leakage.

SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications

IGNITION TIMING IDLE SPEED B.T.D.C. rpm 1 5 " f 2"

M/T 850 f 50 A/T 850 f 50

(in "NW position)

Inspection and Adjustment

IGNITION COIL
Primary voltage Primary resistance [at 20'C (68"F)I Secondary resistance [at 20'C (68'F)I Approximately 0.7 Approximately 8

A.A.C. VALVE
Resistance

L 2 1

Approximately 10

INJECTOR
Resistance

10 - 15

ENGINE TEMPERATURE SENSOR THROTTLE SENSOR

Accelerator pedal conditions Completely released Partially released Completely depressed Resistance M Approximately 1 1-9 Approximately 9

AIR TEMPERATURE SENSOR

FUEL PRESSURE (at idling)

Unit: kPa (kg/cm2, psi) (Measuring point: between fuel filter and fuel pipe) Vacuum hose is connected Vacuum hose is disconnected Approximately 226 (2.3, 33) Approximately 294 (3.0, 43)

IDLE SWITCH
Engine speed when idle switch is changed from "OFF" to "ON" rpm MIT 1.000f 150 A/T 1,000 f 150 (in "NWposition)

SECTION

EC
EC- 3 EC- 5

CONTENTS
CRANKCASE EMISSION CONTROL SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM
,,....

.. ... .... ...

.. .

..

CRANKCASE EMISSION CONTROL SYSTEM Description

This system returns blow-by gas to both the intake manifold and air cleaner. The positive crankcase ventilation (P.C.V.) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the P.C.V. valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air cleaner, through the hose connecting the air cleaner to rocker cover, into the crankcase. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve, and its flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by some of the flow will go through the hose connection to the air cleaner under all conditions.

Inspection
P.C.V. (Positive Crankcase Ventilation)
With engine running at idle, remove ventilation hose from P.C.V. valve; if valve is working properly, a hissing noise will be heard as air passes through it and a strong vacuum should be felt immediately when a finger is placed over valve inlet.

VENTILATION HOSE
1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.

EVAPORATIVE EMISSION CONTROL SYSTEM

Description
KA24E engine
Fuel check valve Throttle chamber

uel filler cap with

Carbon canister : Air

: Fuel vapor

The evaporative emission control system is used to reduce hydrocarbons emitted to the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the carbon canister. The fuel vapor from the sealed fuel tank is led into the canister which contains activated carbon and the vapor is stored there when the engine is not running. The canister retains the fuel vapor until the canister is purged by the air drawn through the bottom of the canister to the intake manifold when the engine is running. When the engine runs at idle, the purge control valve is closed. Only a small amount of stored vapor flows into the intake manifold through the constant purge orifice. As the engine speed increases, and the throttle vacuum increases, the purge control valve opens and the vapor is sucked into the intake manifold through both the main purge orifice and the constant purge orifice.

Carbon Canister Inspection

1. Remove canister.

2. Shake canister - there should be no audible sound of carbon movement. 3. Apply 20-35 kPa of vacuum to the purge valve control port using a hand pump. Using a piece of hose, it should be possible to blow low pressure air through the purge hose connection. Release the vacuum applied to the purge valve control port, and it should not be possible to blow air through the purge connection. 4. Using low pressure compressed air (20-35 kPa), blow into the fuel tank tube connector. Check that air flows freely from the other tube connectors.

EVAPORATIVE EMISSION CONTROL SYSTEM

5. If air flow through the drain tube is poor, clean the bottom filter by blocking off the fuel tank tube connector and blowing compressed air at approximately 300 kPa through the purge port. Recheck air flow through the filter as in Step 4. If air flow through the drain tube is still poor, replace the canister. 6. Apply low pressure compressed air (20-35 kPa) to one of the canister ports while the others are blocked off if any air leaks from the top section of the canister, i.e. around the tubes or lid, the canister must be replaced.

Fuel Tank Vacuum Relief Valve Inspection

1. Wipe clean valve housing. 2. Apply vacuum. A slight resistance indicates that valve is in good mechanical condition. 3. If valve is clogged, or if no resistance is felt, replace cap as an assembled unit.

4
To fuel tank
SEC96

FUEL CHECK VALVE 1. Blow air through connector on fuel tank side. A considerable resistance should be felt and a portion of air flow should be directed toward the canister. 2. Blow air through connector on canister side. Air flow should be smoothly directed toward fuel tank. 3. If fuel check valve is suspected of not properly functioning in steps 1 and 2 above, replace it.

EXHAUST EMISSION CONTROL SYSTEM Catalytic Converter

Hydrocarbon Carbon monoxide nitrogen oxide Carbon dioxide gas, nitrogen gas, water

The exhaust gas contains unburned, harmful gases. While the mixture ratio is maintained to the stoichiometric point by the mixture ratio feedback system, the three-way catalytic converter activates to oxidize and reduce harmful gases (HC, C and NOx) into harmless O O , gases (CO,, H and N,). In this way, the catalytic converter cleans , the exhaust gas and emits C , 0 and N into the atmosphere. O

Engine Management System

The engine in this vehicle is controlled by an engine management system which controls the fuel and ignition systems to maintain optimum efficiency and minimise exhaust emissions. Therefore there is further information, affecting emission output, detailed in section ES.

ENGINE CONTROL, FUEL & EXHAUST SYSTEMS SECTION

FE

CONTENTS
ENGINE CONTROL SYSTEM FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FE-3 . . EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FE-4

ENGINE CONTROL SYSTEM

Accelerator Control System
a When removing accelerator wire, make a mark to indicate lock nut's initial position. a Check that throttle valve fully opens when accelerator pedal is fully depressed and that it returns to idle
position when pedal is released.

a Adjust accelerator wire according to the following procedure.

Tighten "adjusting nut" until "throttle drum" starts to move. From that position turn back "adjusting nut" 1.5 to 2 turns, and fasten it with a lock nut. a Check accelerator control parts for improper contact with any adjacent parts. When connecting accelerator wire, be careful not to twist or scratch its inner wire. a On automatic transaxle models, adjust AIT throttle wire. Refer to "ON-VEHICLE SERVICE" in section AT.

rLock nut

I
nut ,--Accelerator wire

rAdjusting

7 Wire end

Return spring L ~ h r o t t l drum e

: N.m ( k g m , ft-lb)

FUEL SYSTEM
WARNING: When replacing fuel line parts, be sure to observe the following: Put a "CAUTION: INFLAMMABLE" sign in workshop. Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. Be sure to disconnect battery ground cable before conducting operations. Keep drained fuel in an explosion-proof container and put lid on securely. CAUTION: Do not disconnect fuel line unless absolutely necessary. Plug up hose and pipe openings to prevent entry of dust or dirt. Always replace 0-ring and clamps with new ones. Do not kink or twist hose and tube when they are being installed. Do not tighten hose clamps excessively to avoid damaging hoses. When installing fuel check valve, be careful of its designated direction. (Refer t o section EC) Run engine and check for leaks at connections.

: N.rn ( k g m , ft-lb)

L ~ u e l tank band

EXHAUST SYSTEM

CAUTION: Always replace exhaust gaskets with new ones when reassembling. With engine running, check all tube connections for exhaust gas leaks, and entire system for unusual noises. After installation, check to assure that mounting brackets and mounting insulator are free from undue stress. If any of above parts are not installed properly, excessive noise or vibration may be transmitted to vehicle body.

Ma~n muffler

(0.9 - 1.2, 6.5 - 8.7)

Rear exhaust tube

Front exhaust t

(0.5 - 0.7.3.6

- 5.1J
13 - 16 (1.3 - 1.6, 9 - 12) 13 - 16 (1.3 - 1.6.9

CLUTCH, SECTION

CL
. . .

CONTENTS
PRECAUTIONS AND PREPARATION CLUTCH SYSTEM INSPECTION AND ADJUSTMENT HYDRAULIC CLUTCH CONTROL CLUTCH RELEASE MECHANISM CLUTCH DISC AND CLUTCH COVER SERVICE DATA AND SPECIFICATIONS (S.D.S.)
,
. .. .
.. ..

. .
.

.. ..

CL- 2 CL- 3 CL- 4 CL- 6 CL- 8 CL-10 CL- 13

PRECAUTIONS AND PREPARATION Precautions

8 8 8 8 8

Recommended fluid is brake fluid "DOT 4". Never re-use drained brake fluid. Be careful not to splash brake fluid on painted areas. To clean or wash all parts of master cylinder and operating cylinder, use clean brake fluid. Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. Use suitable tool when removing and installing clutch hose. Always tension clutch hose and fittings t o specified torques.

WARNING: After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.

Preparation
SPECIAL SERVICE TOOLS
Tool supplier: Litchfield I Tool number Tool name Description

Aligning clutch plate E7006

Clutch aligning tool

CLUTCH SYSTEM

Hydraulic T v ~ e

,-Clutch

master cylinder

Pedalbracket 16 22 (1.6 2.2, 12

, Fulcrum Pin Assist spring

Pedal stopper

m
Pin

Clevis pin

Clutc Pedal

Clutch Operating cylinder Air bleeder screw

m@ Apply lithium-based grease including molybdenum dtsulphide. :

(Crl
: N,m (kg-m, ft-lb)

INSPECTION AND ADJUSTMENT Adjusting Clutch Pedal

1. Adjust pedal height with pedal stopper. Pedal height "H":
163

173 mm (6.42

- 6.81 in)

2. Adjust pedal free play with master cylinder push rod. Then tighten lock nut. Pedal free play "AI": 1.0 3.0 mm (0.039 0.118 in) Pedal free play means the follwing total, measured at position of pedal pad: Play due to clevis pin and clevis pin hole in clutch pedal. Play due to piston and push rod.

3. As a final check, measure pedal free travel "A2" at center of pedal pad. Pedal free travel ''A2": 13 - 17 mm (0.51 0.67 in)

HYDRAULIC CLUTCH CONTROL Clutch Master Cylinder

Km@ Piston cup

Piston assembly

Reservoir band

m8Rubbing surface to
push rod

Valve stopper

1.5 - 2.9 (0.15 - 0 . 3 , l . l

- 2.2)

Remove this stopper, when removing piston and return spring.

m @ Contact surface to piston assembly

m @ : Apply rubber grease.

: N.m ( k g m , ft-lb)

SC L348

DISASSEMBLY AND ASSEMBLY

Push piston into cylinder body with screwdriver when removing and installing valve stopper.

a Align groove of piston assembly and valve stopper when

installing valve stopper. Check direction of piston cups.

Groove

HYDRAULIC CLUTCH CONTROL Clutch Master Cylinder (Cont'd)

INSPECTION
Check the following items, and replace if necessary. a Rubbing surface of cylinder and piston, for uneven wear, rust or damage a Piston with piston cup, for wear or damage a Return spring, for wear or damage a Dust cover, for cracks, deformation or damage a Reservoir, for deformation or damage

Operating Cylinder

1
,--Bleeder screw PJ) 6

- 10 N.m (0.6 - 1.0 kg-m,

disassernblv

D u s t cover

B@

: Apply r u b b e r grease.

INSPECTION
Check the following items, and replace if necessary. a Rubbing surface of cylinder and piston, for uneven wear, rust or damage a Piston with piston cup, for wear or damage a Piston spring, for wear or damage a Dust cover, for cracks, deformation or damage

Bleeding Procedure
Bleed air according to the following procedure. a Carefully monitor fluid level at master cylinder during bleeding operation. 1. Top up reservoir with recommended brake fluid. 2. Connect a transparent vinyl tube to air bleeder valve. 3. Fully depress clutch pedal several times. 4. With clutch pedal depressed, open bleeder valve to release air. 5. Close bleeder valve. 6. Repeat steps 3 through 5 above until clear brake fluid comes out of air bleeder valve.

CLUTCH RELEASE MECHANISM

Withdrawal lever

Bear~ng retainer

Pay attention to direction of bearing retainer

Reta~ner
spring-

: Apply lithium-based grease including

L Release bearing
SCL259

molybdenum disulphide.

INSPECTION
Check the following items, and replace if necessary. a Release bearing, to see that it rolls freely and is free from noise, cracks, pitting or wear a Release sleeve and withdrawal lever rubbing surface, for wear, rust or damage

LUBRICATION

a Apply recommended grease to contact surface and rubbing

surface.
~~thium-based grease including molybdenum

a Too much lubricant might damage clutch disc facing.

CLUTCH DISC AND CLUTCH COVER

l / l /#S

Clutch disc D o rlot clean in solvent. Whe n installing, be careful that grease applied to main drive shaft does not adhere to clutch disc.

Clutch cover securing bolt

rll~trh cover --/

m@ : Apply lithium-based grease including

molybdenum disulphide.
SCL206

Clutch Disc
INSPECTION
Check the following items, and replace if necessary. m Clutch disc, for burns, discoloration, oil or grease leakage

Clutch disc, for wear of facing Wear limit of facing surface to rivet head: 0.3 mm (0.012 in)

Backlash of spline

Clutch disc, for backlash of spline Maximum backlash of spline (at outer edge of disc): 0.9 mm (0.035 in) m Clutch disc, for runout of facing Runout limit: 215TBL 0.7 mm (0.028 in) 225TBL 1.0 mm (0.039 in) Distance of runout check point (from hub center) 215TBL 102.5 mm (4.04 in) 225TBL 107.5 mm (4.23 in)

CLUTCH DISC AND CLUTCH COVER Clutch Disc (Cont'd)

INSTALLATION
Apply recommended grease to contact surface of spline portion. Too much lubricant might damage clutch facing.

Clutch Cover and Flywheel

INSPECTION AND ADJUSTMENT

Check uneveness of diaphragm spring. Check thrust rings for wear or damage by shaking cover assembly and listening for chattering noise, or lightly hammering on rivets for a slightly cracked noise. Replace clutch cover assembly if necessary. Check pressure plate and clutch disc contact surface for slight burns or discoloration. Repair pressure plate with emery paper. Check pressure plate and clutch disc contact surface for deformation or damage. Replace if necessary.

FLYWHEEL INSPECTION
Check contact surface of flywheel for slight burns or discoloration. Repair flywheel with emery paper. Check flywheel runout. Runout (Total indicator reading): Less than 0.15 mm (0.0059 in)

CLUTCH DISC AND CLUTCH COVER Clutch Cover and Flywheel (Cont'd)
INSTALLATION
Align clutch disc with Tool when installing clutch cover and disc.

SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications

CLUTCH MASTER CYLINDER
Inner diameter mm (in) 15.87 (518)

CLUTCH DISC
Model Engine 215TBL CA20E 225TBL KA24E

CLUTCH OPERATING CYLINDER

Inner diameter mm (in) 19.05 (314)

Facing size mm (in) (Outer dia. X lnner dia. X thickness) Thickness of disc assembly With load mm (in)

215 X 140 X 3.5 (8.46 X 5.51 X 0.138)

225 X 150 X 3.5 (8.86 X 5.91 X 0.138)

l
7.8 -8.2 (0.307 -0.323) with 3,923N (400 kg, 882 Ib) 8 . 0 ~ (0.315-0.331) 8.4 with 3,923N (400 kg, 882 l b)

CLUTCH COVER
Model Engine Full load N (kg, Ib) C2 15s CA20E C225S KA24E

3.923 (400,882)

4410 (450,990)

Inspection and Adjustment

CLUTCH PEDAL
Unit: mm (in) I Type of clutch control Pedal height* Pedal free play
l.O - 3.0

CLUTCH DlSC
Unit: mm (in) Model Wear limit of facing surface to rivet head Runout limit of facing Distance of runout check point (from the hub ceriter) Maximum backlash of spline (at outer edge of disc)

Hydraulic

215TBL

225TBL

0.3 (0.01 2) 0.7 (0.028) 1.O (0.039)

Withdrawal lever play

102.5 (4.04)

107.5 (4.23)

Pedal free travel

* : Measured from surface of melt sheet to pedal pad

0.9 (0.035)

CLUTCH COVER
Unit: mm (in) Model Diaphragm spring height Uneven limit of diaphragm spring toe height C215S 30.5 - 32.5 (1.201 - 1.280) C225S 33.0 - 35.0 (1.299 - 1.378)

0.5 (0.020)

0.7 (0.0281

MANUAL TRANSAXLE, SECTION

MT
MT- 2 MT- 4 MT- 6 MT- 8 MT-1 1 MT-14 MT-27 MT-30 MT-34

CONTENTS
... ........ . ... ...... . ....... . . . . ... PREPARATION.. . . . . . . . . . . . . ON VEHICLE SERVICE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . .... ....... .... REMOVAL AND INSTALLATION... . . . . . . . . . . . . . . . MAJOR OVERHAUL.. . ....... ......... .. . ........ ....... . . ..... DISASSEMBLY ..... . . . . . . .. . . . . . . . . . .... ... . . . .... . . . . . . . . ..... ..... . . ...... . . . . . . . . .................... ......... ... ... .... . . REPAIR FOR COMPONENT PARTS ADJUSTMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :. . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .... .. SERVICE DATA AND SPECIFICATIONS (S.D.S.) . . . . . . . . . . . . . . . . . . . . . . . . . .....

E m

PREPARATION
SERVICE TOOLS
Tool supplier: Litchfield Tool number Tool name

Description

E7 187
Preload adaptor

Measuring turning torque. Selecting differential side bearing adjusting shim

E7 188
Differential oil seal installer

Installing differential side seals

E7 128
Bearing raceloil seal remover

Removing differential oil seal Removing mainshaft front bearing outer race Removing differential side bearing outer race

E6673
Bearinglgear remover

Disassembling input & main shafts

E1673C20 (Use with E1673MT)

Bearing puller

Removing differential side bearings

E7 199
5th gear press plates

Removing 5th synchronizer and 5th input gear

E700 1
Bearing installer

Installing main & input shaft bearings

E7002
Installer 3rd, 4th & 5th gears

Installing 3rd, 4th & 5th main gears

PREPARATION
SPECIAL SERVICE TOOLS
Tool supplier: Litchfield

Tool name

E 1673020 Bearing puller (Use with E1673MT

Removing mainshaft front bearing

E7 177-5 Bearing puller

Removing differential side bearings

E7008 Installer differential side bearing

Installer, differential side bearings

E 1673MT Bearing puller kit

Removing mainshaft front and differential side bearings

ON-VEHICLE SERVICE Checking M/T Oil

Check manual transaxle for leakage.

SMA146B

Checkoil level.

Fill to this level

Filler plug
SMAl44A

BACK-UP LAMP SWITCH AND NEUTRAL SWITCH

-1

Check continuity.
Gear position Reverse Neutral Except reverse and neutral
SMT346B

Continuity

0-0 0-0
No

ON-VEHICLE SERVICE
Replacing Oil Seal
DIFFERENTIAL OIL SEAL
1. Drain gear oil from transaxle. 2. Remove drive shafts - Refer to section FA. 3. Remove differential oil seal.

4. Install differential oil seal. Apply multi-purpose grease to seal lip of oil seal before installing. 5. Install drive shafts - Refer to section FA.

STRIKING ROD OIL SEAL

1. Remove transaxle control rod from yoke. 2. Remove retaining pin of yoke. a Be careful not to damage boot.

3. Remove striking rod oil seal.

4. Install striking rod oil seal. Apply multi-purpose grease to seal lip of oil seal before installing.

REMOVAL AND INSTALLATION Removal

Draw out drive shaft - Refer to section FA. Lower transaxle. Support manual transaxle while removing it.

Installation
Tighten all transaxle bolts.

CA2OE Engine
Bolt No. 1 2 3 4
@

Tightening torque N.m (kg-m, ft-lb) 43 - 58 (4.4 - 5.9,32 43 - 58 (4.4 - 5.9,32

Q mm (in)
120 (4.72) 65 (2.56) 70 (2.76) 25 (0.98) 25 (0.98)

- 43) - 43)

43 - 58 (4.4 - 5.9, 32 - 43) 30 - 40 (3.1 - 4.1, 22 - 30) 3 0 - 4 0 (3.1 -4.1, 2 2 - 3 0 )

Engine (gusset)

Front gusset to engine Rear gusset to engine

3 0 - 4 0 ( 3 . 1 -4.1,22 -30)

45 (1.77)

' IIOM'TB @d(- d X

starter

M/T to engine (gusset) O Engine (gusset) toMIT

Qa
0

KA24E Engine
Bolt No.

Tightening torque N.m (kg-m, ft-lb)

P mm (in)

motor

Front gusset to engine Rear gusset to engine

/ 1

30 - 40 (3.1 - 4.1.22 30 - 40 (3.1 - 4.1.22

- 30) - 301

TRANSAXLE GEAR CONTROL

Control lever knob

(1.2- 1 . 5 . 9 - 1 1 )

(0)

22 - 29 (2.2 - 3.0, 16 - 22)

rn spring bracket

14 - 18 (1.4 - 1.8, 10 - 13)

A
(O)
: N.m (kg-m, f t - l b )
SMT341 B

MAJOR OVERHAUL

Gear Components

3rd & 4th check plug

f i -...-.- 7nti &if+- fork

--

1st & 2nd check plug 5th shift fork

(Cr) 16 - 22 (1.6 - 2.2,

12 - 16)

Thread of bolt

lst & 2nd fork rod

l & 2nd bracket st

Interlock plunger

3rd 814th bracket

eturn bearing bracket Select check spring Reverse lever assembly Reverse check cam

Reverse arm shaft

(L11 :

N.m (kgm, ft-lb) : Apply recommended sealant

L l e c t o r shaft

DISASSEMBLY
1. Before removing transmission case, remove bolts and plugs as shown left. 2. Remove transmission case. Caution: Do not lever on transmission case mating surfaces.

3. Remove position switch.

Remove switch contact assembly from selector. Remove oil gutter.

Position switch

4. Mesh 4th gear, and then .remove reverse idler shaft and reverse idler gear.

5. Remove reverse arm shaft. a) Pull out retaining pin.

b) Use a piece of 5mm wire, as shown, t o remove shaft.

SMT185A

DISASSEMBLY
6. Remove reverse lever assembly.

7. Remove 5th & reverse check plug, spring and ball.

8. Remove lower stopper rings and retaining pins from 5th & reverse, 3rd & 4th, and 1st & 2nd shift fork rods. 9. Remove 5th & reverse and 3rd & 4th fork rods. Then remove forks and brackets.

10. Remove both input and mainshafts with 1st & 2nd fork and fork rod as a set.

11. Remove final drive assembly.

DISASSEMBLY
12. Remove reverse check assembly.

13. Remove retaining rolled pin and detach the selector. Remove detent balls (4)and rod.

14. Remove drain plug for convenience in removing retaining pin which holds striking lever to striking rod.

15. Remove retaining pin and then withdraw striking lever and striking rod.

REPAIR FOR COMPONENT PARTS Input Shaft and Gears

DISASSEMBLY
1. Before disassembly, check 3rd, 4th and 5th input gear end plays. Gear end play
Gears
I

End play mm (in)

3rd input gear

4th input gear

1 1

0.23 - 0.43 (0.0091 - 0.0169) 0.25 - 0.55 (0.0098 - 0.0217) 0.23 - 0.48 (0.0091 - 0.0189)

5th input gear

If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring and thrust washer - Refer to "ASSEMBLY".

2. Remove oil channel and shim from rear bearing. Remove input shaft rear bearing using E6673 press plates.

3. Remove 5th synchronizer and 5th input gear using E7 199 press
plates.

4. Remove thrust washer ring, thrust washers and 4th input gear.

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Cont'd)

5. Remove snap ring.

6. Remove 3rd & 4th synchronizer and 3rd input gear using E6673 press plates.

7. Remove input shaft front bearing using E6673 press plates.

INSPECTION
Gear and shaft Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.

Synchronizer Check spline portion of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Cont'd)

Measure clearance between baulk ring and gear, Clearance between baulk ring and gear: Standard 1.0 1.35 mm (0.0394 0.0531 in) Wear limit 0.7 mm (0.028 in)

Bearing Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

ASSEMBLY
5th synchronizer

3rd 8 4th synchronizer

1. Place inserts in three grooves on coupling sleeve (3rd & 4th synchronizer, 5th synchronizer).

REPAIR FOR COMPONENT PARTS

lnput Shaft and Gears (Cont'd)

2. Install 3rd input gear and 3rd baulk ring. 3. Press on 3rd & 4th synchronizer hub. Pay attention to its direction. 4. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it. Allowable clearance of groove: 0 0.1 mm (0 0.004 in) Snap ring of 3rd & 4th synchronizer hub: Refer to S.D.S.

Thrust washer Thrust washers

5. Install 4th input gear. 6. Select proper thrust washers to minimize clearance of groove. Then install them and thrust washer ring. Allowable clearance of groove: 0 0.06 mm (0 0.0024 in) lnput shaft thrust washer: Refer to S.D.S.

7. Install 5th input gear. 8. Press on 5th synchronizer. Ensure baulk ring and inserts remain aligned during this operation.

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Cont'd)

9, Install input shaft front and rear bearings using E700 1 installer. 10. Measure gear end play as the final check - Refer to "DISASSEMBLY".

Mainshaft and Gears

DISASSEMBLY
1. Before disassembly, check 1st and 2nd main gear end plays. Gear end play
Gears 1st main gear 2nd main gear End play mm (in) 0.23 - 0.43 (0.0091 - 0.0169) 0.23 - 0.58 (0.0091 - 0.0228)

If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring - Refer to "ASSEMBLY".

2. Press out mainshaft rear bearing using E6673 press plates.

3. Remove thrust washer and snap ring.

REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Cont'd)

4. Press out 5th main gear and 4th main gear using E6673 press plates.

5. Press out 3rd main gear and 2nd main gear using E6673 press plates.

6. Remove snap ring.

7. Remove 1st & 2nd synchronizer and 1st main gear.

8. Remove mainshaft front bearing using tools E1673MT, E 1673D20 and E7422.

REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Cont'd)

INSPECTION
Gear and shaft Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.

SMT64OA

Synchronizer Check spline portion of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for deformation.

Baulk ring to gear cleara

Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Standard 1.0 1.35 mm (0.0394 0.0531 in) Wear limit 0.7 mm (0.028 in)

SMT140

Bearing Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set.

REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Cont'd)

ASSEMBLY

Reverse main gear . and 1 2 synchronlzer

-1st

gear

1. Place inserts in three grooves on coupling sleeve (1st & 2nd synchronizer).

2. Install 1st main gear and 1st baulk ring. 3. Press on 1st & 2nd synchrbnizer hub. Pay attention to its direction.

4. Install coupling sleeve with three inserts and 2nd baulk ring. 5. Select proper snap ring of 1st & 2nd synchronizer hub to minimize clearance of groove and then install it. Allowable clearance of groove: 0 0.1 mm (0 0.004 in) Snap ring of 1st & 2nd synchronizer hub: Refer to S.D.S.

REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Cont'd)

6. Install 2nd main gear. 7. Press on 3rd main gear using E7002 installer.

8. Press on 4th main gear using E7002 installer.

9. Press on 5th main gear using E7002 installer. 10. Select proper snap ring 'of 5th main gear to minimize clearance of groove and then install it. Allowable clearance of groove: 0 0.15 mm (0 0.0059 in) t Snap ring of 5 h main gear: Refer to S.D.S.

1 1. Press on thrust washer and press on mainshaft rear bearingusing E7001 installer.

12. Press on mainshaft front bearing using E7001 installer. Do not support shaft assembly by the rear bearing, (i.e.) use a suitable spacer.

13. Measure gear and play as the final check "DISASSEMBLY".

Refer to

REPAIR FOR COMPONENT PARTS Final Drive

DISASSEMBLY 1. Remove final gear. 2. Remove differential side bearings using tools E1673MT. E 1673C20, E7 177-5 and E7422.

3. Drive out retaining pin and draw out pinion mate shaft. 4. Remove pinion mate gears and side gears.

INSPECTION Gear, washer, shaft and case Check mating surfaces of differential case, side gears and pinion mate gears. Check washers for wear.

Bearing Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set.

REPAIR FOR COMPONENT PARTS Final Drive (Cont'd)

ASSEMBLY
1. Attach side gear thrust washers to side gears, then install pinion mate washers and pinion mate gears in place.

2. Insert pinion mate shaft. When inserting, be careful not to damage pinion mate thrust washers. 3 Install pinion mate shaft retaining pin.

4. Measure clearance between side gear and differential case with washers following the procedure below: a. Set Tool and dial indicator on side gear. b. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears. Clearance between side gear and differential case with washers: 0.1 0.2 mm (0.004 0.008 in)

c. If not within specification, adjust clearance by changing thickness of side gear thrust washers. Side gear thrust washer: Refer to S.D.S.

REPAIR FOR COMPONENT PARTS

Final Drive (Cont'd)
5. Install retaining pin. Make sure that retaining pin is flush with case.

6. Install final gear. 7. Install speedometer drive gear.

8. Press on differential side bearing using tool E7008.

Fork rod

Shift Control Components

9
Revam lever assembly

INSPECTION
Check contact surface and sliding surface for scratches, projections or other damage. wear,

Shift fork

SMT633A

REPAIR FOR COMPONENT PARTS

Case Components
REMOVAL AND INSTALLATION
Input shaft oil seal

Apply multi-purpose grease to seal lip of oil seal before installing.

Mainshaft front bearing outer race

Mainshaft rear bearing outer race - Refer to "ADJUSTMENT". Differential side bearing outer race - Refer to "ADJUSTMENT".

ADJUSTMENT lnput Shaft End Play and Differential Side Bearing Preload
If any of the following parts are replaced, adjust input shaft end play. a lnput shaft a lnput shaft bearing a Clutch housing a Transmission case If any of the following parts are replaced, adjust differential side bearing preload. a Differential case a Differential side bearing a Clutch housing a Transmission case

1. Remove differential side beacing outer race (transmission case side) and shim(s) using E7 128 puller. Remove input shaft case welch plug.

2. Reinstall differential side bearing outer race without shim(s). 3. Install input shaft and final drive assembly on clutch housing. 4. Install transmission case without input shaft bearing shim(s). Then tighten it to the spe'cified torque.

5. Using the following procedures, measure clearance between bearings and transmission case. m Differential side a. Attach dial indicator. If clamp diameter of dial indicator is too small or too large, attach dial indicator using a magnetic stand.

ADJUSTMENT lnput Shaft End Play and Differential Side Bearing Preload (Cont'd)
b. Insert Tool all the way into differential side gear. Move Tool up and down and measure dial indicator deflection.

lnput shaft side a. Set dial indicator on rear end of input shaft. b. Move input shaft up and down by pushing through the welch plug hole, and measure dial indicator deflection. 6. Select shims with proper thickness with S.D.S. table as a guide. 7. Install selected differential side bearing adjusting shim and differential side bearing outer race.

8. Check differential side bearing turning torque.

a. Install final drive assembly'on clutch housing. b. Install transmission case on clutch housing. Tighten transmission case fixing bolts to the specified torque.

c. Measure turning torque of final drive assembly using E7187 adapter. (New bearing) : 4.9 7.8 N-m (50 80 kg-cm, 43 69 in-lb) When old bearing is used again, turning torque will be slightly less than the above. Make sure torque is close to the specified range.

9. Apply sealant and install new welch plug to input shatt bearing case.

Mainshaft Bearing Preload

If any of the following parts are replaced, adjust mainshaft bearing preload. Mainshaft Mainshaft bearings Clutch housing Transmission case

ADJUSTMENT

Mainshaft Bearing Preload (Cont'd)

1. Remove mainshaft rear bearing outer race and shim(s) using E7 128 puller.

2. Reinstall mainshaft rear bearing outer race without shims. 3. Clean mating surfaces of clutch housing and transmission case with solvent. 4. Install mainshaft and mainshaft front bearing outer race into transmission case. Turn mainshaft while holding bearing outer race so that bearings are properly seated.

5. Put straightedge [width must be more than 50 mm (1.97 in)] on transmission case, and 'measure the distance from upper surface of straightedge to surface of the bearing outer race using a depth micrometer. m Measure at three places on bearing outer race, and take the average. 6. Determine dimension A to be used by the following equation. Dimension A = Width of straightedge Measured distance

7. Measure the distance from mating surface of clutch housing to portion with which mainshaft front bearing outer race is to be mated. m Measure at three places on the portion, and take the average. Dimension B = Measured distance 8. Determine dimension C to be used by the following equation. C = B-A 9. Determine total thickness of shims with S.D.S. table as a guide. 10. Install selected mainshaft bearing adjusting shim and mainshaft bearing outer race. 11. Check total turning torque after assembly - Refer to "ASSEMBLY".

ASSEMBLY
1. lnstall striking lever and striking rod.

2. lnstall selector and retaining pin.

3. lnstall reverse gate assembly.

4. lnstall final drive assembly.

5. lnstall input shaft and mainshaft with 1st & 2nd shift fork assembly. Be careful not to damage input shaft oil seal.

ASSEMBLY
6. Install interlock balls and plunger.
Interlock plunger

5th shift fork

7. Install 3rd & 4th shift fork and bracket, then install 3rd & 4th shift rod, stopper ring and retaining pin.

8. Install interlock balls.

Fork rod (3rd & 4th)

9. Install 5th shift fork and bracket, then install shift rod, stopper ring and retaining pin.

ASSEMBLY
10. Install 5th & reverse check plug, spring and ball.

5th 81reverse shift

Reverse lever

11. Install reverse lever assembly. a Apply multi-purpose grease to check ball.

SMT343B

arm shaft

12. Install reverse arm shaft and retaining pin.

13. Mesh 4th gear. Then install reverse idler gear and shaft, paying attention to the direction of the tapped hole.

ASSEMBLY
14. Place magnet on clutch housing.

15. If bearing preload was adjusted, install selected shim(s) into transmission case. 'Install oil gutter.
shift selector

To aid in installation of transmission case, place shift selector in the 1st and 2nd shift bracket or between 1st and 2nd bracket and 3rd and 4th bracket. 16. Apply sealant to mating surface of transmission case and install it. 17. Install position switch.

- For 1st 812nd shift

18. Apply sealant to threads of check plugs. Install balls, springs and plugs. 19. After assembly, check that you can shift into each gear smoothly.

For 3rd & 4th shift

' I

SMT017B

20. Measure total turning torque using E7 187 adapter. Total turning torque (New bearing): 8.8 21.6 N-m (90 220 kg-cm, 78 191 in-lb) When old bearing is used again, preload will be slightly less than the above. Make sure torque Is close to the specified range.

SERVICE DATA AND SPECIFICATIONS (S.D.Sl

General Specifications (Cont'd)

TRANSAXLE
Engine CA20E KA24E

Transaxle model Number of speed Synchromeshtype

RS5F50A 5 Warner

RS5F50A 5 Warner

Shift pattern

C 11 ii
2 4 R

p
2 4

11 R

lst

3.285 1.850 1.206 0.91 1 0.795 3.428 14 20 29 45 49 14 46 37 35 41 39 48 29 4.7

3.285 1.850 1.272 0.954 0.740 3.428 14 20 33 44 50 14 46 37 42 42 37 48 29 4.7

2nd Gear ratio 3rd 4th 5th Rev. lst 2nd Input gear 3rd 4th 5th Rev. Number of teeth lst 2nd 3rd Main gear 4th 5th Rev. Reverse idle gear Oil capacity litre

FINAL GEAR
Engine Final gear ratio Number of teeth Final gear/Pinion Side gear/Pinion mate gear CA20E 4.167:l 75118 16/10 KA24E 3.895: 1 74119 16/10

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment

GEAR END PLAY
Gear
lst main gear

5th main gear

End play mm (in1 0.23 - 0.43 (0.0091 - 0.0169) 0.23 - 0.58 (0.0091 - 0.02281 0.23 - 0.43 (0.0091 - 0.0169) 0.25 - 0.55 (0.0098 - 0.021 7) 0.23 - 0.48 (0.0091 - 0.01891 Allowable clearance Thickness mm (in) 1.95 (0.0768) 2.05 (0.0807) 2.15 (0.0846) 2.25 (0.0886) 0 - 0.15 mm (0 - 0.0059 in) Part number 3234805E00 3234805EOl 3234845EO2 3234805E03

2nd main gear 3rd input gear 4th input gear 5th input gear

CLEARANCE BETWEEN BAULK RING AND GEAR

Unit: mm (in) Standard 1st & 2nd 3rd & 4th 5th l.O - 1.35 (0.0394 - 0.0531) 1.o - 1.35 (0.0394 - 0.0531 I 1.o - 1.35 (0.0394 - 0.0531 1 Wear limit 0.7 (0.028) 0.7 (0.028) 0.7 (0.0281

AVAILABLE WASHER Input shaft thrust washer

Allowable clearance Thickness mm (in) 4.500 (0.17721 4.525 (0.1781) 4.550 (0.17911 4.575 (0.1801) 0 - 0.06 mm (0 - 0.0024 in1 Pan number 32278-03E01 32278-03E02 32278-03E03 32278-03E04

AVAILABLE SNAP RING 3rd & 4th synchronizer hub (At input shaft)
Allowable clearance Thickness mm (in) l.95 (0.07681 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 0 - 0.1 mm (0 - 0.004 in) Part number 32269-03E03 32269-03E00 32269-03E01 3226903E02

Differential side gear thrust washer

Allowable clearance between side gear and differential case with washer Thickness mm (in) 0.75 - 0.80 (0.0295 - 0.0315) 0.80 - 0.85 (0.0315 - 0.0335) 0.85 - 0.90 (0.0335 - 0.0354) 0.90 - 0.95 (0.0354 - 0.0374) 0.1 - 0.2 mm (0.004 - 0.008 in) Part number 38424E3000 38424-E3001 38424-E3002 38424-E3003

1st & 2nd synchronizer hub

Allowable clearance Thickness mm (in) 1.95 (0.0768) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 0 - 0.1 mm (0 - 0.004 in) Part number 3226903E03 32269-03E00 32269-03EOl 32269-03E02

SERVICE DATA AND SPECIFICATIONS (S.D.S.) lnspedlRon and Adjustment (Cont'd)

AVAILABLE SHIM - INPUT SHAFT END PLAY AND MAINSHAFT AND DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHlM Bearing preload and end play
Unit: mm (in) Mainshaft bearing preload Input shaft end play Differential side bearing preload

Table for selecting mainshaft bearing adjusting shim

Unit: mm (in) Dimension "C" 0.30 - 0.34 (0.0118 - 0.0134) 0.34 - 0.38 (0.0134 - 0.0150) 0.38 0.42 (0.0150 - 0.0165) 0.42 - 0.46 (0.0165 - 0.01811 0.46 - 0.50 (0.0181 - 0.0197) 0.50 - 0.54 (0.0197 0.0213) 0.54 - 0.58 (0.0213 - 0.0228) 0.58 - 0.62 (0.0228 - 0.0244) 0.62 - 0.66 (0.0244 - 0.0260)
Suitable shim(s)

0.60 (0.0236) 0.64 (0.02521 0.68 (0.0268) 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.0315) 0.40 + 0.44 (0.0157 + 0.0173) 0.44 + 0.44 (0.0173 + 0.0173) 0.44 + 0.48 (0.0173 + 0.0189) 0.48 + 0.48 (0.0189 + 0.0189) 0.48 + 0.52 (0.0189 + 0.0205) 0.52 + 0.52 (0.0205 + 0.0205) 0.52 + 0.56 (0.0205 + 0.0220) 0.56 + 0.56 (0.0220 + 0.0220) 0.56 + 0.60 (0.0220 + 0.0236) 0.60 + 0.60 (0.0236 + 0.0236) 0.60 + 0.64 (0.0236 + 0.0252) 0.64 + 0.64 (0.0252 + 0.0252) 0.64 + 0.68 (0.0252 + 0.0268) 0.68 + 0.72 (0.0268 + 0.0283) 0.72 + 0.72 (0.0283 + 0.0283) 0.72 + 0.76 (0.0283 + 0.0299) Q.76 + 0.76 (0.0299 + 0.0299) 0.76 + 0.80 (0.0299 + 0.0315) 0.80 + 0.80 (0.0315 + 0.0315) 0.44 + 1.20 (0.0173 + 0.0472) 0.48 + 1.20 (0.0189 + 0.0472) 0.52 + 1.20 (0.0205 + 0.0472) 0.56 + 1.20 (0.0220 + 0.0472)

0.25 - 0.31 (0.0098 - 0.0122) -0.06

- 0 (-0.0024 - 0)

0.40 0.46 (0.0167 0.0181)

Turning toque (New bearing)

Unit: N-m (kgcm, in-lb) Final drive only Total 4.9-7.8 (60-80.43-69) 8.8-21.6(90-220.78-191)

0.66 - 0.70 (0.0260 - 0.0276) 0.70 0.74 (0.0276 - 0.0291 ) 0.74 - 0.78 (0.0291 - 0.0307) 0.78 - 0.82 (0.0307 - 0.0323) 0.82 - 0.86 (0.0323 - 0.0339) 0.86 - 0.90 (0.0339 - 0.0354) 0.90 - 0.94 (0.0354 - 0.0370)

Mainshaft bearing adjusting shim

Thickness mm (in) 0.40 (0.01571 0.44 (0.0173) 0.48 (0.0189) 0.52 (0.0205) 0.56 (0.0220) 0.60 (0.0236) 0.64 (0.0252) 0.68 (0.0268) 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.0315) 1.20 (0.0472) Part number 32139-03El1 32 139-03E00 32139-03E01 32139-03E12 32139-03E02 32139-03E03 32139-03E04 32 139-03E05 32139-03E06 32139-03E07 32139-03EOE 3213903E13

0.94 - 0.98 (0.0370 - 0.0386) 0.98 - 1.02 (0.0386 - 0.0402) 1.02 - 1.06 (0.0402 - 0.041 7) 1. l 0 - 1. l 4 (0.0433 - 0.0449)
1. l 4 1. l 8 (0.0449 - 0.0465)

1.06-l.lO(O.0417-0.0433) 0.68+0.68(0.0268+0.0268)

1. l 8 - 1.22 (0.0465 - 0.0480) 1.22 - 1.26 (0.0480 - 0.0496) 1.26 - 1.30 (0.0496 - 0.0512) 1.30 - 1.34 (0.0512 - 0.0628) 1.34 1.38 (0.0528 - 0.0543) 1.38 - 1.42 (0.0543 - 0.0559) 1.42 - 1.46 (0.0559 - 0.0575) 1.46 1.50 (0.0575 - 0.0591

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd)

Input shaft bearing adjusting shim
Thickness mm (in) 0.40 (0.0157) 0.44 (0.0173) 0.48 (0.0189) 0.52 (0.02051 0.56 (0.0220) 0.60 (0.0236) 0.64 (0.0252) 0.68 (0.02681 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.031 5) 1.20 (0.0472) Pan number 32225-08EW 32225-08EO1 32225-08E02 32225-08E03 32225-08E04 3222548E05 32225-08E06 32225-08E07 32225-WE08 32225-08E09 32225-08E 10 32225-08Ell

Differential side bearing adjusting shim

Thickness mm (in) 0.40 (0.0157) 0.44 (0.0173) 0.48 (0.0189) 0.52 (0.0205) 0.56 (0.02201 0.60 (0.0236) 0.64 (0.0252) 0.68 (0.0268) 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.03151 1.20 (0.0472) Pan number 3845343E 11 3845343EW 3845343E01 3845343E l 2 3845343E02 38453-03E03 3845343E04 3845343 E05 3845343E06 38453-03E07 3845343EW 38453436 13

Table for selecting input shaft bearing adjusting shim Unit: mm (in)
Dial indicator deflection 0.65 - 0.69 (0.0256 - 0.0272) 0.69 - 0.73 (0.0272 - 0.0287) 0.73 - 0.77 (0.0287 - 0.0303) 0.77 - 0.81 (0.0303 - 0.0319) 0.81 - 0.85 (0.0319 - 0.0335) 0.85 - 0.89 (0.0335 - 0.03501 0.89 - 0.93 (0.0350 - 0.0366) 0.93 - 0.97 (0.0366 - 0.0382) 0.97 - 1.01 (0.0382 - 0.0398) 1.01 - 1.05 (0.0398 - 0.0413) 1.05 - 1.09 (0.0413 - 0.0429) 1.09 - 1 . l 3 (0.0429 - 0.0445)
1.13-1.17(0.0445-0,0461)

Table for selecting differential side bearing adjusting shim(s)

Unit: mm (in) Dial indicator deflection Suitable him(s) 0.44 + 0.48 (0.0173 + 0.0189) 0.48 + 0.48 (0.0189 + 0.0189) 0.48 + 0.52 (0.0189 + 0.0205) 0.52 + 0.52 (0.0205 + 0.0205) 0.52 + 0.56 (0.0205 + 0.0220) 0.56 + 0.56 (0.0220 + 0.0220) 0.56 + 0.60 (0.0220 + 0.0236) 0.60 + 0.60 10.0236 + 0.0236) 0.60 + 0.64 (0.0236 + 0.0252) 0.64 + 0.64 (0.0252 + 0.0252) 0.64 + 0.68 (0.0252 + 0.0268) 0.68 + 0.68 (0.0268 + 0.0268) 0.68 + 0.72 (0.0268 + 0.0283) 0.72 + 0.72 (0.0283 + 0.0283)

Su~table shim(s) 0.64 (0.0252) 0.68 (0.0268) 0.72 (0.02831 0.76 (0.0299) 0.80 (0.0315) 0.40 + 0.44 (0.0157 + 0.0173) 0.44 + 0.44 (0.0173 + 0.0173) 0.44 0.47 - 0.51 (0.0185 - 0.02011 0.51 - 0.55 (0.0201 - 0.0217) 0.55 - 0.59 (0.0217 - 0.0232) 0.59 - 0.63 (0.0232 - 0.0248) ' 0.63 - 0.67 (0.0248 - 0.0264) 0.67 - 0.71 (0.0264 - 0.0280) 0.71 - 0.75 (0.0280 - 0.0295) 0.75 - 0.79 (0.0295 - 0.0311) 0.79 - 0.83 (0.0311 - 0.0327)

+ 0.48 (0.0173 + 0.0189)

0.48 + 0.48 (0.0189 + 0.0189) 0.48 + 0.52 (0.0189 + 0.0205) 0.52 + 0.52 (0.0205 + 0.0205) 0.52 + 0.56 (0.0205 + 0.0220)
0.56+0.56(0.0220+0.0220)

1. l 7 - 1.21 (0.0461 - 0.0476) 1.21 - 1.25 (0.0476 0.0492) 1.25 - 1.29 (0.0492 - 0.0508) 1.29 - 1.33 (0.0508 - 0.05241 1.33 - 1.37 (0.0524 - 0.0539) 1.37 - 1.41 (0.0539 - 0.0555) 1.41 - 1.45 (0.0555 - 0.0571 1 1.45 - 1.49 (0.0571 0.0587) 1.49 - 1.53 (0.0587 - 0.0602) 1.53 - 1.57 (0.0602 - 0.0618) 1.57 - 1.61 (0.0618 - 0.0634) 1.61 - 1.65 (0.0634 - 0.0650) 1.65 - 1.69 (0.0650 - 0.0665)

0.56 + 0.60 (0.0220 + 0.0236) 0.60 + 0.60 (0.0236 + 0.0236) 0.60 + 0.64 (0.0236 + 0.0252) 0.64 + 0.64 i0.0252 + 0.0252) 0.64 + 0.68 (0.0252 + 0.0268) 0.68 + 0.68 (0.0268 + 0.0268) 0.68 + 0.72 (0.0268 + 0.02831 0.72 + 0.72 (0.0283 + 0.0283) 0.72 + 0.76 (0.0283 + 0.0299) 0.76 + 0.76 (0.0299 + 0.0299) 0.76 + 0.80 (0.0299 + 0.0315) 0.80 + 0.80 (0.0315 + 0.0315) 0.44 + 1.20 (0.0173 + 0.0472)

0.87 - 0.91 (0.0343 - 0.0358) 0.91 - 0.95 (0.0358 - 0.0374) 0.95 - 0.99 (0.0374 - 0.0390) 0.99 - 1.03 (0.0390 - 0.04061
0.83 - 0.87 (0.0327 0.0343) 1.03-1.07(0.0406-0.0421) 1.07 - 1. l 1 (0.0421 0.0437) 1.1 1 - 1.15 (0.0437 - 0.0453) 1. l 5 - 1.19 (0.0453 - 0.0469) 1.19 - 1.23 (0.0469 - 0.04841

0.72+0.76(0.0283+0.0299)
0.76 0.76

+ 0.76

(0.0299 + 0.0299)

+ 0.80 (0.0299 + 0.0315)

0.80 + 0.80 (0.0315 + 0.0315) 0.44 + 1.20 (0.0173 + 0.0472) 0.48+1.20(0.0189+0.0472) 0.52 + 1.20 (0.0205 + 0.0472)

1.23-1.27lO.0484-0.0500)
1.27

- 1.31 (0.0500 - 0.0516)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

NOTES:

AUTOMATIC TRANSAXLE SECTION

'

AT
ATATATAT2 3 4 8 AT- 10 AT- 26 AT- 9 0 AT- 9 2 AT- 9 4 AT- 9 6 AT- 102 AT- 126 AT- 155 AT-1 7 1 AT- 17 4

CONTENTS
PREPARATION ... . . . . . . . PRECAUTIONS A/T CONTROL DIAGRAM . . .. ... . . ON-VEHICLE SERVICE TROUBLE-SHOOTING AND DIAGNOSES (Includes ELECTRICAL SYSTEM) RL4F02A ... . .. ... . . .. ... TROUBLE-SHOOTING AND DIAGNOSES (Includes ELECTRICAL SYSTEM) RE4F02A . . .. . . . .. .. . . . ... , . . .. MAJOR OVERHAUL - RL4F02A. MAJOR OVERHAUL - RE4F02A REMOVAL AND INSTALLATION DISASSEMBLY REPAIR FOR COMPONENT PARTS - RL4F02A .. . REPAIR FOR COMPONENT PARTS - RE4F02A: . . ASSEMBLY SERVICE D A T A AND SPECIFICATIONS (S.D.S.) - RL4F02A SERVICE DATA AND SPECIFICATIONS (S.D.S.) - RE4F02A
When you read wiring diagrams:

m Read GI section, "HOW TO READ WIRING DIAGRAMS". m See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES".

PREPARATION
Tool sup~lier: Litchfield Tool number Tool name Description Removing and installing clutch springs

SPECIAL SERVICE TOOLS

E7 179 Clutch spring compressor

E1344A Oil pressure gauge set

Measuring oil pressure

E7 123 Oil pressure gauge adapter

Measuring oil pressure

E7 187 Preload adapter

Checking differential side bearing preload

E7 128 Side bearing outer race puller

Removing differential side bearing

Aad-.A&

E7 192 Height Gauge

Selecting thrust washers, bearing races and differential side bearing adjusting shims

E7 188 Seal installer

Installing differential side seals

E7008

Installingbearings

Bearing installer

J34296 J34297 Differential side oil seal protector

R.H.

J34297 J34296

L.H.

PRECAUTIONS
Tool Supplier: Litchfield

E l

SPECIAL SERVICE TOOLS (Cont'd)

Bearing removal & installation

E 1673MT Bearing puller kit

E 1673C20 Bearing puller plates

E1673C15 Bearing puller plates E7422 Handle E7 177-5 Drift adapter E70 10 Installer E701 1 Bearing puller plates

Plug

Bear~ng puller

E7009

E6646-22

PRECAUTIONS
Before proceeding with disassembly, thoroughly clean the outside of the transaxle. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. Disassembly should be done in a clean work area. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transaxle. When disassembling parts, place them in order in a parts rack so that they can be put back into the unit in their proper positions. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly. Gaskets, seals and 0-rings should be replaced any time the transaxle is disassembled.

It is very important to perform functional tests

AT-3

whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are removed and serviced. Place removed parts in order on a parts rack so they can be put back in the valve body in the same positions and sequences. Care will also prevent springs and small parts from becoming scattered or lost. Properly installed valves, sleeves, plugs, etc. will slide along their bores in the valve body under their own weight. Before assembly, apply a coat of recommended A.T.F. to all parts. Petroleum jelly may be applied to 0-rings and seals and used to hold small bearings and washers in place during reassembly. Do not use grease. Extreme care should be taken to avoid damage to 0-rings, seals and gaskets when assembling. After overhaul, refill the transaxle with new A.T.F.

AIT CONTROL DIAGRAM Hydraulic Control Circuits

RE4F02A

A/T CONTROL DIAGRAM

Hydraulic Control Circuits (Cont'd)

RL4F02A

A/T CONTROL DIAGRAM

R E ~ F O Only ~A

Electrical Control Chart

Dropping resistor switch Lockup solenoid Timing solenoid Shift solenoid A Shift solenoid B
4

[ Overdrive switch ]

Id* switch Full thronk witch Thronlr rnror

A/T control unit

Thronir owning
t

]
A/T mode
SAT1 58C

Engim control

Mechanical Operation
Reverse clutch High

Range

1 1 y0 1
Low

Band

c'utch

'lutch Operation Release

Parking pawl

Park Reverse Neutral

I
I
On

I
on on on on
l

Drive

-1
l

on

(on) on

on

on* 1 on* 2 on

on on on

on

RL4F02A '1 & '2 Lock-up operates in 4th speed only.

RE4F02A Only
'1.

'2.

Lock-up operates in 3rd speed (lock-up) range when O.D. control switch is "OFF" (Overdrive not allowed). Lock-up operates in 4th speed (lock-up) range when O.D. control switch is "ON" (Overdrive allowed).

AT-6

A/T CONTROL DIAGRAM

Cross-sectional View

I & RE4F02A 1

AT- 7

ON-VEHICLE SERVICE
Control Valve Assembly
1. Remove air cleaner, battery and its bracket. 2. Remove control valve cover. 3. Remove control valve assembly by removing fixing bolts and disconnecting harness connector. Be careful not to drop manual valve out of valve body. 4. Disassemble, inspect and assemble control valve assembly. Refer to "Control Valve Body". Set manual shaft in "N" position, then align manual plate with groove in manual valve of control valve assembly. After installing control valve to transmission case, make sure that selector lever can be moved to all positions.

Inhibitor Switch Adjustment

1. Remove control cable from manual shaft. 2. Set manual shaft in "NWposition. 3. Loosen inhibitor switch fixing bolts.

4. Insert pin into adjustment holes in both inhibitor switch and manual shaft as near vertical as possible. 5. Reinstall any part removed. 6. Check continuity of inhibitor switch. - Refer to "Electrical Components Inspection".

Differential Side Oil Seal Replacement

1. Remove drive shaft assembly. - Refer to section FA 2. Remove oil seal.

3. Install oil seal using E7 188 installer. Apply A.T.F. before installing. 4. Reinstall any part removed.

ON-VEHICLE SERVICE Control Cable Adjustment

Move selector lever from "P" range to "1" range. You should be able to feel the detents in each range. If the detents cannot be felt or the pointer indicating the range is improperly aligned, the linkage needs adjustment. 1. Place selector lever in "P" range. 2. Loosen lock nuts. 3. Screw lock nut @ until it touches select rod end while holding select rod horizontal, and tighten lock nut 0 . 4. Move selector lever from "P" range to "1" range again. Make sure selector lever moves smoothly.

Throttle Wire Adjustment (RL4F02A only)

1. Loosen throttle wire double nuts "A" and "B".

P, (Full throttle position)

,' C!

-- -

'\

p, (Idling position)

2. With throttle drum set at "P1" (fully-open), move fitting "Q" fully in direction "T" and tighten nut "B" in direction "U". 3. Reverse nut "B" by "NW revolutions in direction "T", then tighten nut "A" securely. Throttle drum should be held at "P1". Number of revolutions "N": 2.75 - 3.25 turns
4. Ensure that throttle wire stroke "L" is within specified range between full throttle and idle. Throttle wire stroke "L": 39 43 mm

(at P,)

(at P, )

a Adjust throttle wire stroke when throttle wire/accelerator

wire is installed or after carburetor has been adjusted. Put marks on throttle wire to facilitate measuring wire stroke.

o1

Vehicle speed

If throttle wire stroke is improperly adjusted, the following problems may arise. a When full-open position "P," of throttle drum is closer to direction "T", shift schedule will be as shown by @ in figure at left, and kickdown range will greatly increase. a When full-open position "P," of throttle drum is closer to direction "U", shift schedule will be as shown by @ in figure at left, and kickdown range will not occur. 5. After properly adjusting throttle wire, ensure the parting line is as straight as possible.

TROUBLE-SHOOTING AND DIAGNOSES

RL4F02A

How to Perform Trouble Diagnoses for Quick and Accurate Repair

WORK FLOW

CHECK IN

LISTEN TO CUSTOMER COMPLAINTS.

I I
I

CHECK A/T FLUID LEVEL AND CONDITION.

r----------

PERFORM ROAD TESTING.

INSPECT MALFUNCTION ON THE BASIS OF EACH COMPONENT'S CONDITION.

I
I
I
I N.G.

L - --- - - - - -- -I

I
FINAL CHECK

REPAI RIREPLACE.

I
I

CHECK OUT

AT- 10

TROUBLE-SHOOTING AND DIAGNOSES

RL4F02A

Preliminary Checks (Prior to Road Testing)

FLUID LEAKAGE CHECK
1. Clean area suspected of leaking, - for example, mating surface of converter housing and transmission case. 2. Start engine, apply foot brake, place selector lever in "D" range and wait a few minutes. 3. Stop engine.

4. Check for fresh leakage.

FLUID CONDITION CHECK

Fluid color Dark or black with burned odor Suspected problem Wear of frictional material Water contamination - Road water entering through filler tube or breather Oxidation Over or under filling Overheating

Milky pink

Varnished fluid, light t o dark brown and tacky

FLUID LEVEL CHECK

Refer to section MA.

TROUBLE-SHOOTING AND DIAGNOSES

Road Testing

RL4F02A

Perform road tests using "Symptom" chart. Refer t o page AT-1 5.

"P" RANGE
1. Place selector lever in "P" range and start the engine. Stop the engine and repeat the procedure in all ranges, including neutral. 2. Stop vehicle on a slight upgrade and place selector lever in "P" range. Release parking brake to make sure vehicle remains locked.

"R" RANGE
1 . Manually move selector lever from "P" toUR", and note shift quality. 2. Drive vehicle in reverse long enough to detect slippage or other abnormalities.

"NWRANGE
1 . Manually move selector lever from "R" and "D" to "N" and note quality. 2. Release parking brake with selector lever in "N" range. Lightly depress accelerator pedal to make sure vehicle does not move. (When vehicle is new or soon after clutches have been replaced, vehicle may move slightly. This is not a problem.)

"D" RANGE
1. Manually shift selector lever from "N" to "D" range, and note shift quality. 2. Using the shift schedule as a reference, drive vehicle in "D" range. Record, on symptom chart, respective vehicle speeds at which up-shifting and down-shifting occur. These speeds are to be read at three different throttle positions (light, half and full), respectively. Also determine the timing at which shocks are encountered during shifting and which clutches are engaged. 3. Determine, by observing lock-up pressure, whether lock-up properly occurs while driving vehicle in proper gear position.

TROUBLE-SHOOTING AND DIAGNOSES Road Testing (Cont'd)

pkZq

4. Check to determine if shifting to overdrive gear cannot be made while O.D. control switch is "OFF".

5. When veh~cleis being driven in the 65 to 8 0 km/h range in "D," range at half to light throttle position, fully depress accelerator pedal to make sure it downshifts from 3rd to 2nd gear. 6. When vehicle is being driven in the 25 to 35 km/h ("D," range) at half to light throttle position, fully depress accelerator pedal to make sure it downshifts from 2nd to 1st gear.

"2" RANGE
1. Shift to "2" range and make sure vehicle begins to move in 1st gear. 2. Increase vehicle speed to make sure it upshifts from 1st to 2nd gear. 3. Further increase vehicle speed. Make sure it does not upshift to 3rd gear. 4 . While driving vehicle at the 25 to 35 km/h with throttle at half to light position ("2," range), fully depress accelerator pedal to make sure it downshifts from 2nd to 1st gear. 5. Allow vehicle to run idle while in "2" range to make sure that it downshifts to 1st gear. 6. Move selector to "D" range and allow vehicle to operate at 4 0 to 5 0 km/h. Then, shiftto"2" range to make sure it downshifts to 2nd gear.

"l" RANGE
1. Place selector lever in "1" range and accelerate vehicle. Make sure it does not shift from 1st to 2nd gear although vehicle speed increases. 2. While vehicle is being driven in "1" range, release accelerator pedal to make sure that engine compression acts as a brake. 3. Place selector lever in "D" or "2" range and allow vehicle to run at 20 to 3 0 km/h. Then move selector lever to 1 range to make sure ~t downshifts to 1 st gear.
"
"

TROUBLE-SHOOTING AND DIAGNOSES

Road Testing (Cont'd)
VEHICLE SPEED WHEN SHIFTING GEARS
This check should be carried out when oil temperature is between 50 to 80C (122 to 176F) after the vehicle has been driven approx. 10 minutes.

SHIFT SCHEDULE

- - -Kickdown range

Upshift

Downshift

in -

4-+4Lockup

0 l (01

10

20 (10)

30
(201

40
1

50

60

70

80 (50)

90

100
(60)

110 120 130

1

140
I

150

160
l

170

180 ('lo1

190

200
(120)

(h)

(401

(701

(h1

(901

(1001

Vehicle speed kmlh (MPH)

TROUBLE-SHOOTING AND DIAGNOSES

Road Testing (Cont'd)
ROAD TEST SYMPTOM CHART FOR RL4F02A
Numbers in chart below correspond with those indicated in Troubleshooting chart.

RL4F02A

TROUBLE-SHOOTING AND DIAGNOSES

Road Testing (Cont'd)
TROUBLE-SHOOTING CHART FOR RL4F02A
Numbers are arranged in order of probability. Perform inspections starting with number one and working up. Circled numbers indicate that the transaxle must be removed from the vehicle.

OFF VEHICLE

Too sharp a shock ~nchange from "2nd" t o "3rd".

. . .

. . . ( S ' . . . . . . . . .

AT- 16

TROUBLE-SHOOTING AND DIAGNOSES

Road Testing (Cont'd)
ON VEHICLE-b4
C

RL4F02A

OFF VEHICLE-

g r,
Numbers are arranged in order of probability. Perform inspections starting with number one and working up. Circled numbers indicate that the transaxle must be removed from the vehicle.
m

0 .-

.L .-

r
$ 2

z 'i z
Y

.c
4-

2 n F ur
E

u
L

5
W

c P U a . r , , , m I

2
3 c i,
X

Reference

o * . ' w= 5 ," -% g 2 . g , Ee o o ~ c m _ P % ~ '2 r c L o u _ r + w J u ~ ~ z : a ~ S t S d $ ;E ~ ' +

m -

c C

8 s , - o ~ _ > ~ . z ; $ a 2 gu ? , ~ ) . ? ~ m ' O E ; , o . 5z; a m,=.'

2 . 5 : 3 5 9>.5,'

rE
. C .

C m
c ~

$
m

O $

m ~

$ 0 g

Too sharp a shock in change from "3rd" t o ''4th". Almost no shock or clutches slipping in change from "lst" to "2nd". Almost no shock or slipping in change from "2nd" to "3rd". Engine races extremely fast. Almost no shock or slipping in change from "3rd" to "4th". Vehicle braked by gear change from "1st" t o "2nd". Vehicle braked by gear change from "2nd" t o "3rd". Vehicle braked by gear change from "3rd" to "4th".

. . .
1 2 .

@
@ @

.......a....... . ....a..a.. . . . a . .. . . . . a . .
. .
. . . @ l . @ @ . @ .

. . . . . . . D . . . . @ . .

. . . . . .
. . . . . .

. . . . .

. . . . . .
1 2 .

.:.....a....... ....a..........
7 @ @ .

@
@

Maximum speed not attained. Acceleration poor. Failure t o change gear from "4th" t o "3rd". Failure t o change gear from "3rd" t o "2nd" or from "4th" t o "2nd". Failure t o change gear from "2nd" t o "1st" or from "3rd" t o "1st". Gear change shock felt during deceleration by releasing accelerator pedal. Too high a change point from "4th" t o "3rd", from "3rd" to "2nd8', from "2nd" t o "1st".

.
1 1

5 6 3 3 4 4 2

3 . 2 .

.
. @

. @ .

. . .
. . .
. . .
. l

. .
. .

. . . .@ . .@
. . . . . . .

. . . . .@ . . . .a . .
. . @ . .

@ @

. .
. 3

. . . . . . . E @ . . . . . .
.

. 2

..........@a..

. . . . . . . . . . . . . W .

Kickdown does not operate when depressing pedal in "4th" within kickdown car speed. Kickdown operates or engine overruns when depressing pedal in "4th" beyond kickdown vehicle speed limit.

. . .

1 . . 3 4 2 . . . . @ . . @ . . . . 0 . .

.
.

. . .

. . .

. . . .

. .

@
@

Races extremely fast or slips in changing from "4th" t o "3rd" when depressing pedal. Races extremely fast or slips in changing from "3rd" to "2nd" when depressing pedal.

. . .

....@)..@)......a
. .

. .

. 2

.:v..

. @ .

. . . . . .

TROUBLE-SHOOTING AND DIAGNOSES

Road Testing (Cont'd)
4
ON VEHICLE
&

pLGiq
OFF VEHICLE

E5
Numbers are arranged in order of probability. Perform inspections starting with number one and working up. Circled numbers indicate that the transaxle must be removed from the vehicle. .L .U

,.
G

0 .-

e .E c .L
3
r
C

;'

; g ?m
- 0

3
p

c 5
X

5. % c
8 s
C

&

Reference

Vehicle will not run in any range. Transmission noise in "D", "2". "l and "R" ranges.
"

1 1

. . . . . . .
1

3 2

5
. .

.
.

. . . . . . . .

@
@

. . . . . . . . . @@@ . . l . . . . . . @ . . . . 00.
@

Failure t o change from "3rd" t o "2nd" when changing lever into "2" range. Gear change from "2nd" t o "3rd" in "2" range.

.
.

. . . . . .

. . . . . . . . .@ . . . .

. . . .

. . . . . . . . . . . . . . . .
. 3

G9
@
@

Engine brake does not operate in "l range.

"

. . .
. .

a.... ........a.a.... ....

. . . . . . . . . . . . . .
. @ .

Gear change from "l t o "2nd" st" in "l" range. Does not change from "2nd" t o "1st" in "l range. " Large shock changing from "2nd" t o "1st" in "l" range. Transaxle overheats. Oil shoots out during operation. White smoke emitted from exhaust pipe during operation. Offensive smell at oil charging pipe.

. . .

. . . .
1

. . . . . . . . D @ . . . .B . . . .
. 2

. . .
1

. .
2

3 4

......a.........
3

. . . . . . . . . .
2

5
6

. .

. . @@@@@I@.. . B
. . @@@@@@. . . B

@.
@ .

008 008

Torque converter i s not locked up. Lock-up piston slip. Lock-up point is extremely high or low. Engine is stopped at R.D. 2 and 1 ranges. Torque converter lock-up pressure is not normal. Transaxle shifts t o overdrive even i.f 0.0. control switch is turned t o "OFF". Lamp inside O.D. control switch glows even if transaxle is shifted out of 0.0.

. . . . . . .
1

. . . .

. . . . 2 . . . . @ @ @ @ @ B .. 0 . @ @ @ 0. . 3 1 2 . . . . . @. . . . . . . .@. . @. . @ .a . . 1 . . . . . . . a . . . . . .. . . . . . 1 2 . . . . . . . . . . . . . . B . . . . .
1

. . . . . . . .
1 . 2

. . . . . . . . . . . . . . . a.. l @ . . . . . . .
1

. . . . . . . . . . . 0..
@

. . . . . . . . . . .

. . . . . . . . . .
1

. . . . .

. . . . . . . . . . .

. . . . . . . . . . . . . . .

AT- 18

TROUBLE-SHOOTING AND DIAGNOSES Stall Testing

STALL TEST PROCEDURE

IK&iG-j

1. Check A/T and engine fluid levels. If necessary, add fluid. 2. Warm up engine until engine oil and A.T.F. reach operating temperature after vehicle has been driven approx. 10 minutes. A.T.F. operating temperature: 50 80C (122 - 176OF)

3. Set parking brake and block wheels. 4. Install a tachometer where it can be seen by driver during test. It is good practice to put a mark on point of specified engine rpm on indicator.

5. Start engine, apply foot brake, and place selector lever in "D" range.

6. Accelerate to wide-open throttle gradually while applying foot brake. 7. Quickly note the engine stall revolution and immediately release throttle. During test, never hold throttle wide-open for more than 5 seconds. Stall revolution standard: 2,300 2,600 rpm

8. Shift selector lever to "N". 9. Cool off A.T.F. Run engine at idle for at least one minute. 10. Perform stall tests in the same manner as in steps 5 through 9 with selector lever in "2", "1" and "R", respectively.

TROUBLE-SHOOTING AND DIAGNOSES

Stall Testing (Cont'd)
STALL TEST ANALYSIS FOR RL4F02A

RL4F02A

5 "D" range test

4
Stall revolution is I

0
"R" range test Stall revolution is Too low

Too high

4,
Low clutch or one-way
clutch slips

Lock-up clutch is dragging, converter one-way clutch is faulty (slipping), or engine is not performing properly.

Too high

Too low

]
0.K.l

"1" range test

]
= .

Reverse clutch or low & rev. brake slips

l
Perform road tests to determine whether reverse clutch'or low & rev. brake slips. When selector lever is in "l " range

Lock-up clutch is dragging, converter one-way clutch is faulty (slipping), or engine is not performing properly.

One-way clutch slips

Low clutch slips

No engine braking

Low & rev. brake slips

~ffectivk engine braking

Reverse clutch slips

If one-way clutch converter is frozen, vehicle will have poor high-speed performance and low engine rpm when raced in "NWrange.

TROUBLE-SHOOTING AND DIAGNOSES

Pressure Testing

RL4F02A

m Location of line pressure test port m Always replace line pressure plugs as they are selfsealing bolts.

Governor pressu

Lock-up pressure

LINE PRESSURE TEST PROCEDURE 1. Check AIT and engine fluid levels. If necessary, add fluid. 2. Warm up engine until engine oil and A.T.F. reach operating temperature after vehicle has been driven approx. 10 minutes. A.T.F. operating temperature: 50 80C (122 176OF)

SAT6476

3. Install pressure gauge to line pressure port.

4. Set parking brake and block wheels. m Continue to depress brake pedal fully while line pressure test at stall speed is performed.

TROUBLE-SHOOTING AND DIAGNOSES

Pressure Testing (Cont'd)
I

Line pressure standard

Model Engine speed rpm Line pressure kPa (bar, kg/cm2, psi)

D, 2 and 1 ranges
Approx. 392 (3.92, 4.0,57) Approx. 1,471 (14.71, 15.0,213)

R range
Approx. 392 (3.92, 4.0,57) Approx. 1,471 (14.71, 15.0,213)

Idle

RL4F02A

.
Stall

S'T~~JAI

5. Start engine and measure line pressure at idle and stall speed. When measuring line pressure at stall speed, follow the stall test procedure.

JUDGEMENT BY LINE PRESSURE If line pressure does not rise, first check to make sure that throttle wire is connected properly. 1) When line pressure while idling is low at all positions ("D", "2", " l " , "R" and "P"), the problem may be due to: Wear on interior of oil pump Oil leakage at or around oil pump, control valve body, transmission case or governor Sticking pressure regulator valve Sticking pressure modifier valve 2) When line pressure while idling is low at a particular position, the problem may be due to the following: If oil leaks at or around low and reverse brake circuit, line pressure becomes low in "R" range but is normal in "P", "D", "2" or "1" range. 3) When line pressure is high while idling, pressure regulator valve may have stuck.

TROUBLE-SHOOTING AND DIAGNOSES

LOCK-UP TEST - RL4F02A

RL4FOZA

Install pressure gauge to lock-up pressure port. Shift selector lever in "D" range.
Condition Lock-up "ON" Lock-up "OFF" Torque converter lock-up pressure kPa (bar, kg/cm2, psi) 49 (0.49, 0.5, 7) or less 196 (1.96, 2.0, 28) or more

If lock-up pressure is not within specifications, refer Trouble-shooting chart

(a).

Component Check
OVERDRIVE CONTROL SWITCH
Check continuity between two terminals.
Switch position (ON) OVERDRIVE (OFF) CANCEL Continuity

O.D. control switch "ON" 4 O.D. indicator lamp "OFF". O.D. control switch "OFF" + O.D. indicator lamp "ON".

TROUBLE-SHOOTING AND DIAGNOSES LOCK-UP ELECTRICAL CONTROL

r.-Gzq

The lock-up torque converter function is controlled by the E.C.C.S. control unit and governor pressure (vehicle speed). A lock-up solenoid, located in a line pressure drain is switched "ON" or "OFF". When the solenoid is "ON", the drain is open, and lock-up is disabled. When solenoid is "OFF", the drain is closed, and lock-up is enabled. The E.C.C.S. control unit will switch the lock-up solenoid according to the table below.

Operating Parameters Water Temp. Less than Throttle Position Idle

Lock-up Solenoid

Lock-up Operation (Vehicle Speed above approx. 70-75 kph) OFF OFF ON
A

ON

50'C
Above

Above Idle Idle Above Idle ON OFF

50'C

The circuit from the ECM is shown below. For testing of the ECM input sensors, refer Section ES.

E.C.M. 37

AR 15

Lock UP solenoid

TROUBLE-SHOOTING AND DIAGNOSES

Notes:

TROUBLE-SHOOTING AND DIAGNOSES

Contents

piEiq

How to Perform Trouble Diagnoses for Quick and Accurate Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-28 Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-29 A/T Electrical Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-39 Circuit Diagram for Quick Pinpoint Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-40 .. Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-4 1 Self-diagnosis . . . . . . . . .. . . . . . ... . . . . . . . .. . . . . AT-43 AT-43 SELF-DIAGNOSTIC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JUDGEMENT OF SELF-DIAGNOSIS CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-44 . . . . . . . . . . . . . . AT-48 REVOLUTION SENSOR CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . .. AT-48 SPEED SENSOR CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . . . . THROTTLE SENSOR CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-49 ... . . . . AT-50 SHIFT SOLENOID A CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . ... ................ SHIFT SOLENOID B CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-5 1 . . . ..................... AT-52 TIMING SOLENOID CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCK-UP SOLENOID SENSOR CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-53 FLUID TEMPERATURE SENSOR CIRCUIT AND A/T CONTROL UNIT POWER SOURSE CIRCUIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-54 . ENGINE REVOLUTION SIGNAL CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-55 LINE PRESSURE SOLENOID CIRCUIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AT-56 INHIBITOR, OVERDRIVE AND THROTTLE VALVE SWITCH CIRCUIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-57 . Diagnostic Procedure 1 (SYMPTOM: Power indicator lamp does not come on for about 2 seconds . . . . . . . . . . . . . . . AT-59 when turning ignition switch t o "ON".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . Diagnostic Procedure 2 (SYMPTOM: Power indicator lamp or comfort indicator lamp does not .... . . . . . AT-60 come on when turning A/t mode switch t o the appropriate position.) . . . . . . . . . . . . . . Diagnostic Procedure 3 (SYMPTOM: O.D. OFF indicator lamp doess not come on when setting . . . . . . . . . . . . . . . . . . . . . . . AT-60 . . . overdrive switch t o "OFF" position.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 4 (SYMPTOM: Power indicator lamp does not come on for about 3 seconds when depressing and releasing accelerator pedal fully.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-6 1 Diagnostic Procedure 5 (SYMPTOM: Engine cannot be started with selector lever in "P", or "N" range . . . AT-6 1 or engine can be started with selector lever in "D", "2", 1" or "R" range.) . . . . . . . . . . . . . . " Diagnostic Procedure 6 (SYMPTOM: Vehicle moves when it is pushed forward or backward with . . . . . . . . . . . . . AT-62 selector lever in 'P" range.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 7 (SYMPTOM: Vehicle moves forward or backward when selecting "N" range.) . . . . . . . . . . . . . . . . . . AT-62 Diagnostic Procedure 8 (SYMPTOM: There is large shock when changing from "N" to "R" range.) . . . . . . . . . . . . . . . . . . . . . . AT-63 Diagnostic Procedure 9 AT-64 (SYMPTOM: Vehicle does not creep backward when selecting "R" range.) . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedure 1 0 (SYMPTOM: Vehicle does not creep forward when selecting "D", "2" or " 1" range.) . . . . . . . . . . . . . . . . . . AT-65 Diagnostic Procedure 1 1 (SYMPTOM: Vehicle cannot be started from D,.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-66 . Diagnostic Procedure 1 2 (SYMPTOM: A/T does not shift from D, t o D at the specified speed. , A/T does not shift from D t o D when depressing accelerator pedal fully , , .. . . . . . . . . . . . AT-67 at the specified speed.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . Diagnostic Procedure 1 3 (SYMPTOM: A/T does not shift from D t o D at the specified speed.) . . . . . . . . . . . . . . . . . . . . . . . . AT-68 , ,

TROUBLE-SHOOTING AND DIAGNOSES

Contents (Cont'd)

RE4F02A

Diagnostic Procedure 14 (SYMPTOM: A/T does not shift from D to D at the specified speed.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-69 , , Diagnostic Procedure 15 (SYMPTOM: A/T does not perform lock-up at the specified speed.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-70 . Diagnostic Procedure 16 (SYMPTOM: A/T does not hold lock-up condition for more than 3 0 seconds.) . . . . . . . . . . . . . . . . . AT-7 1 Diagnostic Procedure 17 (SYMPTOM: Lock-up is not released when accelerator pedal is released.) . . . . . . . . . . . . . . . . . . . . . . . . AT-71 Diagnostic Procedure 18 (SYMPTOM: A/T does not shift from D to D when changing , , . overdrive switch to "OFF" position.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-72 Diagnostic Procedure 19 (SYMPTOM: A/T does not shift from D to D when changing , , selector lever from "D" to "2" range.) . . . . . . .......................... . . . . . . . . . . . . . . . . . . . . . . . . . AT-73 Diagnostic Procedure 20 (SYMPTOM: A/T does not shift from 2 to 1, when changing selector , lever from "2" to " 1 range. , Vehicle does not decelerate by engine brake when shifting from 2 (1) to 1,.) . . . . . . . . . . . . . . . . . . . . AT-73 , Electrical Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-74 Final Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-8 1 Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-86
"

TROUBLE-SHOOTING AND DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair
WORK FLOW

CHECK IN

Reference item

LISTEN TO CUSTOMER COMPLAINTS.

I I l
(See page AT-28.) Preliminary

CHECK A/T FLUID LEVEL AND CONDITION.

Check
PERFORM ROAD TESTING. PERFORM SELF-DIAGNOSIS.

(See page AT-43 .)

Self-diagnosis (See page AT-43.) INSPECT MALFUNCTION ON THE BASIS OF EACH COMPONENT'S CONDITION. Diagnostic Procedure (See page AT-59.)

(See page AT-87.)

L - --- - - - - -

N.G.

-4
(

FINAL CHECK

I
)

(See page AT-8 1.)

CHECK OUT

TROUBLE-SHOOTING AND DIAGNOSES

Preliminary Check
A/T FLUID CHECK

[RE4F02A/

Fluid leakage check 1. Clean area suspected of leaking, - for example, mating surface of converter housing and transmission case. 2. Start engine, apply foot brake, place selector lever in "D" range and wait a few minutes. 3. Stop engine.

4. Check for fresh leakage. Fluid level check - Refer Section MA.

Fluid condition check

Fluid color Dark or black with burned odor Suspected problem Wear of frictional material

Milky pink

Water contamination Road water entering through filler tube or breather Oxidation Over or under filling Overheating

Varnished fluid, light to dark brown and tacky

ROAD. TEST PROCEDURE

1. Check before engine is started.

ROAD TESTING

0
2. Check a t idle.

0
3. Cruise test.

SAT786A

I I l

Description a The purpose of this road test is to determine overall performance of automatic transmission and analyze causes of problems. a The road test consists of the following three parts: 1. Check before engine is started 2. Check at idle 3. Cruise test

a Before road test, familiarize yourself with all test procedures

and items to check.

a Conduct tests on all items. Troubleshoot items which check

out No Good after road test. Refer to "Self-diagnosis" and "Diagnostic Procedure".

preliminary Check (Cont'd)

1. Check before engine is started

Park vehicle on flat surface.

UI
I
Set A/T mode switch to " A U T O position. Move selector lever to "P" range.

B
d-k
POWER AUTO

HOLD
I

Does power indicator lamp come on for about 2 seconds?

No

Go to Diagnostic Procedure 1.

D
l

Yes

Does power indicator lamp flicker for about 8 seconds?

2-

No

Perform self-diagnosis. Refer to SELF-DIAGNOSIS PROCEDURE.

Set A/T mode switch to

Does power indicator lamp come on?

I

1
1

I -

Go to Diagnostic Procedure 2.

BD

Yes

1 I
//
11

Set A/T mode switch to 'HOLD" position.

I I
Go t o Diagnostic Procedure 2.

\\\

4
Does comfort indicator lamp come on?
I

1-

Yes

m u

POWER

AUTO

HOLD

TROUBLE-SHOOTING AND DIAGNOSES

Preliminary Check (Cont'd)

Does O.D. OFF indicator lamp come on?

GO to Diagnostic Procedure 3.

B
/

\ o
m
on for about 3 seconds after accelerator pedal is depressed? Yes

Go to Diagnostic Procedure 4.

- Refer to SELF-DIAGNOSIS

Accolrator p . d . 1

l
Release

PROCEDURE and note N.G. items.

- Check at idle".

Depress

[nj
7 , 1 1 1 \\\

[HOLD]

TROUBLE-SHOOTING AND DIAGNOSES

Preliminary Check (Cont'd)
2. Check at idle

Park vehicle on flat surface.

Move selector lever to "P" or

Is engine started?

Go to Diagnostic Procedure 5.

Move selector lever to "D", "l",

4
Is engine started?

l No

Go to Diagnostic Procedure 5.1

Move selector lever to "P" range.

Push vehicle forward or backward.

P~

Does vehicle mov ~ushed forward or backward?

TROUBLE-SHOOTING AND DIAGNOSES

Preliminary Check (Cont'd)

RE4F02A

Move selector lever t o "N" range.

a g
Brake pedal

I Does vehicle move forward o r I backward?

I A p p i . ~ brake. foot H 4
. . .

t--lj( GO t o Diagnostic Procedure 7.1

I
I
1

I Move selector lever t o "R"

changing from "N" t o "R" range?

ranae.

1
Go t o Diagnostic Procedure 8.

I
El

For several seconds

Release f o o t brake for several seconds.

I

Brake pedal

Does vehicle creep backward . when foot brake is released?

1yes

Go t o Diagnostic Procedure 9.

1Yes
Move selector lever t o "D", " 2 and "1" ranges and check i f vehicle creeps forward.

Does vehicle creeD forward i n all three ranges?

k 1 G 0 t o Diagnostic Procedure 10.1

J Yes
Go t o Cruise test.

TROUBLE-SHOOTING AND DIAGNOSES

Preliminary Check (Cont'd)

p i z G q

0 p]
-

3. Cruise test Check all items listed in Parts 1 through 3. Throttle position can be controlled by voltage across terminals @ and @ of A/T control unit.

Cruise test - Part 1

Warm up engine until engine oil and A.T.F. reach operating temperature after vehicle has been driven approx. 10 minutes. AT. F. operating temperature: 5 0 - 8 0 " (122- 1 7 6 " ~ ) ~

SAT9608

Park vehicle on flat surface.

h/\-POWER
AUTO

HOLD

position.

K
ANCEL* OVERDRNE

Move selector lever to "P' range.

IB

!L
lI

Move selector lever to "D0' range.

Accelerate vehicle by constantly depressing accelerator pedal half-

+
Go to Diagnostic Procedure 11. Yes

TROUBLE-SHOOTING AND DIAGNOSES

-

piiGGq

Preliminary Check (Cont'd)

Dbes A/T shift from Dl to D2 at the specified speed? Specified speed when shifting from Dl to D2: Refer to Shift schedule.

No

Go to Diagnostic Procedure 12.

1Yes

II

Does AIT shift from D2 to D3 at the specified speed? Specified speed when shifting from D2 to D3 : Refer to Shift schedule.

Go to Diagnostic Procedure 13.

W Does A/T shift from D3 to D4 at the specified speed? Specified speed when shifting from D3 to D4 : Refer to Shift schedule.

1 yes

Go to ~iagnostic'Procedure 14.

Does A/T perform lock-up at the specified speed? Specified speed when lock-up occurs: 125 135 km/h

Go to Diagnostic Procedure 15

(Throttle opening 4/81 75 85 km/h

(Throttle opening 2/81

I
Go to Diagnostic Procedure 16

Yes

Does A/T hold lock-up condition for more than 30 seconds? Yes m I Release accelerator pedal. a accelerator pedal is released?
I

I
Go to Diagnostic Procedure 17.

1 Yes
Stop vehicle.

4
Go to "Cruise test

- Part 2".

TROUBLE-SHOOTING AND DIAGNOSES

Preliminary Check (Cont'd)
Cruise test - Part 2
Confirm A/T mode switch is in "AUTO" position and overdrive switch is in "OVERDRIVE" position.

r-EGGq

Confirm selector lever is in "D" range.

Accelerate vehicle to about 80 km/h using half-throttle.

then quickly depress it fully.

Does A/T shift from D4 to Da a soon a accelerator pedal is s s depressed fully?

GOto Diagnostic Procedure 12.)

Does A I T shift from D2 to D3 at the specified speed? Specified speed when shifting from D to D3 : , Refer to Shift schedule.

No

Yes

Go to Diagnostic Procedure 13.

Yes

Release accelerator pedal after shifting from Da to Dg.

l
Does AIT shift from D3 to D47 Yes Go to Diagnostic Procedure 14.

TROUBLE-SHOOTING AND DIAGNOSES Preliminary Check (Cont'd)

Cruise test - Part 3
"AUTO" position and overdrive switch is in "OVERDRIVE" position.

piiziq

l
I
SAT812A

Confirm selector lever is in "D" range. Accelerate vehicle to D4 using half-throttle.

I
1
I

Release accelerator pedal.

ks
El
OVERDRIVE

Set overdrive switch to "OF F" position while driving in D4 range.

l
~

shift f

l NO

.i

Go to Diagnostic Procedure 18.

*
8

yes Move selector lever from "D" t o "2" range while driving in DJ.

I 1 I

4 Yes

1 I

Does A/T shift from DJ to 22. and does vehicle decelerate by engine brake? Yes Move selector lever from "2" to "1" range while driving in 2.z.

1 I I

Go t o Diagnostic Procedure 19.

Does A/T shift does vehicle decelerate by engine brake?

1Yes
Stop vehicle. Perform self-diagnosis. - Refer to SELF-DIAGNOSISPROCEDURE.

TROUBLE-SHOOTING AND DIAGNOSES

Preliminary Check (Cont'd)
SHIFT SCHEDULE

RE4F02A

-Hold pattern

Upshift

Vehicle speed kmlh (MPH)

I
---I
Uphift Downshift

SHIFT SCHEDULE - Power pattern

Veh~cle speed kmlh (MPH)

A/T Electrical Parts Location

Located on . .

T o Illumination system

IGNI T I ON SW1 TCH ON o r START

FUSE
To d l s t r l b u t o r

I G N I T I O N CO1 L I G N I T I O N SW1 TCH ON o r START

tt

TOR

7
:i

W T CONTROL U N I T

TROUBLE-SHOOTING AND DIAGNOSES

r-iizq

NOTES:

TROUBLE-SHOOTING AND DIAGNOSES

RE4F02A

SELF-DIAGNOSTIC PROCEDURE

c
I

DIAGNOSIS START

1
I

Start engine and warm it up to normal engine operating temperature.

Set A/T mode switch in "AUTO" oosition.

I
l

Set overdrive switch in 'OVERDRIVE" ~ o s i t i o n l 1

Move selector lever to "P" range.

Does power indicator lamp come on for about 2 seconds?

4Yes
J

4 No

I Go to Diagnostic ~ r o c e d u r e l
l 1

Move selector lever t o "D" range.

Set overdrive switch in "CANCEL" position.

I

U
Move selector lever to "2" range.

Set overdrive switch in "OVERDRIVE" ~osition. I Move selector lever to "1" range.

I
Accelerator pedal

Set overdrive switch in "CANCEL" position. Depress accelerator pedal fully and release it. Check power indicator lamp. Refer to JUDGEMENT OF SELF-DIAGNOSISCODE on next page.

Depress

Release

DIAGNOSIS END

TROUBLE-SHOOTING AND DIAGNOSES

Self-diagnosis (Cont'd)
JUDGEMENT OF SELF-DIAGNOSIS CODE

RE4F02A

All judgement flickers are same.

All circuits that can be confirmed by self-diagnosis are

A/T control unit

ti = 2.5 seconds

t2 = 2.0 seconds

t3 = 1 . second O

AT-44

TROUBLE-SHOOTING AND DIAGNOSES Self-diagnosis (Cont'd)

p G i q

ft solenoid B circuit is short-circuited or disconnected.

Shift solenoid B

A/T control unit

solenoid

AIT control unit

TROUBLE-SHOOTING AND DIAGNOSES Self-diagnosis (Cont'd)

p G 6 q

Fluid temperature

A/T control unit

II) Go to fluid temperature sensor and A/T control

onnected for a long time. (When reconnecting A/T control unit connectors. - This is not a problem.)

t4 = 1.0 second

TROUBLE-SHOOTING AND DIAGNOSES

Self-diagnosis (Cont'd)
Power indicator lamp: Does not come on. Damaged circuit

pi%q

Inhibitor switch, overdrive switch or throttle valve switch circuit is disconnected or AIT control unit is damaged.

Selfdirgnosis Start

--------------------

Light

--- Shade
SAT1466

Go to inhibitor, overdrive and throttle valve switch circuit checks.

SAT9756
h

TROUBLE-SHOOTING AND DIAGNOSES

Self-diagnosis (Cont'd)
REVOLUTION SENSOR CIRCUIT CHECK
Ravolution sensor

RE4F02A

CHECK REVOLUTION SENSOR. - Refer to "Electrical Components Inspection". O.K.

Repair or replace revolution sensor.

Check harness continuity beAIT control unit

SAT965B

tween A/T control unit and revolution sensor.

2. Check voltage between A/T

control unit terminal @ and ground while driving. (Measure with A.C. range.) Voltage: A t 0 km/h: OV A t 30 km/h: 1V or more (Voltage rises gradually in response to vehicle speed.)

O.K.
Perform self-diagnosis again after driving for a while. N.G. 1. Perform A/T control unit input/output signal inspection.

O.K.
INSPECTION END

2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

SPEED SENSOR CIRCUIT CHECK

Combination

9
CHECK INPUT SIGNAL.
sanwr

A/T control unit

Check the following items. Speed sensor and ground circuit for speed sensor - Refer to section EL. Harness continuity between

2. Check voltage between AIT

control unit terminal and ground while driving at 2 to 3 km/h for 1 m or more. Voltage: Varies from O V to 5 v

A/T control unit and speed

sensor

+y-NG
Perform self-diagnosis again after driving for a while.

I + O.K.
INSPECTION END

1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of AIT control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Self-diagnosis (Cont'd)
Throttle sensor

pzq

THROTTLE SENSOR CIRCUIT CHECK

l
l

P e rengine control. l f - d i a g n o s i . Check throttle sensor circuit for form~e

O.K.
engine control. - Refer t o section ES.

E.C.U.

35
34

,
Check harness continuity between E.C.U. and A/T control unit regarding throttle sensor circuit.

31

A/T control unit

CHECK INPUT SIGNAL. 1.

SAT967 B

2. Check voltage between A/T control unit terminals @ and ?

Depress slowly.

34

35

@ while accelerator pedal is depressed slowly. Voltage: Fully-clod throttle: 0.2 0.6V Fullyopen throttle: 2.9 - 3.9V (Voltage rises gradually in response to throttle valve opening.)

Perform selfdiagnosis again after driving for a while.

.O.K.
INSPECTION END

1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A / l control unit pin terminals for damage or connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Self -diagnosis (Cont'd)
SHIFT SOLENOID A CIRCUIT CHECK
Shift solenoid A

1-1
( 8

E !
CHECK GROUND CIRCUIT.
I

- Terminal
cord assembly
B

'
2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20 M 2 S

A/T control unit

SAT968B

1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. Shift solenoid A - Refer to "Electrical Components Inspection". Harness continuity of terminal cord assembly

Solenoids harness

CHECK POWER SOURCE Cl RCUIT.

Repair or replace harness between A/T control unit and terminal cord assembly.

"
f

2. Disconnect A/T control unit

SAT979 B

connector.

3. Check resistance between

terminal @ and AIT control unit terminal @.

Resistance: Approximately OS2

4. Reinstall any part removed.

Perform self-diagnosis after driving for a while. O.K.

N.G.

INSPECTION END

1. Perform A/T control unit inputloutput signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

SAT980B

TROUBLE-SHOOTING AND DIAGNOSES

piiq
P

Shift solenoid B

Self-diagnosis (Cont'd)
SHIFT SOLENOID B CIRCUIT CHECK
CHECK GROUND CIRCUIT.

Terminal cord assembly

l-

A/T conttol unit

I
Solenoids harness connector

2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20 - 4Oi2

1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. Shift solenoid B - Refer to "Electrical Components Inspection". Harness continuity of terminal cord assembly

O.K.

CHECK POWER SOURCE Cl RCUIT.

+ Repair or replace harness

terminal cord assembly..

N.G.

I between A/T control unit and

Solenoids

2. Disconnect A/T control unit connector. 3. Check resistance between terminal @ and A/T control unit terminal @. Resistance: Approximately 0i2 4. Reinstall any part removed.

perform-zf-diagnosisafter driving for a while.

N.G. + 1. Perform A/T control unit

0
INSPECTION END

I O.K.

input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

AT- 5 1

TROUBLE-SHOOTING AND DIAGNOSES Self-diagnosis (Cont'd)

Timing solenoid

RE4F02A

TIMING SOLENOID CIRCUIT CHECK

CHECK GROUND CIRCUIT. Terminal cord

1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items.

A1T control unit

SAT9708

2. Disconnect terminal cord

assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20 - 40S2
m

Timing solenoid. - Refer to

"Electrical Components Inspection". Harness continuity of terminal cord assembly

I O.K.

CIRCUIT. 1.

I
I

Repair or replace harness between A/T control unit and terminal cord assembly.

Disconnect 1 2. connector. A/T control unit I

@g f
ZiTj
LIB

I
1
L

3. Check resistance between terminal @ and A/T control unit terminal @ . Resistance: Approximately OS2 4. Reinstall any part removed.

II
N.G.J 1. Perform A n control unit inputloutput signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

driving for a while.

I O.K.
INSPECTION END

TROUBLE-SHOOTING AND DIAGNOSES

pGiEq

Self-diagnosis (Cont'd)
Lookup solenoid

LOCK-UP SOLENOID CIRCUIT CHECK

CHECK GROUND CIRCUIT. l. 1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. Lock-up solenoid - Refer to "Electrical Components Inspection". Harness continuity of terminal cord assembly.

r-I
l

-Terminal cord assembly

,l

A I T control unit
SAT971B

Solenoids harness

2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 10 20Q

O.K.

CHECK POWER SOURCE CIRCUIT.

Repair or replace harness between A/T cont'rol unit and terminal cord assembly.
h

SAT986B
-

2. Disconnect A/T control unit

connector. 3. Check resistance between terminal @ and A/T control unit terminal @. Resistance: Approximately 0Q 4. Reinstall any part removed.

(
L

Solenoids harness

Fr

Perform self-diagnosis after driving for a while. O.K.

5 1. Perform A/T control unit

INSPECTION END

input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES Self-diagnosis (Cont'd)

Ignition witch Fluid temperature Terminal cord

RE4F02A

'
1.

FLUID TEMPERATURE SENSOR CIRCUIT AND A/T CONTROL UNlT POWER SOURCE CIRCUIT CHECKS
Check the following items. Harness continuity between
ignition switch and AIT con-

CHECK A/T CONTROL UNIT POWER SOURCE.

4

33

36

trol unit

A/T control unit

lgnition switch and fuse

2. Check voltage between A/T

- Refer t o section EL.

'

FJj
GIB GIB

SAT9726

control unit terminals @ , @ and ground.

~ , F ~ i o l l r o n , ] ,
I

Battery voltage should exist.

O.K.

CHECK FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY

1. Remove control valve cover. 2. Check the following items.

Fluid temperature sensor - Refer to "Electrical Components Inspection". Harness continuity of terminal

SAT9866

2. Disconnect terminal cord

assembly connector in engine compartment. 3. Check resistance between terminals @ and @$ when A n is cold.

Solenoids

Resistance: Cold [20c] Approximately 2.5 k 2 S

4. Reinstall any part removed.

SAT9896

TROUBLE-SHOOTING AND DIAGNOSES

Self-diagnosis (Cont'd)

p E i 6 q

CHECK INPUT SIGNAL OF FLUID TEMPERATURE SENSOR.

11

m
control unit terminal @ and ground while warming up A/T. Voltage: Cold [ ~ O ~ C ] + Hot [80c]: 1.56V - 0.45V ,

Check harness continuity between A/T control unit and terminal cord assembly.

-IT

101oO.cDm1) 2. Check voltage between A/T

33

E
0 0 -

.
I

Perform self-diagnosis after driving for a while.

N.G.

1. Perform A/T control unit inputloutput signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

ENGINE REVOLUTION SIGNAL CIRCUIT CHECK

Perform self-diagnosis for engine control. Check ignition signal circuit condition.
O.K. N.G.

Check ignition signal circuit for engine control. -Refer to section ES.

CHECK INPUT SIGNAL

A/T control unit
SAT973B

N.G. c Check harness continuity b e tween A/T control unit and

2. Check voltage between A/T control unit terminal @ and grwnd. Voltage: 0.9 4.5V

O.K.
l

driving for a while.

O.K.
SAT991 B

INSPECTION END

A/T control unit inputloutput signal inspection. 2. If N.G., recheck A D control unit pin terminals for damage or connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Self-diagnosis (Cont'd)

RE4F02A

1-Terminal cord assembly

1 soleno~d I
A

Line pressure

LINE PRESSURE SOLENOID CIRCUIT CHECK

m
CHECK GROUND CIRCUIT.

Dropping reslstor

1
O.K.

z A/T control unit

m
-

S A T ~ ~

Solenoids harness

2. Disconnect terminal cord assembly connector in engine compartment. ~3.B Check resistance between terminal @ and ground. Resistance: 2 5 - 5L? .

1. Removecontrol valve assembly. Refer to "ON-VEHICLE SERVICE". 2. Check the following items. Line pressure solenoid Refer to "Electrical Components Inspection". Harness continuity of terminal cord assembly

I'._I~
""m m)

star
SAT992B

CHECK POWER SOURCE CIRCUIT.

c,

l.

2. Disconnect AIT control unit

connector.

Check the following items. Dropping resistor - Refer to "Electrical Components Inspection". Harness continuity between AIT control unit @ and terminal cord assembly

3. Check resistance between

terminal @ and A/T control unit terminal @ . Resistance: 1 . - 12.8Q 12

Solenoids harness

- G

CHECK POWER SOURCE CIRCUIT

J
l.

rJi&l
0.K.
lNSPECTlON END

- N.G.

Repair or replace harness between AIT control unit @ and terminal cord assembly.

2. Check resistance between

terminal @ and A/T control unit terminal @ . Resistance: Approximately OS2 3. Reinstall any part removed.

-m C

1
2

* *
s ~ ~ 9 9 3 B

JRJ

Perform self-diagnosis after driving for a while.

l . Perform AIT control unit

inputJoutput signal inspection.

2. If N.G., recheck A D control

unit pin terminals for damage or connection of A D control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

RE4F02A

Self-diagnosis (Cont'd)
INHIBITOR, OVERDRIVE AND THROTTLE VALVE SWITCH CIRCUIT CHECKS

CHECK INHIBITOR WITCH Cl RCUIT.

1.

Check the following items. Inhibitor switch Refer to "Electrical Components Inspection".

Harness continuity b e e n

,i

2. Check voltage between AIT control unit terminals 0 ,@ and ground while moving selector lever through each range. Voltage: B: Battery voltage 0: ov

m,

m,0,

ignition switch and inhibitor switch Harness continuity between inhibitor switch and A/T control unit

16 17 18 19 20

I CIRCUIT.
1.

CHECK OVERDRIVE SWITCH

I 1 I
-

2.

W
ANCELOVERDRIVE

control unit terminal @ and ground when overdrive switch is in "OVERDRIVE" position and in "CANCEL"
Switch position

Check the following items. Overdrive switch - Refer to "Electrical Components Inspection". Harness continuity between A/T control unit and overdrive switch Harness continuity of ground circuit for overdrive switch

Voltage Battery voltage

:
G /Y

OVERDRIVE
CANCEL

I V or less

O.K.

SAT9966

TROUBLE-SHOOTING AND DIAGNOSES

pGii5q

Self-diagnosis (Cont'd)

Bla

a
CHECK IDLE SWITCH CIRCUIT. 1.

N.G.

Perform self-diagnosis for engine control. Check idle switch circuit.

O.K.

N.G.

11

CAMIT
14

11
21
GIR

2. Check voltage between A/T

control unit terminal @ and ground while depressing accelerator pedal slowly. Voltage: When releasing accelerator pedal: 8 - 15V When depressing accelerator pedal fully: 1V or less
1

LGM~

Check harness continuity between A h control unit and idle switch.

Check idle switch c~rcuit for engine control. Refer to section ES.

m
SATQ96B

CHECK FULL THROTTLE SWITCH CIRCUIT. Check voltage between A/T control unit terminal @ and ground in the same way as idle switch circuit. Voltage: When releasing accelerator pedal: 1V or lea When depressing accelerator pedal fully: 8 - 15V

Check harness continuity be tween A/T control unit and full throttle switch.

Perform self-diagnosisagain after driving for a while.

O.K.

INSPECTION END

1. Perform A/T control unit input,output signal inspection. 2. IfN.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.
4

TROUBLE-SHOOTING AND DIAGNOSES

-1

Diagnostic Procedure 1
SYMPTOM: Power indicator lamp does not come on for about 2 seconds when turning ignition switch to "ON".

CHECK M % POWERCONTROL UNlT SOURCE. 1.

SAT~Q~B

2. Check voltage between AIT

control unit terminals @ , @ and ground. Battery voltage should exist.

Check the following items. Harness continuity between ignition switch and A/T control unit Ignition switch and fuse - Refer t o section EL.

O.K.
p

N.G. CHECK M CONTROL UNIT + Check harness continuity GROUND CIRCUIT. between A/T control unit and ground.
SAT9986

El
2. Disconnect A/T control unit
lgnition
witch

Fuse

.
Power

(> indicator
lamp
4

connector. 3. Check resistance between AIT control unit terminals B,@ and ground. ~esibtance: Approximately 0!2

A/T control unit

El

O.K. Check the following items. Power indicator lamp - Refer to section EL. Harness continuity between ignition switch and power indicator lamp Harness continuity between power indicator lamp and A/T control unit

CHECK LAMP CIRCUIT.

IT

~comcm ]

l.+,2. Disconnect AIT control unit

connector. 3. Check resistance between AIT control unit terminals and@. RBsistance: 5 20!2 4. Reinstall any part removed.

SAT9996

O.K. 1. Perform AIT control unit input/output signal inspection. 2. If N.G., recheck AIT control unit pin terminals for damage or connection of AIT control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 2

RE4F02A

SYMPTOM: Power indicator lamp or comfort indicator lamp does not come on when turning A/T mode switch to the appropriate position.
A/T mode switch

Go t o Diagnostic Procedure 1.

Comfort indicator

Check the following items. A/T mode switch Comfort indicator lamp Harness continuity between ignition switch and A/T mode switch Harness continuity between A/T mode switch and A/T control unit

Repair or replace damaged parts.

SAT001C

Diagnostic Procedure 3
O.D. OFF indicator lamp

SYMPTOM: O.D. OFF indicator lamp does not come on when setting overdrive switch to "OFF" position.

38

I
SATOO2C

A/T control unit

Check the following items. Overdrive switch O.D. OFF indicator lamp Harness continuity between ignition switch and O.D. OFF indicator lamp

Repair or replace damaged parts.

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 4

RE4FOZA

SYMPTOM: Power indicator lamp does not come on for about 3 seconds when depressing and releasing accelerator pedal fully.
Does self-diagnosisshow damage to throttle sensor circuit?

,-

Check throttle sensor circuit. Refer to "Self-diagnosis".

Check throttle sensor. - Refer to section ES.

Repair or replace throttle sensor.

O.K.
1. Perform AIT control unit inputloutput signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

Diagnostic Procedure 5
SYMPTOM: Engine cannot be started with selector lever in "P" or "NW range or engine can be started with selector lever in "D", "2", "1" or "R" range.

L
-------------------

Light

- -- Shde
SAT1468

Yes Check inhibitor switch circuit. ' Does self-diagnosisshow damage - Refer t o "Self-diagnosis". to inhibitor switch circuit?

H
Check continuity of inhibitor switch Cpin connector. - Refer to "Electrical Components Inspection".

Inhibitor witch 4-pin connector

Re~air re~lace or inhibitor switch.

'

I O.K.

I Check starting system. - Refer

to section EL.
SATOOBC

~~~~i~ or

d a m aparts. ~

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 8

SYMPTOM: There is large shock when changing from "NWto "R" range.

Check engine idling speed. O.K.

p p
v
Yes
+

Adjust engine idling speed. Refer to section ES.

Does self-diagnosis show damage to throttle sensor, line pressure solenoid or fluid temperature sensor circuit?

Check damaged circuit. - Refer to "Self-diagnosis".

Check throttle sensor. - Refer to section ES.

Dropping resistor

Repair or replace thrpttle sensor.

Check line pressure at idle with selector lever in "D" range. - Refer to "PRESSURE TESTING".

0.K.

1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. Valves to control line pressure (Pressure regulator valve, pilot valve and oil filter) Line pressure solenoid

1. Perform AIT control unit inputloutput signal inspection. 2. If N.G., recheck AIT control unit pin terminals for damage or connection of AIT control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 9
SYMPTOM: Vehicle does not creep backward when selecting "R" range.

Check A/T fluid level. O.K. N.G. in both "1" and "R" range
v

Refill A.T.F.

SAT638A

1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. Valves to control line pressure (Pressure regulator valve, pilot valve and oil filter) Line pressure solenoid 3. ~ i ~A/T. ~ ~ ~ 4. Check the following items. Oil pump assembly

Check stall revolution with selector lever in "1" and "R" range. O.K. in "l" range N.G. in "R" range.
+

Check line pressure at idle with !.G. selector lever in "R" range. Refer to "PRESSURE TESTING".

O.K.

.
I

Reverse clutch assembly

Low & reverse brake assembly Torque converter

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 10

RE4F02A

SYMPTOM: Vehicle does not creep forward when selecting "D", "2" or "1" range.

0
Check A/T fluid level. Refill A.T.F.

B
SAT638A

O.K. 1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. Valves to control line pressure (Pressure regulator valve, pilot valve and oil filter) Line pressure solenoid 3. Disassemble A/T 4. Check the following items. Oil pump assembly Low clutch assembly Low & reverse brake assembly Torque converter'
L

' G' .N . Check stall revolution with selector lever in "D" and "1" ranges. - Refer to "STALL TESTING".

O.K.

Check line pressure a t idle with selector lever in " D , "2" and "1" ranges. - Refer to "PRESSURE TESTING".

-.. NG

-F

El

N.G. Check A/T fluid c o n d d l o n .

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 11
Shift solenoid B

RE4F02A

SYMPTOM: Vehicle cannot be started from D,.

Is Diagnostic Procedure 10 O.K.? Yes Does self-diagnosisshow damage t o revolution sensor, speed sensor, shift solenoid A or B after cruise test? Go to Diagnostic Procedure 10.

N.G.

Y e s - Check damaged circuit.

- Refer

to "Self-diagnosis".

N0 Repair or replace throttle sensor.

Check throttle sensor. - Refer to section ES.

Check line pressure at stall point with selector lever in " D range. - Refer t o "PRESSURE TEST1NG".

El
Check A/T fluid condition. N.G.

I
4

Remove eomrol valve bly. - Refer t o "ON-VEHICLE SERVICE. 2. Check the following items. 1-2 shift valve 2-3 shift valve O.K. 3-4 shift valve b Shift solenoid A Shift solenoid B O.K. 3. Disassemble AIT. O.K. 4. Check the following items. Low clutch assembly One-way clutch Torque converter Oil pump assembly

5
.

'

,,,, ,,,

1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

magnostrc Proceaure 12
~lfdiagnosis start

RE4F02A

SYMPTOM: A/T does not shift from D1 to D at the specified speed. 2 4 2 A/T does not shift from D to D when depressing accelerator pedal fully at the specified speed.
Light
I

--------------------

Are Diagnostic Procedures 10 and 11 O.K.?

--- S h d r
SAT1468

Go to Diagnostic Procedure 10 or 11.

Does self-diagnosisshow damage to inhibitor switch after cruise

Combination meter sensor

Yes

' Check inhibitor switch circuit. - Refer to "Self-diagnosis".

No

Check revolution sensor and ' or replace revolution N.G. Repair sensor and speed knsor circuits. speed sensor circuit. - Refer to "Self-diagnosis".

N.G.

25

35

27

H
-

O.K. Repair or replace throttle sensor.

A/T control unit

Check throttle sensor. - Refer to section ES.

O.K.

O.K.
4-

O.K.

1. Remove control valve. Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 1-2 shift valve 2-3 shift valve 3-4 shift valve Shift solenoid A Shift solenoid B
3. Disassemble A/T. 4. Check the following items. Servo piston assembly Brake band

El

1. Perform A/T control unit

input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 13
&Ifdirgnorir
Start

SYMPTOM: A l l does not shift from Dz to D3 at the specified speed.

Are Diagnostic Procedures 1 0 and 11 O.K.? Yes Does self-diagnosisshow damage to inhibitor switch after cruise Yes Check inhibitor switch circuit. No

________-----------Light
4--Shade

.
r

Go to Diagnostic Procedure 1 0 or 11.

- Refer t o "Self-diagnosis".

Repair or replace throttle sensor. to section ES.

O.K.

O.K.
4-

1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 2-3 shift valve Shift solenoid B

3. Disassemble AIT. 4. Check the following items. Servo piston assembly High clutch assembly

SAT638A

1. Perform A/T control unit inputloutput signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of AIT control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES Diagnostic Procedure 14

piiiq

A l l does not shift from D3 to D, at the specified speed.

Are Diagnostic Procedure 10 and No Go to Diagnostic Procedure 10 or 1 1 .

Does selfdiagnosis show damage to inhibitor switch, overdrive switch, shift solenoid A, B, revolution sensor, speed sensor or fluid temperature sensor circuit after cruise test?

Yes

Check damaged circuit. - Refer to "Self-diagnosis".

Repair or replace throttle sensor. to section ES.

O.K.

O.K.
4

1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 3-4 shift valve Servo release timing valve Shift solenoid A
3. Disassemble AIT. 4. Check the following items. Servo piston assembly Brake band

O.K.

SAT638A

1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or'connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

r-iEEG-1

Diagnostic Procedure 15
SYMPTOM: A/T does not perform lock-up at the specified speed.

Does self-diagnosisshow damage to lock-up solenoid circuit after cruise test?

Yes

Check lock-up solenoid circuit. - Refer to "Self-diagnosis".

No Repair or replace throttle sensor.

N.G. Check throttle sensor. - Refer

O.K.

to section ES. N.G. 1. Remove control valve. - Refer -----* Repair or replace damaged Parts. t o "ON-VEHICLE SERVICE. 2. Check following items. Lock-up control valve Lock-up shuttle valve Torque converter relief valve Lock-upsolenoid Pilot valve Oil filter O.K. 1. Perform A/T control unit inputloutput signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 16

pzq

SYMPTOM: A/T does not hold lock-up condition for more than 30 seconds.
Check revolution sensor circuit.
*

Does self-diagnosisshow damage to engine revolution signal circuit after cruise test?

yes

- Refer to "Self-diagnosis".

Check A/T flui

O.K.

1. Remove control valve assernbly. Refer to "ON-VEHICLE SERVICE". 2. Check the following items. b Lock-up control valve O.K. 0 Pilot valve Oil filter

4 SAT638A

O.K.

3. Disassemble AIT. 4. Check torque converter and oil pump assembly.

t
1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

I, ,]
Selfdiagnosis start

Diagnostic Procedure 17
SYMPTOM: Lock-up is not released when accelerator pedal is released.
Check idle switch circuit. - Refer ' to "Self-diagnosis".

________-----------Light

Does self-diagnosisshow damage to idle switch circuit after cruise test?

Yes

---

Sheds

SAT1466

1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 18
Sllfdia@W~i~ start

SYMPTOM: AIT does not shift from D, to DJ when changing overdrive switch to "OFF" position.
Yes

_________----------Light
--SAT1466

Does self-diagnosisshow damage to overdrive switch circuit after cruise test?

Check overdrive switch circuit. - Refer to "Self-diagnosis".

B
O.K.
1. Remove control valve assembly. - Refer to "ON-VEH ICLE SERVICE". 2. Check the following items. 3-4 shift valve Servo release timing valve Shift solenoid A

-4
SAT638A

O.K.
O.K.
-

3. Disassemble AIT. 4. Check the following items. Servo piston assembly Low clutch assembly

v
1. Perform AIT control unit inputloutput signal inspection. 2. If N.G., recheck AIT control unit pin terminals for damage or connection of A/T control unit harness connector.

TROUBLE-SHOOTING AND DIAGNOSES

Diagnostic Procedure 19
a~fdirgnosis

p k G q

nart

SYMPTOM: A/T does not shift from from "D" to "2" range.
v

D 3

to 2 when changing selector lever 2

--------------------

Light

---

Shdo

Does self-diagnosisshow damage Yes Check inhibitor switch circuit. t o inhibitor switch circuit after B - Refer to "Self-diagnosis". cruise test? NO Go to Diagnostic Procedure 12.

SAT1466

Diagnostic Procedure 20
SelfdirgnoSiS

nart

-------------------- Light
--- Shde
~ ~ ~ 1 4

SYMPTOM: A/T does not shift from 2 to 11 when changing selector lever 2 from "2" to "1" range. Vehicle does not decelerate by engine brake when shifting from 2~ (l2) to l*.

Does self-diagnosisshow damage t6 inhibitor switch after cruise o6

Yes

Check inhibitor switch circuit.

- Refer t o "Self-diagnosis".

- Refer to "ON-VEHICLE

Check manual control linkage.

N.G.

Adjust manual control linkage.

- Refer t o "ON-VEHICLE
SERVICE".

Go to Diagnostic Procedure 9.

TROUBLE-SHOOTING AND DIAGNOSES

Electrical Components Inspection
INSPECTION OF AIT CONTROL UNlT

RE4FO2A

Measure voltage between each terminal and terminal @ or

@ by following "AIT CONTROL UNlT INSPECTION TABLE".

a Pin connector terminal layout.

I

123491111I31I5 1111101121I41 5 1 1 71 116117118119f20121l22 6 8

SAT01 lC

TROUBLE-SHOOTING AND DIAGNOSES

Electrical Components Inspection (Cont'd)
A/T CONTROL UNIT INSPECTION TABLE (Data are reference values.)
Terminal No. Judgement standard

Item

Condition When releasing accelerator pedal

after warming up engine.

1.5 - 2.5V 0.5V or less 5 - 14V 0.5V or less

1V or less

Line pressure solenoid When depressing accelerator pedal fully after warming up engine. When releasing accelerator pedal after warming up engine. When depressing accelerator pedal fully after warming up engine. When setting AIT mode switch in "POWER" position.

*
3

Line pressure solenoid (with dropping rksistor)

Power indicator lamp When setting AIT mode switch except in "POWER" position. When turning ignition switch to ,.ON,,. Battery voltage

Battery voltage

Power source When turning ignition switch to "OFF". When A/T performs lock-up.

1V or less
8 - 15V

Lock-up solenoid When A/T does not perform lock-up. When shift solenoid A operates. (When driving in "D1" or "D4".)

1V or less
Battery voltage

Shift solenoid A

When shift solenoid A does not operate. (When driving in "D2" or "D3".) When shift solenoid B operates. (When driving in "D1" or "D2".)

1V or less

Battery voltage

Shift solenoid B

When shift solenoid B does not operate. (When driving in "D3" or "D4".) When timing solenoid operates. (When driving in "D1" or "D4".)

1V or less

Battery voltage

Timing solenoid

When timing solenoid does not operate. (When driving in "D," or "D3".)

1V or less

TROUBLE-SHOOTING AND DIAGNOSES

Electrical Components Inspection (Cont'd)

Terminal No.

Condition

Judgement standard Same as No. 4

1 Power source
-

I
-

p -

12
13

14

Idle switch (in t h r o t t l e valve switch)

When releasing accelerator pedal after warming u p engine.

8 - 15V

after warming u p engine.

l6

Inhibitor "l" switch

range

When setting selector lever t o "1" range. When setting selector lever t o other ranges. When setting selector lever t o "2" range. When setting selector lever t o other ranges.

Battery voltage

1V o r less

Battery voltage

lnhibitor "2" range switch

1V o r less

l*

lnhibitor "D" range switch

range. When setting selector lever t o other ranges. When setting selector lever t o "N" range. When setting selector lever t o other ranges. When setting selector lever t o "R" range. When setting selector lever t o other ranges.
--

Battery voltage

1V o r less

Battery voltage

l9

lnhibitor "N" o r "P"

range w i t c h

1V o r less

Battery voltage

20

Inhibitor "R" range switch

1V o r less

accelerator pedal more than half-way after warming u p engine. When releasing accelerator pedal after warming u p engine.

8 - 15V

1V o r less

22

*: This terminal is connected t o terminal No. 36 o f E.C.C.S. control unit. When code No. 54 appears during engine self-diagnosis, check line between above terminals for proper continuiw.

TROUBLE-SHOOTING AND DIAGNOSES

Electrical Components Inspection (Cont'd)
Terminal No. Judgement standard Battery voltage Battery voltage 0.OV Approximately 3.7v 1V or more Voltage rises gradually in response to vehicle speed. OV

Item

Condition When turning ignition switch to "OFF". When turning ignition switch to "ON". When engine runs at idle speed.

: :. >;

23

Power source (Back-up)

:.

"

.g:..... oh
.:.::I..

or

$ .... ...,. ..:.:..OFF

.., .

24

Engine revolution signal

When engine runs at 3,000 rpm.

25

Revolution sensor (Measure in AC range)

When vehicle cruises a t 30 kmlh (19 MPH). When vehicle parks.

26

Speed sensor

When moving vehicle at 2 t o 3 km/h for 1m or more.

Vary from 0 to 5v

27

28 29
30
31

Throttle sensor (Power source)

4.5 - 5.5v

When A.T.F. temperature is 2 0 ' ~

32

1.56V 0.4SV Fullyclosed throttle: 0.2 - 0.6V Fully-open throttle: 2.9 - 3.9V

33

Fluid temperature sensor

When A.T.F. temperature is 8 0 ' ~

When depressing accelerator pedal slowly after warming up engine. 34 Throttle sensor Voltage rises gradually in response to throttle opening angle.

35

Throttle sensor (Ground)

When setting A/T mode switch in "POWER" position. When setting A/T mode switch except in "POWER" position.

Battery voltage 1V or less

36

AIT mode switch "POWER"

AT- 7 7

TROUBLE-SHOOTING AND DIAGNOSES

Electrical Components Inspection (Cont'd)

Terminal No.

Item

Condition

Judgement standard

37 38

When setting overdrive switch in "OVERDRIVE" position.

Overdrive switch

Battery voltage

39

When setting overdrive switch in "CANCEL" position. 40

1V or less

41

A/T mode switch 'HOLD"

When setting A/T mode switch in "HOLD" position. When setting A/T mode switch except in "HOLD" position.

Battery voltage

42

1V or less

43
44

45 46 47 48
Ground

TROUBLE-SHOOTING AND DIAGNOSES

/-KGq

Electrical Components Inspection (Cont'd)

INHIBITOR SWITCH
1. Disconnect control cable from manual shaft.

2. Check continuity between terminals @ and @ and between terminals @ and 0, @, 0, @ while moving selector 0, @, lever through each range.

SAT014C

3. If N.G., adjust inhibitor switch. 4. Check terminal continuity again. 5. If N.G., replace inhibitor switch.

Terminal cord assembly Wrapped

FLUID TEMPERATURE SENSOR

For removal and installation, refer to "ON-VEHICLE SERVICE". Check resistance between two terminals while changing temperature as shown as left.
Resistance kS2

SAT02 1C

TROUBLE-SHOOTING AND DIAGNOSES

REVOLUTION SENSOR

pGGGq

Electrical Components Inspection (Cont'd)

For removal and installation, refer to "ON-VEHICLE SERVICE". Check resistance between terminals @, @ and 0.
Terminal No. Resistance

0 0 0

0
0

500 - 6 5 0 a
No continuity

No continuity

TIMING SOLENOID
For removal and installation, refer to "ON-VEHICLE SERVICE". Check resistance between two terminals. Resistance: Timing solenoid 20 4052

4-UNIT SOLENOID ASSEMBLY (Shift solenoid A, B, lock-up solenoid and line pressure solenoid)
For removal and installation, refer to "ON-VEHICLE SERVICE". Check resistance between terminals of each solenoid.
Solenoid Shift solenoid A Shift solenoid B Lock-up solenoid Line pressure solenoid Terminal No. Resistance

L ?

0
@
Ground terminal

20 - 40 10 - 20 2.5 - 5

DROPPING RESISTOR
Check resistance between two terminals. Resistance: 11.2 1 2 . 8 a

TROUBLE-SHOOTING AND DIAGNOSES

OVERDRIVE SWITCH
Check continuity between two terminals.
O.D. switch position

RE4F02A

Electrical Components Inspection (Cont'd)

Continuity

OVERDRIVE

CANCEL

Final Check
STALL TESTING
Stall test procedure 1. Check AIT and engine fluid levels. If necessary, add. 2. Warm up engine until engine oil and A.T.F. reach operating temperature after vehicle has been driven approx. 10 minutes. A.T.F. operating temperature: 50 80C

3. Set parking brake and block wheels. 4. Install a tachometer where it can be seen by driver during test. It is good practice to put a mark on point of specified engine rpm on indicator.

5. Start engine, apply foot brake, and place selector lever in "D" range.

6. Accelerate to wide-open throttle gradually while applying foot brake. 7. Quickly note the engine stall revolution and immediately release throttle. During test, never hold throttle wide-open for more than 5 seconds. Stall revolution: 2,350 2,650 rpm

TROUBLE-SHOOTING AND DIAGNOSES

Final Check (Cont'd)

pzGiiq

8. Shift selector lever to "NW. 9. Cool off A.T.F. Run engine at idle for at least one minute. 10. Perform stall tests in the same manner as in steps 5 through 9 with selector lever in "1" and "R", respectively.

JUDGEMENT OF STALL TEST

PD" test I range

4
Stall revolution is

I
Too high Too low

L-i
"R" range test Stall revolution is

Low clutch or one-way clutch s l i ~ s

&
"1" range test
K . ~

Lock-up clutch i s dragging, converter one-way clutch i s malfunctioning (slipping), or engine is not performing properly.

Too hi$

Too low

Reverse clutch or low & rev. brake slips

Lock-up clutch is dragging, converter one-way clutch is malfunctioning (slipping), or engine is not performing

.
Perform road tests to determine whether reverse clutch or low & rev. brake slips.

One-way clutch slips

Low clutch slips

4
When selector lever is in "l " range

No engine braking

Low & rev. brake slips

Effective engine braking

Reverse clutch slips

If converter oneway clutch is frozen, vehicle will have poor high-speed performance and low engine rpm when it is raced in "N" range. If converter oneway clutch is slipping, vehicle will be sluggish up to 50 or 60 km/h

TROUBLE-SHOOTING AND DIAGNOSES

Final Check (Cont'd)
PRESSURE TESTING

pz6q

Location of line pressure test port Always replace line pressure plugs as they are selfsealing bolts.

Lock-up pressure

I
SAT779A

Line pressure test procedure 1. Check A/T and engine fluid levels. If necessary, add. 2. Warm up engine until engine oil and A.T.F. reach operating temperature after vehicle has been driven approx. 10 minutes. A.T.F. operating temperature: 50 80C

3. Install pressure gauge to line pressure port.

4. Set parking brake and block wheels. a Continue to depress brake pedal fully while line pressure test at stall speed is performed.

TROUBLE-SHOOTING AND DIAGNOSES

Final Check (Cont'd)
5. Start engine and measure line pressure at idle and stall speed. When measuring line pressure at stall speed, follow the stall test procedure.

Line pressure:
Engine speed rPm Idle Stall Line pressure kPa (kg/cm2, psi)

D, 2, 1 and R ranges 382 - 422 (3.9 - 4.3,55

- 61)

1,285 - 1,363 (13.1 - 13.9, 186 - 198)

JUDGEMENT OF LINE PRESSURE TEST

-

Judgement Line pressure is low in all ranges.

Suspected parts Oil pump wear Control piston damage Pressure regulator valve or plug sticking Spring for pressure regulator valve damaged Fluid pressure leakage between oil strainer and pressure regulator valve Fluid pressure leakage between manual valve and particular clutch. m For example; If line pressure is low in "R" and "1" ranges but is normal in "D" and "2" range, fluid leakage exists at or around low & reverse brake circuit. Mal-adjustment of throttle sensor Fluid temperature sensor damaged Line pressure solenoid sticking Short circuit of line pressure solenoid circuit Pressure regulator valve or plug sticking Mal-adjustment of throttle sensor Control piston damaged Line pressure solenoid sticking Short circuit of line pressure solenoid circuit Pressure regulator valve or plug sticking Pilot valve sticking

P
0

Line pressure is low in particular range.

3
Line pressure is high.

P
Q

Line pressure is low.

E) X
m

TROUBLE-SHOOTING AND DIAGNOSES

Final Check (Cont'd)
LOCK-UP TEST

pEGEi-1

Install pressure gauge to lock-up pressure port. Shift selector lever in "D" range.
Condition Lock-up "ON" Lock-up "OFF" Torque converter lock-up pressure kPa (kg/cm2, psi)

49 (0.5,7) or less 196 (2,281 or more

If lock-up pressure is not within specifications, refer to Diagnostic Procedures 15 and 16.

TROUBLE-SHOOTING AND DIAGNOSES

,,

pzFiq

Symptom Chart
ON whicle
79 11 79. 80

OFF vehicle 96'

102

Refemnw p -

(AT-

83

80. 131

8o

8o

105. 149

81

167

Numbers are arr8ng.d in order of pmbebility. PIrform i m p m i o m starting with number one and working up.

- 4 E H
a ,

I
61 61

Engine d o n not start i n " N . " P ranger. Engine starts in r a n p other than "N" and "P". T n n u x l e noise i n "P" and "N" ranges. Vehicle m w w when changing into "F"' range or parking gear d o a not d i M n W . when shifted out of "P' renp. Vehicle runs in "N" n n p . Vehicle will not tun in "R" range (but runs in "D", "2" and "l" ranges). Clutch slips. Very poor acceleration. Vehicle bnked when shifting into "R" nnge. Sharp shock in shifting f m m "N" t o " D raw. Vehicle will not run i n " D end "2" rang(but runs in "1" and "R" ranges).

3 .

. l

62

. .
.

1 .

.............. 2 . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6 . . . . . . . . . 3 4 5 . . 2
4

. . . . . . . . . . . . . . . . . . . . . . . . .

62

. l

. . . . . . . . . . . . . . . . . . .3
......
2 4 . . 3

. 2 . . .

. .

. . . . . .

64

. . . . . . . . .

5 6 7 . 8 .

.
~

. 1 2...... 35..4 . . . . . . . . .6 8 . . 7 . . . . 2 . 6 5 1 3 8 . . 7 . 4 9 . . . . . . .I O . . . . .
. l
. . . . . . . a . . . . . . . . . . . . . . .

2 . .

. .

62

Vehicle will not run i n "D", "l",2 n n g ~ " (but runs in "R" range). Clutch slips. Very poor acwhration. Clutcha or brake slip wm8whm i n starting. Excariw crwp.

.......

2 4 . . 3 . . 5 .

. . . .6

7 8 9 . .

61, 62

No crwp at all.
Feilun to change p e r . Failum to change gear fmm "D, Failum to chenp g p r from "D," Failum t o chanp gmr from "D,"
"

64
65 66

to "D,". to "D, t o "D.".

"

".

. 1 3 . 4 . . . . 5 7 . . 6 . . 8 . . .131210. 9 . 1 1 . 2 . . . . . . . . . l . . . . . . . . .. . . . . . . . . . . . . . . 1.......23 . . . . . . . . . .6 5 . . 4 . . . . 1 ...52. ... .34.. . . . . . . . . . . . . . . . . . . 2 1 . 5 . . . . 4 3 . . . . . . . . . . . . . . . .6 . . . . . 2 1 . 5 . . . . 4 . 3 . . . . . . . . . . .6 . . . 7 . . .31..5.6...4 . . . . . . 2 ........7 . .

Too high a gear change point from "D, "D,", f r a n "D," to "D,", fmm "D," t o "D,". Gmr change directly from "D, occurs.

to

. . .
.
3

1 2

. . . . .

4 5

. . . . .
2 .

. . . . . . . . . .
1 .

" to "D,"

. . . . . . . . . . . . . . .
1 2 4 . . . 3 . . .

. . . . . . . . .
. . 5

. .

" 2 and "1".

Engine stops when shifting I m r into "R", "D".

. . . . . . .

. . . . . . . . .
9 .

Too sharp e shock in change from "D, " t o "D,

".

. . .

1 . 7 8 . 2 5 . . 3 . 4 . 6 .

. . . . . . . . .

Too sharp a shock in change fmm "D," "D,".

to

. . .

....

2 4 . . 3

. . . . . . . . . .5 . . . .

$"*

TROUBLE-SHOOTING AND DIAGNOSES Symptom Chart (Cont'd)

\

4
Reference p q e (AT)

ON vehicle 9. 11 79 79. 80 83 80. 131 80 105. 149

OFF whicla

81

96, 102

167

Numben are arranged i n order of prob.bility. Perform inspections starting with number one and working up.

i 4

i
S

I e ' E

Too sharp a shock in changa from "D," "D,".

to

Almost no shock or clutchsr slipping in change from "D, " to "D,

".

. . . .... . ....
1 1 . . 2

2 4 . . 3

Almost no shock or slipping i n changa from "D," to "D,". Almost no shock or slipping i n change from "D, " to "D, ". Vehicle braked by gear change from "D, "D, ". Vehicle braked by gear c h o w from "D," "D, ". Vehicle braked by gear change from "D," "D, ".

1 . . 2 . . . . 3 6 . . 4 . . . .

.
.

" to
to

.
.

to

1 1

Maximum speed not attained. Amlaration poor. Failure to change gear from "D," Failure t o change gear from "D," or from "D," to "D,". Failure to change gear from "D," or from "D," to "D, ". to "D, to "D,"

.
. . .

. . .
. .

. . .... . ................... . . ........................ . ..................... . . . . . ...... . . . . . . .. . .

3 7 4 . 6 . 8 5 . 7 . . . . 5 2 3 4 . . 8 6 . . . 7 5 2 4 . 5 3 . 2 . 3 . 2 5 3 4 6 12 l 1 7 8 10 9 7 . 6 4 . 5 . 3 . . 5 3 4 . . . 8 . .
P-

............... .... ......... . . . . . . . . . . . . .

".

t o "D,"

Gear change shock felt during deceleration by releasing accelerator pedal. Too high a change point from "D," to "D, ", from "D," t o "D, ",from "D," to "D,

.
.

".

Kickdown does not operate when depressing pedal in "D," within kickdown cpw, Kickdown operates or engine owrruns when depressing pedal in "D," beyond kickdown vehicle speed limit. Races extremely fast or slips i n changing from "D," to "D," when depressing pedal. Recns extremely f a t or slips i n changing from "D," to "D," when depressing pedal. Reces extremely fast or slips i n changing from "D," to "D," when depressingpedal.

.
.

..... . . . . . . . .... . . . . . . . . . ..... ........... . . . .... . . . . . . . . . . . . ............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 . . 2 l 2 . 7 . . . 8 6 1 . . 2 5 3 4 7 . 6 . 8 . 1 2 4 . . . . 3 . . 6 5 . 1 2 . 3 1 2
' S . . .

3 4

. 2 1 . .

..

. 3 4 . .

. . . . . . . . . . . . . . . .

.
. . . .

1 . . 3

....
....

4 6 . . 5 . 2 . .

1 . . 3

1 . . 3

....

4 6 . . 5 . 2 . .

Races extremely fast or slips in changing from 1 . 2 . .~~,~~or~D,~to,,D,~~whend~r~ln~pe~a~~ Vehicle will not run i n any rape. Transaxle noise in "D", "2". "1" and "R" ranges. 1 2 1

4 .

...... . . . . . . ......... . . . . . . . . . . .
7 8 . 8 . . . 7 . 6 7 . . . 1 0 6 . 7 9 8 . . . . 2 5 11
. . . . . . . . S

......
. . . . . . . . . .

3 . . . 4

. . . .

TROUBLE-SHOOTING AND DIAGNOSES

Symptom Chart (Cont'd)
ON vehicle Reference page (AT-

pizzq
OFF vehicle

11

79

79'
80

83

'Or 131

80

80

105, 149

81

96z 102

167

Numbers are errenped i n order of probabilitv. Perform inspections starting with number one

Gear change from "1,"

to "1,"

in "1" range. in "1" range.

to Does not change from "l," "1," Large shock changing from "1," ran@. Tranmxle overheats.

to "1, " in "l"

. . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2....43. . . . . . . . . . . . .5.6 . . . . . . . . . . . . l . . . . . . .. . . . . . . . . 2 . . . 1 . . 3 . . . 2 4 6 . . 5 . . . . . . .1378911.1210 .

.
. 2 1

.
.

.
. . . . . . .

A.T.F. shoou out during operation. White smoke emitted frqm exhaust pipe during operation. Offensive smell et fluid charging pipe. Toque converter is not locked up. Lockup piston slip. Lockup point is extremely high or low.

. .

l . . .

.................
.
. . 7 . . 5 4 . .

. 2 3 5 . 6 4 .

l . . . . . . . . . . . . . . . .

. . 2 3 4 5 7 . 8 6 . . . g . .

56

. .

. . 3 1 2 4 5 . 6 8 . 1 . . 2 . . . . 3 6 . .

. .

AIT does not shift to "D," when setting overdrive w i t c h to "ON" position.
Engine is stopped at "R", "D", "2" end "1" ranges. Lockup judder occurs. Engine UMS too much gawline.

. . . . . . .3

1 2 . 4 . . 5 . . . 3 . . . 2 4 . 8 . 9 7 5 . . . 6 . .

. . . . ..7.. . . . . . . . . . . . . . . . 1........

. . . .

. . . .

........ 543.2... . . . . . . . . . . . . . . . . 7 6 . . . . . . . . . . .5..4.1...23... . 4..3...5 .......... 12. . . . . . . . . .

1

TROUBLE-SHOOTING AND DIAGNOSES

Notes:

Differential side bearing adjusting shim Differential side bearingFinal gear\ Differential case Governor drive gear Differential side bearing Differential spacer

*\

,
~ d gear thrust washer e

Pinion mate thrust was Control cylinder, Pinion mate shaft-' oear LPinion mate L , Needle bearing-)

[(

everse clutch assembly

Thrust washer

Governor valve and shaft

Speedometer case

Converter housing

Torque converter

Differential side oil s e a 1 0 Front oil seal

clutch assembly

l ~ e e d l bearing e

* *

: Seloct with propof thick-. : Adjustmmt is w d i n . : Apply A.T.F.

LOW

clutch assembly

(41 : N.m (kg-m, h-lb) @ : 39 - 49 (4.0 - 5.0.29 - 36) @6.3 - 8.3 (0.64- 0.85.4.6 - 6.1) :l 21 - 23 (2.1 - 2.3, 15 - 17) 19 - 23 (1.9 - 2.3, 14 - 17) @ - 26 (2.0 - 2.7.14 - 20) : 20 l @ 5 - 7 (0.5 - 0.7,3.6 - 5.1 ) :l
@ : 6.3 - 8.3 (0.64 - 0.85, 4.6 - 6.1) @ : 74 - 88 (7.5 - 9.0.54 - 65) @ : 16 - 21 (1.6 - 2.1, 12 - 15)
: 16 - 21 (1.6 2.1, 12 15) : l 6 21 (1.6 - 2.1, 12 15)
/

0 : 31 - 37 (3.2 - 3.8.23 - 27)

@

0
Throttle shaft One

@ : 3.7 - 5.0 (0.38 - 0.51, 2.7 - 3.7) @ : 5 - 7 (0.5 - 0.7.3.6 - 5.1) : 9.1 -11.8(0.93-1.20,6.7-8.7)

5 - 7 (0.5 - 0.7, 3.6 - 5.1)

21 - 23 (2.1 - 2.3, 15 - 17) 19 - 23 (1.9 - 2.3, 14 - 17)

Manual shaft

Band servo assembly

Differential side bearing preload adjusting shim Differential side bearing

*
Reverse clutch assembly

Differential side bearing

Thrust washer

Speedometer case

Converter housing

Torque converter

High clutch assembly

L Needle bearing

* *

: Always replace when disauembled. : Select with proper thickness. : Adjustment is required.

m
@ @
Low clutch assembly

: N.rn (kgm,ft-lb) : 44 - 59 (4.5 - 6.0.33 - 43)

: 6.3-8.3(0.64-0.85.4.6-6.1) l@.@ : Refer to rction "ASSEMBLY".

@ @

: 20 - 26 (2.0 - 217.14 - 20)

l : 5 - 7 (0.5 - 0.7,3.6 - 5.1) @

: 6.3-8.3(0.64-0.85.4.6-6.1) @74 - 88 (7.5 - 9.0.54 - 65) :l

@@l@ (1.6 - 2.1,12 - 15) : l 6 21

: 31 42 (3.2 4.3.23

- 31)

7 - 9 (0.7 - 0.9.5.1 - 6.5) 3.7 5.0 (0.38 - 0.51.2.7 - 3.7)

@@
Needle bearing Rear internal gear

: 5 7 (0.5 -0.7.3.6

- 5.1)

Control valve

0-ring* Revolution sensor

Inhibitor switc

Band sew0 assembly -

REMOVAL AND INSTALLATION

Removal

E l

Remove battery and its bracket Drain A.T.F. by removing drain plug. Disconnect drive shafts. - Refer to section FA.

Remove bolts securing torque converter to drive plate. Remove those bolts by turning crankshaft. Plug up opening such as oil charging pipe hole, etc.

Installation
Drive plate runout Maximum allowable runout: 0.5 mm (0.020 in) If this runout is out of allowance, replace drive plate with ring gear.

When connecting torque converter to transaxle, measure distance "A" to be certain that they are correctly assembled. Distance "A": 19.0 m m or more Install converter to drive plate. After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that transaxle rotates freely without binding. Torque engine t o transaxle bolts as shown on following page. Re-install any part removed. Check fluid level in transaxle. Move selector lever through all positions to be sure that transaxle operates correctly. With parking brake applied, rotate engine at idling. Move selector lever through "N" to "D", to "2", to "1" and to "R". A slight shock should be felt by hand gripping selector each time transaxle is shifted. Perform road test. - Refer to "Road Testing".

REMOVAL AND INSTALLATION

Tighten bolts securing transaxle. KA24E Engine

CA2OE Engine
Bolt No. Tightening torque N-m (kg-m, ft-lb)
I mm

1 2 3 4 5
Front gusset to engine Rear gusset to engine

29-39 (3.0-4.0.22-29) 39-49 (4.0-5.0,29-36) 39-49 (4.0-5.0,29-36) 29-39 (3.0-4.0, 22-29) 6- 8 (0.6-0.8,4.3-4.8) 29-39 (3.0-4.0,22-29) 29-39 (3.0-4.0, 22-29)

85 50 70 30 12 25 35 45

DISASSEMBLY
Disassembly
1. Drain A.T.F. through drain hole.

2. Remove torque converter.

3. Remove control cylinder.

4. Remove control valve cover.

(i) Remove throttle lever (RL4F02A Only). (ii) Remove control valve cover.

5. Disconnect harness connectors on control valve and remove

control valve assembly.

DISASSEMBLY
Disassembly (Cont'd)

& RE4F02A

6. Remove terminal assembly. The terminal retrieving hooks will break if they are forced inward too far. Bend them gently inward while pulling carefully outward on the terminal. Do not pull on the wires.

7. Remove accumulator.

8. Remove side cover.

9. Remove output gear.

10. Draw out idler gear.

DISASSEMBLY

Disassembly (Cont'd)
11. Remove parking pawl, return spring, parking shaft and spacer.

12. Remove speedometer case and speedometer gear

Speedometer case

13. a) Remove governor cap. b) Remove governor bolt, then pin using 4mm10.75 pitch screw or equivalent. c) Remove governor shaft (RL4F02A). Remove speedometer shaft (RE4F02A).

14. Support transaxle assembly on wooden blocks and remove converter housing. m Caution: Do not lever on casing mating surfaces.

15. Remove differential assembly and reduction pinion gear. 16. After removing 0-ring from input shaft, extract input shaft from converter housing.

DISASSEMBLY
Disassembly (Cont'd)
17. Remove oil strainer.

SAT794

18. Remove differential lubrication tube bolts and gutter

19. Loosen band brake stem lock nut, then back off piston stem.

20. Remove brake band and high clutch & reverse clutch pack with high clutch hub and front sun gear as a unit.

Flexible type band brake

To prevent brake linings from cracking or peeling, do not stretch the flexible band unnecessarily. Before removing the brake band, always secure it with a clip as shown in the figure at left. Leave the clip in position after removing the brake band.

2 mm (0.08 in) dia. wira

SAT656

DISASSEMBLY
Disassembly (Cont'd)

!-zq

2 1. Remove one-way clutch, front carrier, rear carrier and low clutch as a set after first removing the circlip.

22. Remove low & reverse brake clutches, and detach low & reverse brake retainer snap ring pushing retainer.

23. Remove low and reverse brake piston by applying low pressure compressed air as shown.

24. Remove bearing retainer assembly.

25. Remove band servo outer snap ring and remove outer piston by applying low pressure compressed air to the rearward centre port.

AT- 100

DISASSEMBLY
Disassembly (Cont'd)
26. Remove band brake servo, piston snap ring and remove piston and return spring.

27. Loosen manual shaft lock nuts and remove manual plate. 28. Pull out retaining pin, then remove manual shaft.

REPAIR FOR COMPONENT PARTS

Oil Pump

p i G q

Oil pump cover

Rotor support ring

Return spring

Oil pump spring retainer

L Seal

ring

h o t o r Vane ring

DISASSEMBLY
1. Remove oil pump cover. Remove differential lubrication tube.

SAT806

2. Remove cam ring spring taking care not to damage converter housing. Remove oil pump components.

AT- 102

REPAIR FOR COMPONENT PARTS

Oil Pump (Cont'd)

RL4F02A

INSPECTION a Inspect oil pump cover, cam ring, rotor and vanes for
damage and visible wear.

a Measure clearance between housing and cam ring, rotor and

vanes in at least four places along their circumstances. The maximum measured value should be within the specified range. a Be sure to remove friction ring and vane ring when measuring clearance. Standard clearance: 0.010 0.024 mm (0.0004 0.0009 in) Wear limit: 0.034 mm (0.0013 in) If the clearance is out of wear limit, replace oil pump as an assembly.

Measuring polnts
SAT900

Clearance

a Measure clearance between new seal ring and ring groove

Standard clearance: 0.10 0.25 mm (0.0039 0.0098 in) Wear limit: 0.25 mm (0.0098 in) If not within wear limit, replace oil pump as an assembly.

SAT659

ASSEMBLY
1. Install cam ring, oil pump spring retainer and cam ring spring. a Pay attention to direction of spring retainer. With screwdriver between cam ring (behind spring) and housing, move cam ring to install cam ring pivot.

SAT808

REPAIR FOR COMPONENT PARTS

Oil Pump (Cont'd)

RL4F02A

otor support ring

2. Assemble rotor, vanes, friction ring, rotor support ring and vane rings. Pay attention to direction of rotor.

SATOOBA

3. Install oil pump cover. Tighten down cover evenly in a criss-cross type pattern.

B : Big diameter
SATOOOA

4. Rotate pump when it has been assembled to ensure that all parts have been correctly assembled. 5. Install seal rings. Refer to figure at left for proper locations of two different types of seal rings. These seal rings can be cut or deformed if they are improperly seated in their grooves when drum is installed. Clean ring grooves carefully and fill with petroleum jelly. Then install rings making sure they fit into the grooves as tightly as possible.

AT- 104

REPAIR FOR COMPONENT PARTS

Control Cylinder

RL4F02A

Inspect control cylinder body, control piston and cylinder plug for scratches or damage. Replace if necessary. Pay attention to direction of lip seal.

After assembling, check the operation.

REPAIR FOR COMPONENT PARTS

Control Valve Body (Cont'd)

RL4F02A

Spring seat

Lock-up control valve

AT- 106

REPAIR FOR COMPONENT PARTS

Control Valve Body (Cont'd)
Table of control valve springs
Valve spring

piz5i.q
Free length mm (in) 35.5 (1.398)

@ Throttle valve @ Pressure modifier valve

@ Pressure regulator valve

25.5 (1.0039)
43.0 (1.693)

@ 1st-2nd shift valve

@ 3rd-2nd downshift valve @ 2nd-3rd shift valve @ 3rd-4th shift valve @ 3rd-4th shift plug

48.0 (1.890) 42.0 (1.654) 40.9 (1.610) 60.5 (2.382) 44.5 (1.752) 29.7 (1.169) 23.0 (0.906)

4th-3rd timing valve

@ 3rd-2nd timing valve @ 2nd-4th timing valve

34.2 (1.346)
20.6 (0.811) 28.1 (1.106) 27.0 (1.063) 29.7 (1.169) 36.0 (1.417) 29.7 (1.169) 32.8 (1.291) 22.6 (0.890) 41.8 (1.646)

@ 4th-2nd timing valve

@ ls t reducing valve
@ Torque converter regulator valve
@$ Low clutch timing valve

@ Lock-up control valve

(@ Lock-up timing valve

@ 2nd-3rd throttle modulator valve @ 4th speed cut valve @ Lock-up accumulator

AT- 107

REPAIR FOR COMPONENT PARTS

Control Valve Body (Cont'd)
DISASSEMBLY

RL4F02A

1. Set control valve assembly upside down. Remove lock-up body, then control valve lower body. During valve body separation, do not lose the steel balls on valve body. Number of steel balls: Upper body - 12 Lower body - 1

2. To remove parallel pin, push it out with a thin wire.

INSPECTION
Check valves for burning. Replace if necessary. Check separator plate for scratches or damage. Replace if necessary. Scratches or score marks can cause oil to by-pass correct oil passages and result in system malfunction. Check oil passages in upper and lower valve bodies for varnish deposits, scratches or other damage that would impair valve movement. Check threaded holes and related bolts and screws for stripped threads; replace as needed. Check valve springs for damage. Measure their free length. If the free length is out of specification, replace valve springs.

REPAIR FOR COMPONENT PARTS

Control Valve Body (Cont'd)
ASSEMBLY

1. Reinstall steel balls in valve body. Caution: Ball shown in section A-A is smaller than the other balls.

Section A-A

2. Assemble separator plate and lower valve body on upper valve body and lock-up body. m Dip gasket in A.T.F. before installation. m Pay attention to the position of gaskets.

AT- 109

REPAIR FOR COMPONENT PARTS

RL4F02A

8 Use two reamer bolts as a guide while assembling upper

and lower bodies.

8 Pay attention to the position of harness clamps when

installing control valve bolts.

3. Install lock-up solenoid and O.D. cancel solenoid.

REPAIR FOR COMPONENT PARTS

High Clutch
For the number of clutch sheets (drive plate and driven plate), refer t o the below cross-section.

p G 6 q

Snap ring Retaining plate High clutch piston High clutch drum

SAT362A

DISASSEMBLY
1. Compress clutch springs using E7 179 spring compressor and remove snap ring from spring retainer.

2. Place clutch drum onto oil pump, and remove clutch piston with compressed air.

v
Thickness

REPAIR FOR COMPONENT PARTS

High Clutch (Cont'd)
INSPECTION
Fac~ng

Core plate

Check clutch drive plate facing for weak or damage. Standard drive plate thickness: 2.0 mm (0.079 in) Wear limit: 1.8 mm (0.071 in) If not within wear limit, replace. Check for wear on snap ring, weak or broken coil springs, and warped spring retainer.

SAT845A

ASSEMBLY
1. Lubricate clutch drum bushing, and install inner seal and piston seal. Be careful not to stretch seals during installation. Never assemble clutch dry; always lubricate its components thoroughly. Pay attention to direction of piston seal.

SAT819

2. Assemble piston, being careful not to allow seal to kink or become damaged during .installation. After installing, turn piston by hand to ensure that there is no binding.

3. Install clutch springs using E7 179 spring compressor. 4. Reinstall snap ring. Be sure snap ring is properly seated.

5. Install driven plates, drive plates, and secure with snap ring.

REPAIR FOR COMPONENT PARTS

High Clutch (Cont'd)
Snap ring Retainer plate

[ X i E q

7
Clearance
SAT396A

6. Measure clearance between retaining plate and snap ring. Always measure the existing minimum clearance, since snap ring is a wave type. Specified clearance between retaining plate and snap ring: Standard 1.8 2.2 mm (0.071 0.087 in) Allowable limit 2.8 mm (0.110 in) Available retaining plate: Refer to S.D.S.

7. Check high clutch operation using compressed air

Low Clutch
For the number of clutch sheets (drive plate and driven plate), refer to the below cross-section. Low clutch piston Low clutch hub

Low dished plate

Low dished plate

SAT7026

REPAIR FOR COMPONENT PARTS

RL4F02A

a Service procedures for low clutch are essentially the same

as those for high clutch, with the following exception. Specified clearance between retaining plate and snap ring: Standard 0.5 0.8 mm (0.020 0.031 in) Allowable limit 1.6 mm (0.063 in) Available retaining plate: Refer to S.D.S.

a After assembly, check operation of clutch.

REPAIR FOR COMPONENT PARTS

Reverse Clutch
F o r t h e number o f clutch sheets (drive plate and driven plate), refer t o t h e below cross-section. Snap ring

pLG6q

Retaining plate7 Drive plate Driven plate

Lathe c u t seal ring Reverse clutch piston Reverse clutch d r u m

\; :.
G
A !

Reverse dished plate

m, n o
li- Spring

L Snap ring
Spring retainer

L Retaining plate *
Driven plate

* : Select w i t h proper thickness.

SAT6598

Service procedures for reverse clutch are essentially the same as those for high clutch, with the following exception. Remove reverse clutch piston.

Specified clearance between retaining plate and snap ring: Standard 0.5 0.8 mm (0.020 0.031 in) Allowable limit 1.2 mm (0.047 in) Available retaining plate: Refer to S.D.S.

REPAIR FOR COMPONENT PARTS

Reverse Clutch (Cont'd)
After
assembly,

piziq
clutch.

check operation of

Low & Reverse Brake

For the number of clutch sheets (drive plate and driven plate), refer t o the below cross-section. Low & reverse clutch piston

* : Select with proper thickness.

Retaining plate

*
SAT706B

REPAIR FOR COMPONENT PARTS

Low & Reverse Brake (Cont'd)
Th~ckness

INSPECTION
Fac~ng

Core plate

SAT845A

Examine low and reverse brake for damaged clutch drive plate facing and worn snap ring. Check drive plate facing for wear or damage; if necessary, replace. Drive plate thickness: Standard 2.0 mm (0.079 in) Allowable limit 1.8 mm (0.071 in) Specified clearance between retaining plate and snap ring: Standard 2.2 2.6 mm (0.087 0.102 in) Allowable limit 3.6 mm (0.142 in)

REPAIR FOR COMPONENT PARTS

Brake Band and Band Servo

[pizkq

Accumulator spring retainer

3.8 - 5.1 N.m (0.39 0.52 kg-m, 2.8 - 3.8 ft-lbl

cumulator piston

Servo piston retainer

Servo piston assembly

Servo cushion spring

SAT397A

INSPECTION
Check band friction material for wear. If there are cracks, chips or burn spots, replace band. Check band servo components for wear and scoring.

REPAIR FOR COMPONENT PARTS

Governor

pi6iq

A newly developed governor valve assembly has been used to improve the shift timing. I t is made of pressed steel instead of aluminum. Replace the assembly if damaged because it cannot be disassembled and assembled.

Construction
View A

4
High secondary High boost spring

Low boost spring

Center boost spring

Primary weight Low secondary weight

Low
overnor valve weight primary weight

Governor pressure outlet Line pressure inlet Governor plunger

View A
SAT683A

The governor plunger and the valve are moved upward by the return spring force and the line pressure circuit is shut by the governor valve when driving at low speed. There are two secondary weights, that is a low secondary weight and a high secondary weight, on the top of the assembly and they contact the upper end of the governor valve. Both secondary weights have primary weights. The weights are as follows: High secondary weight < High Low secondary weight primary weight < Low primary weight Each secondary weight is pushed downward by centrifugal force when driving a t a rather high speed, and governor pressure exsists.

REPAIR FOR COMPONENT PARTS

Governor (Cont'd)

lnspection Make sure that the governor valve moves smoothly when pushing it with your finger. Check to see that all springs s i t on their original positions.

Check t o see that distance "+L" i s within the specifications. Distance "L": 34.0 - 34.4 mm (1.339 - 1.354 in)

Planetary Carrier INSPECTION

m Check clearance between pinion washer and planetary
carrier with a feeler gauge. Standard clearance: 0.15 0.70 mm (0.0059 0.0276 in) Allowable limit: 0.80 mm (0.0315 in) m If not within allowable limit, replace. m Check planetary gear sets and bearings for damaged or worn gears.

Bearing Retainer and Output Shaft INSPECTION

m Measure clearance between new seal ring and ring groove.
Standard clearance: 0.10 0.25 mm (0.0039 - 0.0098 in) Wear limit: 0.25 mm (0.0098 in) If not within wear limit, replace.

Converter Housing and Transmission Case

BEARING OUTER RACE
Reduction pinion gear front bearing outer race

a Remove reduction pinion gear front bearing outer race using

E7 128 puller.

a Install reduction pinion gearfront bearing outer race using E7008

installer.

Differential side bearing outer race Note: The remaining differential side bearing components are covered in "Final Drive" and "Assembly".

a Remove differential side bearing outer race using suitable drift.

a Install differential side bearing outer race using E7422 handle

with E70 10 adapter.

OIL SEAL
Torque converter oil seal

REPAIR FOR COMPONENT PARTS

pGGGiq

Converter Housing and Transmission Case (Cont'd)

DHhnntial side oil 8 1 0 . Installseal using E7 188 installer.

BEARING Idler Gear Bearing Removal Use E1673MT puller in conjunction with E 1673C20 plates. lnstallation Use E7008 to install bearing. Output Gear Bearings Removal Use E 1673MT puller in conjunction with E 1673C20 plates. Installation Use suitable tool (e.g. tube) to install.

Reduction Pinion Bearing Removal Use E 1673MT puller in conjunction with E 1673C15 plates. Installation Use E700 1 to install bearing.

REPAIR FOR COMPONENT PARTS

RL4FOZA

SAT841

DISASSEMBLY
1. Remove final gear.

2. Drive out pinion mate shaft lock pin and draw out pinion mate shaft.

REPAIR FOR COMPONENT PARTS

Final Drive (Cont'd)

RL4F02A

3. Remove bearing using E 1673MT puller with E6673 plates and E7422 & E7 177-5 drift and plug.

4. Remove differential side bearing inner cone using E7 158 puller with E7009 leg and plug set.

INSPECTION
Check mating surface of differential case, side gears and pinion mate gears. Replace as required. a Check tapered roller bearings for wear, scratches, pitching or flaking.

ASSEMBLY
1. Install side gear and thrust washer in differential case. 2. Install pinion mate gear and thrust washer in differential case while rotating them. 3. Insert pinion mate shaft. When inserting, be careful not to damage pinion mate washers.

Dial gauge

4. Measure clearance between side gear and differential case with washer following the procedure below: a. Set Tool and dial gauge on side gear.

REPAIR FOR COMPONENT PARTS

Final Drive (Cont'd)

p% i q

b. Move side gear up and down to measure dial deflection. Always measure indicator deflection on both side gears. Clearance between side gear and differential case with washer: 0.1 0.2 m m (0.004 0.008 in) c. If not within specification, adjust clearance by changing thickness of side gear washers. Side gear thrust washer: Refer to S.D.S.

5. Install pinion mate shaft lock pin using a punch. Make sure that lock pin is flush with case.

6. Press on differential side bearing inner cone and outer race. 7. Install final gear.

Oil Pump

Rotor support ring

Oil pump spring retainer

SAT043C

DISASSEMBLY
1. Remove oil pump cover. Remove differential lubrication tube.

2. Remove return spring taking care not to damage converter

housing. Remove oil pump components.

'

j&
"

REPAIR FOR COMPONEN+^PARTS

Oil Pump (Cont'd)
INSPECTION

pziiiq

1. Inspect oil pump cover, cam ring, rotor and vanes for damage and visible wear. 2. Measure clearance between clutch housing and cam ring, rotor and vanes in at least four places along their circumstances. The maximum measured value should be within the specified range. Be sure to remove friction ring and vane ring when measuring clearance. Standard clearance: 0.010 0.024 mm (0.0004 0.0009 in) Wear limit: 0.034 mm (0.0013 in) If the clearance is out of above specification, replace oil pump as an assembly.

Measuring points
SAT900

Clearance

3. Measure clearance between seal ring and ring groove. Standard clearance: ' 0.10 0.25 mm (0.0039 0.0098 in) Wear limit: 0.25 mm (0.0098 in)

SAT659

ASSEMBLY
1. Install cam ring, 0-ring and friction ring.

2. Install return spring and spring retainer.

SAT808

REPAIR FOR COMPONENT PARTS

pi iq

Oil Pump (Cont'd)

3. Assemble rotor, vanes, rotor support ring and vane rings. Pay attention to direction of rotor.

e--

Rotor support ring Punch mark

Vane ring

SAT041C

4. Install oil pump cover. Tighten down cover evenly 'in a criss-cross type pattern.

5. Rotate the pump when it has been assembled to ensure that all parts have been correctly assembled. 6. Install seal rings. Refer to the figure at left for proper locations of the two different types of seal rings.

SATOOOA

These seal rings can be cut or deformed if they are improperly seated in their grooves when the drum is installed. Clean the ring grooves carefully and fill them with petroleum jelly. Then install the rings making sure they fit into the grooves as tightly as possible.

REPAIR FOR COMPONENT PARTS

Control Cylinder
1

Control cylinder

Gasket

0
INSPECTION AND ASSEMBLY

SAT8696

Inspect control cylinder body, control piston and cylinder plug for scratches or damage. Replace if necessary. When assembling, pay attention to the direction of lip seal.

After assembling, check the operation.

REPAIR FOR COMPONENT PARTS Control Valve Assembly

RE4F02A

Lower body

Solenoid separator gasket

Separator plate

Solenoid separator gasket

Lower b o d y 1 Solenoid body

Support plate

Timing solenoid 0-ring

4unit rolelioid assembly (line pressure solenoid, lockup solenoid and shift solenoids A and B)

7-9N-m (0.7 - 0.9 kg-m, 5.1 6.5 ft-lb)

AT- 130

REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont'd)

DISASSEMBLY
1. Remove solenoids. a. Remove timing solenoid. b. Remove 0-ring from solenoid.

RE4F02A

c. Remove shift solenoid A, shift solenoid B, line pressure solenoid and lock-up solenoid. d. Remove 0-rings from solenoids.

2. Remove solenoid body. , a. Place lower body facedown and remove bolts. Be careful not to drop solenoid body.

b. Place upper body face down, and remove solenoid body with separator gaskets and separator plate. c. Remove separator gaskets, separator plate and oil filter from solenoid body.

3. Dissasemble upper and lower bodies. a. Place lower body facedown, and remove bolts, reamer bolts and support plate.

REPAIR FOR COMPONENT PARTS

Control Valve Assembly (Cont'd)

piiq

b. Position upper body downward. Remove lower body with separator plate and separator gasket attached to upper body.

c. Remove oil filter, separator gaskets and separator plate from upper body.

d. Check to see that steel balls are properly positioned in upper body and then remove them from upper body.

REPAIR FOR COMPONENT PARTS

Control Valve Upper Body
3 - 2 timing valve

RE4F02A

This valve is fixed.

Lock-up shuttle valve Pressure modifier accumulator valve

REPAIR FOR COMPONENT PARTS

Control Valve Upper Body (Cont'd)

RE4F02A

Pilot valve

Manual valve

Lock-up shuttle valve

. Lock-up control

valve Pressure modifier accumulator valve Pressure regulator valve

. Feedbeck

accumulator valve

1 2 shift valve

. 1st reducing valve

Torque converter relief valve

2-3
shift valve

3 - 2 timing valve

This clutch timing

REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont'd)

DISASSEMBLY
1. Remove valves at parallel pins. Do not use a magnetic hand.

pz6q

a. Remove parallel pins while pressing their corresponding plugs and sleeves. Remove plug slowly to prevent Internal parts from jumping out.

b. Place mating surface of valve facedown, and remove internal parts.

a If a valve Is hard to remove, place valve body facedown

and lightly tap It with a soft hammer.

a Be careful not to drop or damge valves and sleeves.

2. Remove valves at retainer plates. a. Remove retainer plates while pressing their corresponding plugs, sleeves or springs.

b. Place mating surface of valve facedown, and remove internal parts.

a If a valve Is hard to remove, lightly tap valve body with a

soft hammer.

a Be careful not to drop or damage valves, sleeves, etc.

REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont'd)

L
Q)

INSPECTION Valve springs Measure free length and outer diameter of each valve spring. Also check for damage or deformation. Numbers of each valve spring listed in table below are the same as those in the figure on AT-1 33.
Q
Free length

SAT829A

Inspection standard
lt e m Parts

Unit: m m (in)

@ @ @
@

Pilot valve spring Lock-up shuttle valve spring

Part No.

Q
56.6 (2.228) 28.8 (1.134) 31.4 (1.236) 37.3 (1.4691 37.7 (1.484) 24.9 (0.980) 24.9 (0.980) 24.9 (0.980) 21.7 (0.854) 2 1.7 (0.854) 44.7 (1.760) 48.8 (1.92 1) 33.75 (1.3287) 41.8 (1.646)

D 10.9 (0.429) 9.0 (0.354) 9.8 (0.386) 12.9 (0.508) 7.95 (0.3130) 7.0 (0.276) 7.0 (0.276) 7.0 (0.276) 6.65 (0.2618) 6.65 (0.2618) 7.0 (0.276) 6.8 (0.268) 6.35 (0.2500) 7.0 (0.276)

31742-27x60 31742 -27x65 31742-27x70 31742-27x61 31742-27x62 31762-27x61 31762-27x61 31762-27x61 31736-01X02 3173641x02 31742-27x01 31742-27x67 31742-27x71 31742-27x69

Pressure modifier accumulator valve spring Pressure regulator vlave outer spring Pressure regulator valve inner spring

@
@

1 - 2 shift valve spring 2 - 3 shift valve spring 3 - 4 s h i f t valve spring

L o w clutch timing valve spring

@
@ @

3 - 2 timing valve spring

Torque converter relief valve spring 1st reducing valve spring Feedback accumulator valve spring Lock-up control valve spring

0
@ @ @

Replace valve springs if deformed or fatigued.

Control valves Check sliding surfaces of valves, sleeves and plugs. ASSEMBLY 1. Lubricate the control valve body and all valves with A.T.F. Install control valves by sliding them carefully into their bores. Be careful not to scratch or damage valve body.

REPAIR FOR COMPONENT PARTS

Control Valve Upper Body (Cont'd)

piGEq

Wrap a small screwdriver with vinyl tape and use it to insert the valves into proper position.

- Pressure regulator valve -

Position plug in sleeve and install pressure regulator valve on upper body.

Sleeve
SAT8898

2. Install parallel pins and retainer plates.

SAT8838

While pushing plug, install parallel pin.

Insert retainer plate while pressing their corresponding plugs, sleeves or springs.

REPAIR FOR COMPONENT PARTS Control Valve Assembly

INSPECTION

7 1

Separator plates Check to make sure that separator plate is free of damage and not deformed and oil holes are clean.

Oil filter Check to make sure that filter is not clogged or damaged.

SAT8906

Timing solenoid Measure resistance - Refer to "Electrical Components Inspection".

SAT891 B

Shift solenoid B

4-unit solenoid assembly (Line pressure solenoid, lock-up solenoid and shift solenoids A and B) Check that filter is not clogged or damaged (line pressure solenoid and lock-up solenoid). Measure resistance of each solenoid - Refer to "Electrical Components Inspection".

SAT8928

Fluid temperature sensor Measure resistance - Refer to "Electrical Components Inspection".

B
SAT8938

AT- 138

REPAIR FOR C O M P O N E N T PARTS

Control Valve Assembly (Cont'd)
ASSEMBLY

RE4F02A

1. Assemble upper and lower bodies. a. Place oil circuit of upper body face up. Install steel balls in their proper positions.

b. Install upper body separator gasket, separator plate and lower body separator gasket on upper body.

c. Fit oil filter and install lower body on upper body.

d. Temporarily assemble lower and upper bodies, using reamer bolt as a guide. Be careful not to dislocate or drop steel balls and oil filter.

REPAIR FOR COMPONENT PARTS

Control Valve Assembly (Cont'd)

RE4F02A

2. Install solenoid body on control valve body. a. Fit oil filter and install solenoid body separator gaskets and separator plate on solenoid body.

Oil filter

SAT8968

b. Install solenoid body on control valve body and temporarily tighten bolts.

SAT8976

c. Install accumulator support plate and harness clips in thier proper locations, and tighten all bolts. Bolt @ : (nl: 3.4 4.4 Nom (0.35 0.45 kg-m, 2.5 3.3 ft-lb) Other bolts: (nl: 7 9 Nom (0.7 0.9 kg-m, 5.1 6.5 ft-lb)

3. lnstall solenoids. a. Attach 0-ring and install 4-unit solenoid assembly on solenoid body. (nl: 7 9 N-m (0.7 0.9 kg-m, 5.1 6.5 ft-lb)

b. Attach 0-ring, and install and tighten timing solenoid firmly.

i

AT- 140

REPAIR FOR COMPONENT PARTS

RE4F02A

High Clutch
For the number of clutch sheets (drive plate and driven plate), refer to the below cross-section.

Driven plate (31536 21 XW)

High clutch drum Retaining plate*

DISASSEMBLY 1. Compress clutch springs using E7 179 spring compressor and

remove snap ring from spring retainer.

2. Place clutch drum into oil pump, and remove clutch piston with compressed air.

REPAIR FOR COMPONENT PARTS High Clutch (Cont'd)

Thtckness

INSPECrlON a Check clutch drive plate facing for weak or damage.

Fac~ng

Core plate

Standard drive plate thickness: 1.6 mm (0.063 in) If not within wear limit, replace. a Check for wear on snap ring, weak or broken coil springs, and warped spring retainer.

SAT845A

ASSEMBLY
1. Lubricate clutch drum bushing, and install inner seal and piston seal. Be careful not to stretch seals during installation. Never assemble clutch dry; always lubricate its components thoroughly. Pay attention to direction of piston seal.

SAT819

2. Assemble piston, being careful not to allow seal to kink or become damaged during ' installation. After installing, turn piston by hand to ensure that there is no binding.

3. Install clutch springs using E7 179 spring compressor. 4. Reinstall snap ring. Be sure snap ring is properly seated.

5. Install driven plates, drive plates, and secure with snap ring.

AT- 142

REPAIR FOR COMPONENT PARTS

High Clutch (Cont'd)
6. Measure clearance between retaining plate and snap ring. Always measure the existing minimum clearance, since snap ring is a wave type. Specified clearance: Standard 1.4 1.8 mm (0.055 0.071 in) Allowable limit 2.6 mm (0.102 in)

Retaining plate of high clutch

Thickness mm (in) 3.6 (0.142) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) Part number 31567-21x00 31567-21X01 31567-21X02 31567-21x03 31567-21x04 31567-21X05 31567-21x06

7 . Check high clutch operation using compressed air.

AT- 143

REPAIR FOR COMPONENT PARTS

Low Clutch
For the number of clutch sheets (drive plate and driven plate), refer to the below cross-section. Low clutch hub

I
7

RE4F02A

Lathe cut seal ring Spring retainer Snap ring

.ive plate

-A

Driven plal

L Dished plate
Retaining plate

LSnap ring
Dished plate

-1
Snap ring

Retaining plate*

*:

Select w i t h proper thickness.

SAT212C

Use Tool to remove the clutch spring snap ring.

AT- 144

REPAIR FOR COMPONENT PARTS

Low Clutch (Cont'd)

R E ~ F O ~( A

Service procedures for low clutch are essentially the same as those for high clutch, with the following exception: Specified clearance between retaining plate and snap ring: Standard 0.5 0.8 mm (0.020 0.031 in) Allowable limit 2.0 mm (0.079 in)

Retaining plate of low clutch

Thickness mm (in) Part number

3.2 (0.126) 3.4 (0.134) 3.6 (0.142) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165)

31597-21x10 31597-21x11 31597-21x12 31597-21x13 31597-21x14 31597-21x15

After assembly, check the operation of clutch.

AT- 145

REPAIR FOR COMPONENT PARTS

pEGEiq

Reverse Clutch
For the number of clutch &oats (drive plate and driven plate), rofar to the Mt crorraion.

Dished plate

: Select with proper thickness.

y Driven plate
Snap ring

L Drive plate

Driven plate

'

'-snap

ring

L Reverse clutch drum

SAT91 86

Service procedures for reverse clutch are essentially the same as those for high clutch, with the following exception: a Remove reverse clutch piston.

Specified clearance between retaining plate and snap ring: Standard 0.5 0.8 mm (0.020 0.031 in) Allowable limit 1.2 mm (0.047 in)

AT- 146

REPAIR FOR COMPONENT PARTS

Reverse Clutch (Cont'd)
Retaining plate of reverse clutch
Thickness mm (in) 4.6 (0.181) 4.8 (0.189) 5.6 (0.220)

pzzq
Part number

31537-21x10 31537-21x11 31537-21x12

5.8 (0.228)
6.0 (0.236)

31537-21x13
31537-21x14

After assembly, check the operation of clutch.

Low & Reverse Brake

or the number of clutch sheets (drive plate and driven late), refer t o the below cross-section.

Low 81reverse clutch piston

Lathe cut seal ring

07

L Driven plate
iRetaining plate 131667 2 3 x 0 8 ) Retaining plate* Snap ring

*:

Select with proper thickness.

S A T 2 13 C

AT- 147

REPAIR FOR COMPONENT PARTS

Low & Reverse Brake (Cont'd)
INSPECTION

p z q

Examine low and reverse brake for damaged clutch drive plate facing and worn snap ring. Check drive plate facing for wear or damage; if necessary, replace. Specified clearance between retaining plate and snap ring:

Standard
1.2 1.6 mm (0.047 Allowable limit 3.0 mm (0.118 in)

0.063 in)

Retaining plate of low & reverse brake

Thickness mm (in)
Part number

3.4 (0.134) 3.6 (0.142) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) 5.0 (0.197)

3 1667-23x00 31 167-23x01 31667-23x02 31667-23x03 31667-23x04 31667-23x05 31667-23x06 31 667-23x07 31667-23x08

Part A (Driven plate or

If clearance exceeds specified value after using 5.0 mm (0.197 in) retaining plate (31667-23X08), change part A to 3.4 mm (0.134 in) retaining plate (31667-23x00) and readjust clearance by adding another suitable retaining plate.

SAT039C

AT- 148

REPAIR FOR COMPONENT PARTS

Brake Band and Band Servo
r
Spring retainer

riizGq
I

Accumulator

Snap ring Q

SAT920B

INSPECTION
8 Inspect band friction material for wear. If cracked, chipped

or burnt spots are apparent, replace the band.

8 Check band servo components for wear and scoring.

AT- 149

REPAIR FOR COMPONENT PARTS

Planetary Carrier
INSPECTION

p z q

Check clearance between pinion washer and planetary carrier with a feeler gauge. Standard clearance: Front carrier
0.15

Rear carrier

- 0.70 mm (0.0059 - 0.0276 in) 0.20 - 0.70 mm (0.0079 - 0.0276 in)

Replace if the clearance exceeds 0.80 mm (0.0315 in). Check planetary gear sets and bearings for damaged or worn gears.

Bearing Retainer and Output Shaft

INSPECTION
Measure clearance between seal ring and ring groove. Standard clearance: 0.10 0.25 mm (0.0039 0.0098 in) Wear limit: 0.25 mm (0.0098 in)

Converter Housing and Transmission Case

BEARING OUTER RACE
Reduction pinion gear front bearing outer race Remove and refit as shown. Reduction pinion gear front bearing. Remove using E1673MT puller in conjunction with E 1673C 15 plates. Refit using E7001.

REPAIR FOR COMPONENT PARTS

Converter Housing and Transmission Case (Cont'd)

Differential side bearing outer race

OIL SEAL
Torque converter oil seal

Differential side oil seal

BEARINGS
Idler Gear Bearing Remove using E 1673MT puller with E 1673C20 plates. Refit using E7008 to install bearing. Output Gear Bearing Remove using E 1673MT puller with E 1673C20 plates. Refit using suitable tool (e.g.) tube.

REPAIR FOR COMPONENT PARTS Final Drive

Differential side bearing adjusting shim Differential side bearing 74 - 88 N.m (7.5 - 9.0 kg-m, 54 - 65 ft-lb)

RE4F02A

Differential case

Governor shaft drive gear

Pinion mate thrust washer Pinion mate gear

Pinion mate shaft

SAT841

DISASSEMBLY
1. Remove final gear. Where fitted, remove viscous coupling.

SMT6lO

2. Drive out pinion mate shaft lock pin and draw out pinion mate shaft.

REPAIR FOR COMPONENT PARTS

Final Drive (Cont'd)
I

RE4F02A

3. Remove bearing using E1673MT puller with E6673 plates and E7422 & E7 177-5 drift and plug.

4. Remove differential side bearing inner cone using E7 158 puller with E7009 leg and plug set.

INSPECTION
1. Check mating surface of differential case, side gears and pinion mate gears. Replace as required. Check viscous coupling (where fitted) for cracks, silicone leakage, etc.

2. Check clearance between side gear and differential case with washer following the procedure below. a Set Tool and dial gauge on side gear.

b. Move side gear up and down to measure dial gauge deflection. Always measure gauge deflection on both side gears. Clearance between side gear and differential case with washer: 0.1 0.2 m m (0.004 0.008 in) c. If clearance exceeds the specified value, check for wear and replace necessary parts. 3. Check tapered roller bearings for wear, scratches, pitching or flaking.

REPAIR FOR COMPONENT PARTS

Final Drive (Cont'd)
ASSEMBLY
1. Install the side gear and thrust washer in the differential case. 2. Install the pinion mate gear and thrust washer in the differential case while rotating them.

3. Insert pinion mate shaft. When inserting, be careful not to damage pinion mate washers. 4. Measure clearance between side gear and pinion mate gear, referring to "Inspection". If necessary, adjust. Side gear to pinion mate clearance: 0.1 0.2 mm (0.004 0.008 in) Side gear thrust washer: Refer to S.D.S. 5. Install pinion mate shaft lock pin using a punch. Make sure that lock pin is flush with case.

6. Press on differential side bearing inner cone and outer race. 7. Install final gear.

AT- 154

ASSEMBLY
When installing/assembling needle bearing and bearing race, use the following illustrations as a guide to installation procedures and locations.

SAT860

ASSEMBLY

E l

1. Install differential lubrication tube and differential gutter to converter housing.

2. Install oil strainer.

3. Install detent spring assembly.

4. Pass parking rod into the hole in the manual plate and then install manual plate on manual shaft.

5. Install band brake servo, retainer and return spring and secure with snap ring.

ASSEMBLY

1 &EEA 1

6. lnstall reduction gear. a. Position reduction gear in transmission case so that it meshes with idler gear. b. Press reduction gear into place using a drift, and install idler gear.

7. lnstall bearing retainer assembly. a. lnstall seal rings onto bearing retainer with great care. Clean the grooves and liberally apply petroleum jelly to hold the rings in place. Otherwise, they could be cut or deformed when the low clutch and carrier assembly are installed.

b. lnstall bearing retainer assembly.

8. lnstall parking pawl and parking shaft.

9. lnstall spacer and return spring.

ASSEMBLY

E l

10. Lubricate low and reverse brake piston seal, then install piston by tapping it evenly with Tool.

11. Install low and reverse brake retainer, and secure with snap
ring. 12. Install low and reverse brake driven & drive plates and retaining plate, then secure with snap ring. Use tool E7 179.

13. Install output gear.

14. Temporarily install side cover and gasket.

ASSEMBLY
15. After low and reverse brake has been completely assembled, measure clearance between snap ring and retainer plate. If measurement exceeds specifications, it can be adjusted by replacing retainer plate with one of a different thickness. Low and reverse brake clearance: Standard 1.2 1.6 mm (0.047 0.063 in)

Allowable limit
3 0 mm (0.118 in) .
Retaining plate of low & reverse brake
Thickness m m (in) 2.0 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 (0.079) (0.134) (0.142) (0.150) (0.157) (0.165) (0.173) (0.181) (0.189) (0.197)
Part number

31666-23x00 31667-23x00 31667-23x01 31667-23x02 31667-23x03 31667-23x04 31667-23x05 3 1667-23x06 31667-23x07 31667-23x08

Check low & reverse brake operation using air.

ASSEMBLY
r

16. Assemble front carrier, rear carrier and low clutch. Caution: This must be done prior to installing the carrier set to the transaxle.
Front carrier assembly

Rear carrier assembly

Low clutch assembly

SAT856

17. Install carrier set.

18. lnstall one-way clutch assembly while rotating front carrier with high clutch hub.

19. Remove high clutch hub, and install clutch snap ring.

ASSEMBLY
20. Assemble reverse clutch and high clutch.
Reverse clutch

High clutch assembly

High clutch hub assembly

Sun gear assembly

SAT860

21. lnstsll reverse and high clutph as a pack.

22. Install brake band and anchor pin. Temporarily tighten anchor bolt by hand.

23. Adjust total end play and clutch pack end play as follows:
Transmission

ASSEMBLY
Total end play a. Place removed bearing race onto high clutch drum. b. Measure dimension A from transmission case surface to installed bearing race.

H~gh clutch and reverse clutch assembly

brigrp+
SAT864

c. Install needle bearing on top of oil pump cover.

d. Set tools on converter housing and place a straightedge on tools. e. Measure dimension B from straightedge to installed needle bearing. Total end play =A B 99.6 mm (3.921 in) Specified total end play: 0.25 - 0.55 mm (0.0098 0.0217 in) Total end play can be adjusted with oil pump bearing races. Available oil pump bearing races: Refer to S.D.S.

+ -

P I
I
Thrust washer

H~gh clutch and reverse clutch assembly

Clutch pack end play a. Measure dimension C from transmission case surface to reverse clutch drum. b. Install the removed thrust washer on oil pump cover.

SAT866 -

Stratghtedge

~ 7 1 9 2T ,
\
I
7

c. Set up Tool in a manner similar to measuring total end play, and measure dimension D between staightedge and thrust washer. Clutch pack end play = C D 99.6 mm (3.921 in) Specified clutch pack end play: 0.4 0.8 mm (0.016 0.031 in) Clutch pack end play can be adjusted with clutch pack thrust washers. Available clutch pack thrust washers: Refer to S.D.S.

+ -

ASSEMBLY

20. Adjust differential side bearing preload as follows:

a. Remove left side bearing inner cone from transmission case.

b. Measure dimension E from transmission case surface to the mating surface of bearing.

Transrniss~oncase

SAT870

ASSEMBLY

E l

,,

Bearing inner cone

c. Put differential case assembly into converter housing, then put side bearing inner cone on differential case.

SAT87 1

92

d. Set tools on converter housing and place a straightedge on tools. e. Measure dimension F from straightedge to top of side bearing inner cone. Clearance G = E F 60 mm (2.36 in) f. Select shim(s) of appropriate thickness, using S.D.S. as a guide.

+ -

g. Install selected shims and left side bearing inner cone.

2 1. Place transmission case onto wooden blocks, and install differential case assembly and input shaft.

SAT874

ASSEMBLY

1 ~EE~A 1

26. Install selected thrust washer and bearing on oil pump cover.

27. Place gasket on transmission case and install converter housing.

Bolt Tightening torque N.m (kg-m, ft-lb) 21 - 23 (2.1 - 2.3, 15 - 17)

Q mm (in)
3 1.5 ( 1.240) 27 (1.06)

0
@
Converter housing

0 0 0 0 63 0 0

19 - 23 (1.9 - 2.3, 14 - 17) 3 1.5 ( 1.240) 43 - 47 (4.4 - 4.8, 32 - 35) 21 - 25 (2.1 - 2.6, 15 - 19) 43 - 47 (4.4 - 4.8, 32 - 35) 39 (1.54) 45 - 47 (4.6 - 4.8,33 35 (1.38) 50 (1.97)

- 35)
35 (1.38)

Always use new bolts at portions 0 , , @ and 0 as they @ are self-sealing bolts. Apply A.T.F. to thread of other bolts by that fix converter housing to transmission case when installing them.

28. Install 0-ring onto input shaft.

ASSEMBLY
29. Adjust output shaft and idler gear bearing preload as follows:
a. Remove output gear and idler gear bearing outer races and shims. (The races will interchange, so be sure to keep each race with its correct bearing.)

b. Measure dimension H and K between mating surface of side cover and fitting surface of bearing.
(Output gear side)

SAT878

c. Put bearing outer races on output gear and idler gear. d. Place Tool on transmission case and place a straightedge on Tool. e. Measure dimension I and L from straightedge to top of bearing outer races. Output gear side: I 60 mm (2.36 in) Clearance J = H Idler gear side: Clearance M = K L 60 mm (2.36 in) f. Select shim(s) of appropriate thickness, using S.D.S. as a guide.

+ + -

*\& F
Drift

SAT880

ASSEMBLY

& RE4F02A

30. Move manual lever until parking pawl engages idler gear. Measure clearance between parking pawl and parking actuator. If clearance is outside specifications, replace parking pawl.
Part number 31 989-21 X00 Identification letter
D

31989-21x01
3 1989-21 X02

E
F

;
Parking p a w l

{0, ;

Example : When parking pawl with identification letter "E" is used: Clearance "L" is larger. -+ Replace with parking pawl with identification letter "D". Clearance "L" is smaller. -+ Replace with parking pawl with identification letter "F".

ldentification letter

SAT914

@ : 31.5 (1.240)

31. Install side cover and gasket. Always use new bolts at portions @ and @ as they are self-sealing bolts. Apply A.T.F. to thread of other bolts by that fix side cover to transmission case when installing them. Bolts @ and @ : 0 : 1 9 23 N-m (1.9 2.3 kg-m, 14 - 17 ft-lb) Bolts @ and @ : 0:21 - 23 N-m (2.1 2.3 kg-m, 15 17 ft-lb)

U n i t : mm ( i n )

SAT925B

32. Insert Tool into final drive portion to see if internal parts rotates smoothly. Rotating in direction "B" is slightly harder than in direction "A". If abnormalities are noted, proceed with the following: Disassemble parts to see if they are properly assembled. Readjust bearing preloads of final drive, output shaft and idler gear.

33. Adiust brake band. a. First tighten anchor end pin. Anchor end pin: (C?: 4 6 N.m (0.4 0 . 6 kg-m, 2 . 9 - 4.3 ft-lb) b. Back off anchor end pin "N" turns. Number of returning revolutions for anchor end pin "NW: 5.25 turn c. Tighten lock nut while holding anchor end pinstationary. Lock nut: (C? : 3 1 4 2 N.m (3.2 - 4 . 3 kg-m, 23 - 3 1 ft-lb)

ASSEMBLY
34. Install terminal assembly, paying attention to the direction of its hook.

35. Install accumulator and spring. Note: The accumulator and spring are arranged as shown, for RE4F02A. For the RL4F02A transaxle, the spring is below the accumulator, i.e. reversed from the illustration.
Install throttle shaft and return spring - RL4F02A only.

36. Insert manual valve to control valve body, then assemble them to transmission case.' Bolt @ : (nl: 3.7 - 5.0 Nom (0.38 0.51 kg-m, 2.7 - 3.7 ft-lb) Other bolts: [cl: 7 9 N-m (0.7 - 0.9 kg-m, 5.1 - 6.5 ft-lb)

Set throttle shaft return spring against valve body.

Pay attention to the direction of manual valve groove.

37. Connect harness connectors between terminal assembly and solenoids.

ASSEMBLY
38. Put gasket on transmission case and install valve cover. Always use new bolts as they are self-sealing bolts. lnstall throttle lever (RL4F02A).

39. lnstall control cylinder.

40. lnstall revolution sensor RE4F02A only.

41. lnstall governor shaft.

42. Install speedometer parts.

ASSEMBLY
43. Pour approx. 2 liters (1-314 Imp qt) of A.T.F. into torque converter. 44. Install torque converter to converter housing. Be careful not to scratch front oil seal. 45. Apply sealant to threads of drain plug and install it in place. 46. Install inhibitor switch to transmission case. 47. Adjust inhibitor switch. Refer to On-vehicle Service. 48. Make sure that manual lever operates smoothly.

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
Engine model Automatic transaxle model Transaxle gear ratio lst 2nd 3rd CAZOE RL4F02A

pzq

Stall revolution

rpm

2.300-2.600

3.876: 1
2.785 1.545 1.O 0.694 2.272 4.133 Automatic Transmission Fluid Type DEXRON 6.8

4th
Reverse Final drive Recommendedoil Oil capacity (litres)

Specifications and Adjustment

CLUTCHES AND BRAKES
Number of drive plates Number of drive plates Number of driven plates Thickness of drive plate mm (in) Standard Allowable limit Clearance Standard Allowable limit mm (in) 1.8-2.2 (0.07 1-0.087) 2.8 (0.1 10) Thickness mm (in) 3.6 (0.142) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) Part number 3 1567-21x00 31 567-21x01 3 1567-21X02 31567-21x03 31567-21x04 31567-21x05 3 1567-2 1X06 3 5 Number of driven plates Thickness of drive plate mm (in) Standard Allowable limit 4 5

2.0 (0.079) 1.8 (0.071)

2.0 (0.079) 1.8 (0.07 1)

Clearance Standard Allowable limit

mm (in) 0.5-0.8 (0.020-0.031) 1.6 (0.063)

Thickness mm (in)

Thickness of retaining plate

Part number 31597-21x00 31597-21x01 31597-21x02 31597-21x03 3 1597-2 1X04 3 1597-2 1X05 3 1597-2 1X06

Thickness of retaining plate

4.8 (0.189) 5.0 (0.197) 5.2 (0.205) 5.4 (0.213) 5.6 (0.220) 5.8 (0.238) 6.0 (0.236)

1Number of drive plates Number of driven plates Thickness of drive plate mm (in) Standard Allowable limit Clearance Standard Allowable limit mm (in) 0.5-0.8 (0.020-0.031) 1.2 (0.047)
Thickness mm (in)

2 2

2.0 (0.079) 1.8 (0.07 1)

Thickness of retaining plate

Part number 31537-21x00 31537-21x01 31537-21x02 31537-21x03 31537-21x04 31537-21x13 31537-21x14 31537-21x15

4.6 (0.181) 4.8 (0.189) 5.0 (0.197) 5.2(0.205) 5.4(0.213) 5.6(0.220) 5.8 (0.228) 6.0 (0.236)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Specifications and Adjustment (Cont'd)
TOTAL END PLAY
Number of drive plates Number of driven plates Thickness of drive plate mm (in) Standard Allowable limit Clearance Standard , Allowable limit mm (in) 1.2-1.6 (0.047-0.063) 3.6 (0.142)
Thickness mm (in)

pizzq

5 5

Total end play Thickness of oil pump housing bearing race

0.25-0.55 mm (0.0098-0.0217 in) Thickness mm (in) 0.8 (0.031) 1.O (0.039) 1.2 (0.047) 1.4 (0.055) l.6 (0.063) 1.8 (0.071) 2.0 (0.079) Part number 31429-21x00 3 1429-2 1X01 3 1429-2 1X02 31429-21x03 3 1429-2 1X04 31429-2 1x05 3 1429-2 1X06

2.0 (0.079) 1.8 (0.07 1)

Thickness of retaining plate

Pan number 3 1667-23x13 31667-23x14 31667-23x15 31667-23x16 3 1667-23x7 1 3 1667-23x72 31667-23x73 31667-23x74 31667-23x75

12.4 (0.488) 12.6 (0.496) 12.8 (0.504) 13.0 (0.512) 13.2 (0.520) 13.4 (0.528) 13.6 (0.535) 13.8 (0.543) 14.0 (0.551)

CLUTCH PACK END PLAY

Clutch pack end play Thickness of clutch pack thrust washer 0.4-0.8 mm (0.016-0.031 mm) Thickness mm (in) 0.7 (0.028) 0.9 (0.035) 1.1 (0.043) 1.3 (0.051) 1.5 (0.059) 1.7 (0.067) 1.9 (0.075) Pan number 31528-21X00 31 528-21 X01 31 528-21x02 31528-21x03 3 1528-2 1X04 3 1528-2 1X05 3 1528-2 1X06

Isn*.b.nd]
Piston size Big dia. Small dia. mm (in) 65 (2.56) 36 (1.42)

PLANETARY CARRIER
Unit: mm (in)

DIFFERENTIAL SIDE BEARING PRELOAD Differential side bearing adjusting shim

I

Thickness mm (in) washer and planetary carrier Standard Allowable limit 0.12 (0.0047) 0.16 (0.0063) 0.20 (0.0079) 0.24 (0.0094) 0.28 (0.01 10) 0.32 (0.0126) 0.36 (0.0142) 0.40 (0.0157) 0.44 (0.0173) 0.48 (0.0189) 0.52 (0.0205) 0.56 (0.0220) 0.60 (0.0236) 0.64 (0.0252) 0.68 (0.0268) 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.0315) 0.84 (0.0331) 0.88 (0.0346) 0.92 (0.0362)

Pan number

0.20-0.70 (0.0079-0.0276) 0.80 (0.03 15)

OIL PUMP, BEARING RETAINER AND OUTPUT SHAFT

Unit: mm (in) Oil pump clearance Cam ring - oil pump cover Standard Allowable limit Rotor -oil pump cover Standard Allowable limit Vane -oil pump cover Standard Allowable limit Seal ring clearance Standard Allowable limit

0.0 10-0.024 (0.0004-0.0009) 0.034 (0.0013)

0.010-0.024 (0.0004-0.0009) 0.034 (0.00 13)

0.010-0.024 (0.0004-0.0009) 0.034 (0.0013)

0.10-0.25 (0.0039-0.0098) 0.25 (0.0098)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Specifications and Adjustment (Cont'd)
OUTPUT SHAFT PRELOAD Output Shaft preload adiustina shim
Thickness mm (in) Part number 3 1499-2 1X00 31499-21x01 3 1499-2 1X02 3 1499-2 1X03 3 1499-2 1X04 3 1499-2 1X05 3 1499-2l X06 3 1499-2 1X07 3 1499-2 1X08 3 1499-2 1X09 31499-21x10 31499-21x11 31499-21x12 31499-21x13 31499-21x14 31499-21x15 31499-21x16 31499-21x17 31499-21x18 31499-21x19 3 1499-2 1X20 3 1499-2 1X2 1 3 1499-2 1X22

piiziq

DIFFERENTIAL SIDE GEAR THRUST WASHER

Allowable clearance between side gear and differential case with washer Thickness mm (in)

0.1-0.2 mm (0.004-0.008 in)

Part number
38424-E3020 38424-E302 1 38424-E3022 38424-E3023

0.75-0.80 (0.0295-0.03 15) 0.80-0.85 (0.03 15-0.0335) 0.85-0.90 (0.0335-0.0354) 0.90-0.95 (0.0354-0.0374)

PARKING PAWL
Clearance 'L" Identification letter D E F

0.27-0.61 mm (0.0 106-0.0240 in)

Part number

3 1989-2 1X00 31989-21x01 3 1989-2 1X02

IDLER GEAR PRELOAD Idler gear preload adjusting shim

Thickness mm (in) Part number

0.36 (0.0142) 0.40 (0.0157) 0.44 (0.0173) 0.48 (0.0189) 0.52 (0.0205) 0.56 (0.0220) 0.60 (0.0236) 0.64 (0.0252) 0.68 (0.0268) 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.0315) 0.84 (0.0331) 0.88 (0.0346) 0.92 (0.0362) 1.44 (0.0567) 1.96 (0.0772)

3 1499-21X06 3 1499-2 1X07 3 1499-2 1X08 3 1499-2 1X09 31499-21x10 31499-21x11 31499-21x12 3 1499-2 1X 13 31499-21x14 31499-21x15 31499-21x16 31499-21x17 31499-21x18 31499-21x19 3 1499-2 1X20 31499-21x21 3 1499-2 1X22

h d e n t i f i c a t i o n letter
SAT914

REMOVAL AND INSTALLATION

Throttle wire Stroke 'L" Number of returning revolution for lock nut Lock nut tightening torque Distance between end of clutch housing and torque convener Drive plate runout limit

39-43 mm (1.54-1.69 in) 2.75-3.25 8-10 N-m (0.8-1.0 kg-m, 5.8-7.2 h-lb) 19.0 mm (0.748 in) or more 0.5 mm (0.020 in)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
Engine Automatic transaxle model Automatic transaxle assembly Model code number Transaxle gear ratio lst 2nd 3rd 4th Reverse Finaldrive Recommended oil Oil capacity (Imp qt) KA24E Stall revolution rpm

piizGq

2,200-2,500

RE4F02A (V)
27x61

2.785 1.545 1.O 0.694 2.272 3.876 Automatic Transmission Fluid Type DEXRON 'M 7.4 (6-112)

Specifications and Adjustment

CLUTCHES AND BRAKES
Number of drive plates Number of drive plates Number of driven plates Clearance Standard Allowable limit Drive plate thickness Standard Allowable limit mm (in) 1.4-1.8 (0.055-0.071) 2.6 (0.102) mm (in) 1.6 (0.039) 1.4 (0.055) Thickness mm (in) 3.6(0.142) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) 5.0 (0.197) Part number 31537-41x61 31537-41x62 31537-41x63 31537-41x64 31537-41x65 31537-41x66 3 1537-41X67 31537-41x68 4 4
I

Number of driven plates Clearance Standard Allowable limit Drive plate thickness Standard Allowable limit mm (in)

0.5-0.8 (0.020-0.031) 2.0 (0.079) mm (in) 2.0 (0.079) 1.8 (0.07 1)

I

Thickness of retaining plate

Thickness mm (in)

Pan number

Thickness of retaining plate

I Reverse clutch 1
Number of drive plates Number of driven plates
I

I
mm (in)

2 2

Clearance Standard Allowable limit Drive plate thickness Standard Allowable limit

0.5-0.8 (0.020-0.03 1) 1.2 (0.047) mm (in) 2.0 (0.079) 1.8 (0.071)

I

Thickness of retaining plate

Thickness mm (in)

Pan number

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Specifications and Adjustment (Cont'd)
CLUTCH PACK END PLAY

RE4F02A

0.4-0.8 mm (0.016-0.031 in) Number of drive plates Number of driven plates Clearance Standard Allowable limit Drive plate thickness mm (in) Standard Allowable limit Thickness of retaining plate 2.0 (0.079) 1.8 (0.071) Thickness mm (in) 3.4 (0.134) 3.6 (0.142) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) 5.0 (0.197) Part number 31667-23x00 3 1667-23x01 31667-23x02 3 1667-23x03 3 1667-23x04 3 1667-23x05 3 1667-23x06 3 1667-23x07 3 1667-23x08 mm (in) 1.2-1.6 (0.047-0.063) 3.0 (0.1 18) Thickness mm (in) 0.7 (0.028) 0.9 (0.035) 1.1 (0.043) 1.3 (0.051) 1.5 (0.059) 1.7 (0.067) 1.9 (0.075) Part number 3 1528-2 1X00 31528-21x01 3 1528-2 1X02 3 1528-2 1X03 3 1528-2 1X04 3 1528-2 1X05 3 1528-2 1X06 6 6

CLUTCH PACK THRUST WASHER

TOTAL END PLAY

0.25-0.55 mm (0.0098-0.0217 in)

I Brake band I
Brake band piston size mm (in) Big dia. Small dia. 75 (2.95) 36 (1.38)

OIL PUMP HOUSING BEARING RACE (For total end play)

Thickness mm (in) 0.8 (0.03 1) 1. (0.039) O 1.2 (0.047) 1.4 (0.055) 1.6 (0.063) 1.8 (0.07 1) 2.0 (0.079) Pan number 3 1429-2 1X00 31429-21x01 3 1429-2 1X02 3 1429-2 1X03 3 1429-2 1X04 3 1429-2 1X05 3 1429-2 1X06

PLANETARY CARRIER AND OIL PUMP

F ]
Clearance between pinion washer and planetary carrier Front carrier Standard Allowable limit Rear carrier Standard Allowable limit

mm (in)

0.15-0.70 (0.0059-0.0276) 0.80 (0.0315)

0.20-0.70 (0.0079-0.0276) 0.80 (0.0315)

E l
Oil pump clearance mm (in) Cam ring - oil pump cover Standard Allowable limit Rotor - oil pump cover Standard Allowable limit Vane - oil pump cover Standard Allowable limit Seal ring clearance mm (in) Standard Allowable limit 0.0 10-0.024 (0.0004-0.0009) 0.034 (0.0013)

0.017-0.031 (0.0007-0.0012) 0.034 (0.0013)

0.017-0.03 1 (0.0007-0.0012) 0.034 (0.0013)

0.10-0.25 (0.0039-0.0098) 0.25 (0.0098)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Specifications and Adjustment (Cont'd)
Output Shaft preload adjusting shim

pGG5iq

CLEARANCE BETWEEN SIDE GEAR AND DIFFERENTIALCASE WITH WASHER

0.1-0.2 mm (0.004-0.008 in)

0.16 (0.0063) 0.20 (0.0079)

3 1499-2 1X0 1 3 1499-2 1X02

SlDE GEAR THRUST WASHER

PARKING PAWL Clearance "L":

0.25-0.50 mm (0.0098-0.0197 in)

Idler gear preload adjusting shim

I

Thickness mm (in)

Pan number

hdentification letter
SAT914

Identificationletter

Pan number 3 1989-2 1X00 31989-21x01 3 1989-2 1X02

ELECTRICAL COMPONENTS

FRONT AXLE & FRONT SUSPENSION

i

SECTION

FA
FA- 2 FA- 3 FA- 4 FA- 9 FA- 10 FA- 15 FA-23 FA-24 FA-26 FA-27 FA-28 FA-30

CONTENTS
PRECAUTIONS AND PREPARATION FRONT AXLE AND FRONT SUSPENSION CHECK AND ADJUSTMENT FRONT AXLE FRONT AXLE - Wheel Hub and Knuckle FRONT AXLE - Drive Shaft FRONT SUSPENSION FRONT SUSPENSION - Coil Spring and Strut Assembly FRONT SUSPENSION - Stabilizer Bar FRONT SUSPENSION - Transverse Link and Transverse Link Gusset FRONT SUSPENSION - Lower Ball Joint SERVICE DATA AND SPECIFICATIONS (S.D.S.)

PRECAUTIONS AND PREPARATION Precautions

When installing each rubber part, final tightening must be carried out under un1ade.n condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. When removing each suspension part, check wheel alignment and adjust if necessary. Always tension brake pipes and fittings t o specified torques (refer S.D.S.). Where fitted, self-locking (nyloc) nuts must not be re-used, they must be renewed.

Preparation
SPECIAL SERVICE TOOLS
Tool sup~lier: Litchfield
I

Tool number Tool name

Description

E2237 Ball joint remover

Removing tie-rod outer end and lower ball joint

E2M 1OF Spring compressor

Removing and installing coil spring

J34296 (Left Hand) J34297 (Right Hand) Differential side oil seal protector

Installing drive shaft

Press plates -wheel

bearing removal

E7422 (use with E7 177-5) E7 177-5 (use with E7422)

Handle -wheel bearing removal/installation. Drift adapter -wheel bearing removal/installation.

Press tool -wheel bearing removal/installation. E7 177-8 Wheel bearing removal/installation tools Press tool wheel bearing removal/installation.

0 D

FRONT AXLE AND FRONT SUSPENSION

Wheel bearing Refer to FRONT A X L E -Wheel Hub and Knuckle. Axial end play: 0.05 mm (0.0020 in) or less Wheel alignment Caster and kingpin inclination cannot be adjusted. The vehicle requires camber and toein adjustments. Toe-in : 1 - 3 mm (0.04 - 0.12 in) (Total toe-in) : 6' - 18'

Strut mounting insulator assembly 7

Front

(2.6 - 3.6, 18 - 26) Support bearing

(4.2 - 5.2, 30 - 38)

(1.3 - 1.9, 9 - 14

(1.6 - 2.2, 12 - 16)

118 - 147 (12 - 15-87 - 108)

When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

(C1 :

N.m (kg-m, ft-lb)

sFA481A

CHECK AND ADJUSTMENT

Front Axle and Front Suspension Parts
Check front axle and front suspension parts for looseness, cracks, wear or other damage. (1) Shake each front wheel.

(2) Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to FA-23 (3) Check front axle and front suspension parts for wear, cracks or other damage.

Check strut (shock absorber) for oil leakage or other damage.

Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage.

CHECK AND ADJUSTMENT Front Wheel Bearing

Check that wheel bearings operate smoothly. Check axial end play. Axial end play: 0.05 mm (0.0020 in) or less If axial end play is not within specification or wheel bearing does not turn smoothly, replace wheel bearing assembly. Refer to FRONT AXLE - Wheel Hub and Knuckle.

Front Wheel Alignment

Before checking front wheel alignment, be sure to make a preliminary inspection (Unladen). "Unladen" Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

PRELIMINARY INSPECTION
1. Check tires for wear and improper inflation 2. Check wheel runout.

1
3. 4. 5. 6.

Alloy

0.5mm

0.3mm

Check front wheel bearings for looseness. Check front suspension for looseness. Check steering linkage for looseness. Check that front shock absorbers work properly by using the standard bounce test. 7. Check vehicle posture (Unladen).

CAMBER, CASTER AND KINGPIN INCLINATION

Caster and kingpin inclination are preset at factory and cannot be adjusted. Measure camber, caster and kingpin inclination of both right and left wheels with a suitable alignment gauge and adjust camber in accordance w i t h the following procedure.

Kingpin inclination (Unladen): 13'25' - 15'05'

CHECK AND ADJUSTMENT Front Wheel Alignment (Cont'd)

Caster (Unladen): 1'20' 0'45'

SFAlO3A

Camber (Unladen):

-0'10' k 0'30'

If camber is not within specification, adjust by turning the adjusting pin. (1) Remove the adjusting pin. Adjusting pin is factory-installed with the flat portion facing down.

SFA5llA

Front strut Flat portion

(2) Install adjusting pin with the flat portion facing up. (3) Turn the adjusting pin to adjust. Camber changes about 15' with each graduation of the adjusting pin. (4) Tighten to the specified torque.

Adjusting pin

\
SFA513A

TOE-IN
1. Draw a baseline across the tread. After lowering front of vehicle, move it up and down to eliminate friction, and set steering wheel in straight-ahead position.

FA- 6

CHECK AND ADJUSTMENT Front Wheel Alignment (Cont'd)

2. Measure toe-in. Measure distance "A" and "B" at the same height as hub center. Toe-in (Unladen):
A -B
mm (in)

1 - 3 (0.04 - 0.12)

26

degree

6' - 18'

3. Adjust toe-in by varying the length of steering tie-rods. (1) Loosen lock nuts. (2) Adjust toe-in by turning tie-rod tubes forwards or backwards.

Length "L" should be approximately equal L/H to R/H sides. Maximum variance: 2 m m (3) Tighten lock nuts, then torque them. Refer to ST section.

FRONT WHEEL TURNING ANGLE

1. Set wheels in straight-ahead position and then move vehicle forward until front wheels rest on turning radius gauge properly.

2. Rotate steering wheel all the way right and left; measure turning angle.
Wheel turning angle Inside wheel Full turns Outside wheel Inside wheel Toe-out turn (at 20') Outside wheel 20" Values

34"-38"

27"-3 1'
22'20'

FA- 7

CHECK AND ADJUSTMENT Front Wheel Alignment (Cont'd)

3. Adjust by stopper bolt if necessary.
Standard length "L": 31.3 mm

Drive Shaft
Check for grease leakage or other damage.

FRONT AXLE

7 Drive shaft

Front

eel bearing lock nut 235 - 314 (24 - 32,174

- 231)

Wheel nut (al 9 8 - 1 1 8 ( 1 0 - 12.72-87)

Adjusting cap Cotter p i n

CAUTION: When replacing wheel bearing, replace inner and outer wheel bearings at the same time t o prevent m i x use of bearings of different brands. install inner race of wheel bearing at the seme position as they were installed before disassembly.

(al :

N.m (kg-m, ft-lb)

FRONT AXLE - Wheel Hub and Knuckle Removal

Remove wheel bearing lock nut while depressing brake pedal.

Remove brake caliper assembly. Brake hose need not be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted.

Separate tie-rod from knuckle with Tool. Install stud nut conversely on'stud bolt to prevent damage to stud bolt.

Loosen drive shaft from knuckle.

Remove bolts and nuts as shown at left. Make a matching mark before removing adjusting pin. Draw knuckle assembly from drive shaft. Support drive shaft assembly to prevent damage to rubber boot.

FA- 10

FRONT AXLE - Wheel Hub and Knuckle Installation

Install knuckle with wheel hub. When installing camber adjusting bolt, use the marks made during removal. Tighten wheel bearing lock nut. [nl: 235 314 Nom (24 32 kg-m, 174 - 231 ft-lb)

Disassembly
CAUTION: When removing wheel hub or wheel bearing from knuckle, replace wheel bearing assembly (outer race, inner race and grease seals) with new parts.

WHEEL HUB

m Driveout hub with inner raceAfrom knucklewith toolasshown. m Refer to FRONT AXLE.
WHEEL BEARING
When replacing wheel be&ing, replace wheel bearing assembly (inner and outer races). Using suitable puller and half plates E6673 remove bearing inner race (outside), then remove outer grease seal.

m Remove inner grease seal from knuckle.

Remove inner and outer snap rings.

FRONT AXLE -Wheel Hub and Knuckle

Disassembly (Cont'd)
Press out bearing outer race using tools as shown.

Inspection
WHEEL HUB AND KNUCKLE
Check wheel hub and knuckle for cracks. Check snap ring for wear or cracks. Replace if necessary.

WHEEL BEARING & GREASE SEAL

Removal of wheel bearing and grease seal necessitates replacement with new parts.

Assembly
1. Install snap ring into groove of knuckle. 2. Press bearing outer race into knuckle until it contacts the sharp ring using tool as shown.

3. Pack each bearing cone with wheel bearing grease.

FRONT AXLE

- Wheel

Hub and Knuckle

Assembly (Cont'd)
4. Pack grease seal lip with multi-purpose grease.

5. Install snap ring into groove of knuckle. 6. Install bearing inner race 'A' and then install outer grease seal.

7. Invert knuckle and insert inngr race 'B' in preparation for next step. 8. Place hub into press with knuckle and bearing sitting above it. Method A (In cases where drive shaft is not removed 9. from transaxle) Spin knuckle several turns in both directions and then measure bearing preload.
J

P kN
(tonne, US ton, Imp ton)

Rotation running torque N.m (kgcm, in-lb) 0.3 - 2.5 (3 - 26, 2.6 - 22.6) 0.3 - 2.4 (3 - 24, 2.6 - 20.8)

As measured a t knuckle as shown a t left N (kg, Ib) 2.0 - 17.7 (0.2 - 1.8, 0.4 - 4.0) 2.0 - 15.7 (0.2 - 1.6, 0.4 - 3.5)

Standard

49 (5,5.5,4.9)

34.3 (3.5,3.9,3.44)

*: If a load of approximately 49 kN (5 tonne, 5.5 US ton, 4.9 Imp ton) cannot

be applied.

If bearing preload does not meet the speclficatlon, replace wheel bearing assembly.

FRONT AXLE - Wheel Hub and Knuckle Assembly (Cont'd)

Method B (In cases where drive shaft is removed from transaxle) (1) Draw out drive shaft from transaxle. Refer to FRONT AXLE - Drive Shaft. (2) Put drive shaft into hub and tighten wheel bearing lock nut. (nl: 235 314 N-m (24 - 32 kg-m, 174 231 ft-lb) Note torque just tightened in this procedure.

(3) Spin wheel hub several turns in both direction, and then measure bearing preload. Rotation running torque: 0.3 2.5 Nom (3 26 kg-cm, 2.6 22.6 in-lb) As measured at wheel bolt: 5.10 44.62 N (0.52 4.55 kg, 1.15 10.03 Ib) If bearing preload does not meet the specification, replace wheel bearing assembly. When tightening wheel bearing lock nut on-vehicle, tighten by the tightening torque which was noted in step (2). (4) Remove wheel bearing lock nut, and then draw out drive shaft from hub.

10. Install inner grease seal into knuckle.

FRONT AXLE - Drive Shaft

Removal
Remove wheel bearing lock nut while depressing brake pedal. Remove brake caliper assemblv and rotor. Brake hose need not be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted and support caliper.

Remove tie-rod ball joint. Separate drive shaft from knuckle by slightly tapping it. When removing drive shaft, cover boots with waste cloth to prevent damage to them. Refer to FRONT AXLE - Wheel Hub and Knuckle. For A/T models, remove left drive shaft after removing right drive shaft. Caution When removing drive shaft from transaxle, take care not t o damage transaxle side seals.

1. Remove right drive shaft f r ~ m transaxle. Remove bolts holding support bearing t o support bearing bracket. Carefully lever drive shaft to remove it from transaxle using suitable pry bar.

2. Remove left drive shaft from transaxle. Carefully lever drive shaft to remove it from transaxle using suitable pry bar.

FRONT AXLE - Drive Shaft

Installation
TRANSAXLE SlDE
1. Set Tool along the inner circumference of oil seal (transaxle side). 2. Using petroleum jelly, centralise the drive shaft retaining snap ring on driveshaft spline (L/H shaft only).

3. Insert drive shaft into transaxle. Be sure to properly align the serrations and then withdraw Tool. 4. L/Hshaft Push drive shaft, then press-fit circular clip on the drive shaft into circular clip groove of side gear. m After its insertion, try to pull the flange out of the slide joint by hand. If it pulls out, the circular clip is not properly meshed with the side gear. R/H shaft Refit drive shaft support bearing bolts and tension. Refit FA-3 for correct torque.

WHEEL SlDE m Install knuckle to strut assembly.

m Tighten wheel bearing lock nut. Adjust bearing preload. Refer to Method B in FRONT AXLE Wheel Hub and Knuckle.

FRONT AXLE - Drive Shaft

Components
Circular clip: Make sure circular clip is properly meshed with side gear (transaxle side) and joint assembly (wheel side), and will not come o l t . Boot band Drive shaft joint grease: Use NISSAN GENUINE GREASE or equivalent after every overhaul.

0
L~ o i nassembly t

Drive sf h ,a t
b A

& , Q
7 7
\circular clip B

..-

,-=

Boot

Spider assembly Snap ring C Q

/'

3 0 - 40 (3.1 - 4.1.22

r A 2s-3~I2.6-3.6, 19-28)

- 30)

>

Support bearing retainer 1 3 - 1 9 (1.3 - 1.9.9 I S n a p ring D o Dust shield

'0

- 14)

Ba careful not to damage boots. Use suitable protector

or cloth during removal and installation.

Disassembly
TRANSAXLE SIDE
1. Remove boot bands. 2. Put matching marks on slide joint housing and drive shaft before separating joint assembly. 3. Put matching marks on spider assembly and drive shaft.

4. Pry off snap ring, then remove spider assembly. CAUTION: Do not disassemble spider assembly. 5. Draw out boot. Cover drive shaft serration with tape to prevent damage to the boot.

FRONT AXLE - Drive Shaft Disassembly (Cont'd)

WHEEL SIDE
(Sl~d~ng hammer)

CAUTION: The joint on the wheel side cannot be disassembled. Before separating joint assembly, put matching marks on drive shaft and joint assembly. Separate joint assembly with suitable tool. Be careful not to damage threads on drive shaft. Remove boot bands.

SF A 0 9 2 A

SUPPORT BEARING
Remove dust shield.

SFA613

SFA614

Pry off snap ring.

Press support bearing assembly out of drive shaft.

FA- 18

FRONT AXLE - Drive Shaft Disassembly (Cont'd)

8 Press support bearing out of retainer.

Inspection
Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for deformation or other damage.

DRIVE SHAFT
Replace drive shaft if it is twisted, bent or cracked.

BOOT
Check boot for fatigue, cracks, or wear. Replace boot with new boot bands.

JOINT ASSEMBLY (Transaxle side)

8 Check spider assembly for needle bearing and washer

damage. Replace if necessary. Check roller surfaces for scratches, wear or other damage. Replace if necessary. 8 Check serration for deformation. Replace if necessary. 8 Check slide joint housing for any damage. Replace if necessary.

JOINT ASSEMBLY (Wheel side)

Replace joint assembly if it is deformed or damaged.

SUPPORT BEARING
Make sure wheel bearing rolls freely and is free from noise, cracks, pitting or wear.

SUPPORT BEARING BRACKET

Check support bearing bracket for cracks.

Assembly
After drive shaft has been assembled, make sure it moves smoothly over its entire range without binding. Use GENUINE GREASE or equivalent after every overhaul.

FRONT AXLE - Drive Shaft

Assembly (Cont'd)
WHEEL SIDE
1. Install boot and new small boot band on drive shaft. Cover drive shaft serration with tape to prevent damage to boot during installation.

SFA8OO

Wheel bearing lock nut

2. Set joint assembly onto drive shaft by lightly tapping it with a hammer. Install joint assembly securely, ensuring that marks made during disassembly are properly aligned.

SFAl3OA

3. Pack drive shaft with specified amount of grease. Specified amount of grease: 155 175 g (5.47 6.17 OZ)

SFA885

4. Set boot so that it does not swell and deform when its length is "L,".

Length "L,": 96 98 mm (3.78 3.86 in) Make sure that boot is properly installed on the drive shaft groove.

5. Lock new larger and smaller boot bands securely with a suitable tool.

FRONT AXLE - Drive Shaft

Assembly (Cont'd)

SFA472

TRANSAXLE SIDE
1. lnstall boot and new small boot band on drive shaft. Cover drive shaft serration with tape to prevent damage to boot during installation.

2. lnstall spider assembly securely, making sure the marks which were made during disassembly are properly aligned. 3. Install new snap ring.

Length "L, ": 101.5 - 103.5 mm (4.00 - 4.07 ~ n )

4. Pack drive shaft with specified amount of grease. Specified amount of grease: 220 240 g (7.76 8.46 OZ) 5. lnstall slide joint housing. 6. Set boot so that it does not swell and deform when its length is "L2". Length "L2": 101.5 103.5 mm (4.00 4.07 in) Make sure that boot is properly installed on the drive shaft groove.

SFA507A

7. Lock new larger and smaller boot bands securely with a suitable tool.

FRONT AXLE - Drive Shaft

Assembly (Cont'd) SUPPORT BEARING

a Press bearing into retainer

SFA618

a Press drive shaft into bearing.

a Install snap ring. a Install new dust shields.

Transaxle side

I.

FRONT SUSPENSION

CAUTION: When disassembling and assembling, be careful not to damage piston rod. *When installing, final tightening needs to be carried out at curb weight with tires on ground.

R 39-54

(4.0 - 5.5, 29 - 40)

, -

Spacer

59 - 78 16 - 8.43 - 58)

Strut insulator

Lower rubber

(11.4-16.2.62-117)

Wheel bearing lock nut 235-314-124-32. (12 - 15-87 - 108) 54 - 72 (5.5 - 7.3.40

- 53)
Insulator (Rubber)

Transverse link*

(1.6 - 2.2, 12 - 16)

: N.m (kg-m, ft-lb)

FRONT SUSPENSION - Coil Spring and Strut Assembly Removal and Installation
Remove strut assembly fixing bolts and nuts (to hood ledge). Do not remove piston rod lock nut on vehicle. Put matching marks on strut lower bracket.

Disassembly
1. Set strut assembly on vise with suitable tool, then loosen piston1 rod lock nut. Do not remove piston rod lock nut.

2. Compress spring with Tool so that the strut mounting insulator can be turned by hand.

3. Remove piston rod lock nut

FRONT SUSPENSION

- Coil Spring and Strut Assembly

Inspection
STRUT ASSEMBLY
If oil is oozing from the gland packing or welded portions, replace the strut assembly. Inspect piston rod for cracks, deformation or other damage. Replace strut assembly if necessary. lnspect threads for cracks or other damage. Replace strut assembly if necessary.

STRUT MOUNTING INSULATOR

Check cemented rubber-to-metal portion for melting or cracks. Check rubber parts for deterioration.

THRUST SEAT
Check for cracks, deformation or other damage. Replace if necessary.

COIL SPRING
Check for cracks, deformation or other damage. Replace if necessary.

Upper Upper end

Flat tail

Assembly
When installing coil spring on strut, it must be positioned as shown in the figure at left. Ensure that rubber spring seats are installed correctly.

Seats

Lower end

SFA508A

When installing upper spring seat, make sure that it is positioned as shown in the figure at left.
Front

SFA501 A

FRONT SUSPENSION - Stabilizer Bar Removal and Installation

Remove stabilizer bar.

When installing stabilizer, make sure that paint mark and clamp face in their correct directions.

When removing and installing stabilizer bar, fix portion A.

Install stabilizer bar with ball joint socket properly placed

View from B

q@
O.K.
N.G.
SFAOOZA

FRONT SUSPENSION - Transverse Link and Transverse Link Gusset Removal and Installation
TRANSVERSE LINK AND GUSSET
Remove stabilizer bar. Remove fixing bolts.

m Install bolts in order of number.

Tightening torque: Refer to page FA-23. During installation, final tightening must be carried out at curb weight with tires on the ground. After installation, check wheel alignment. Refer to CHECK AND ADJUSTMENT.

Transverse link gusset

Front

link

SFA503A

Inspection
Check transverse link for damage, cracks or deformation. Replace it if necessary. Check rubber bushing for damage, cracks and deformation. Replace transverse link if necessary. Check transverse link gusset for damage, cracks or deformation. Replace it if necessary.

FRONT SUSPENSION - Lower Ball Joint Removal and Installation

1. Remove wheel bearing lock nut. 2. Remove tie-rod ball joint. 3. Loosen (do not remove) strut mounting nuts.

SFAOOBA

4. Remove nuts securing lower ball joint to transverse link and knuckle. 5. Separate drive shaft from knuckle by slightly tapping drive shaft end.

Cover boots with waste cloth so as not to damage them when removing drive shaft.

6. Remove lower ball joint from knuckle with Tool.

Lower ball joint

Inspection
Check ball joint for play. If ball stud is worn, play in axial direction is excessive or joint is hard to swing, replace lower ball joint. Before checking, turn ball joint at least 10 revolutions so that ball joint is properly settled. Turning torque "A": (measuring point: between threaded portion and taper.) New parts 11.0 - 77.ON Used parts 5.5 - 38.5N Turning torque "B": New parts 0.5 - 3.5N-M Used parts 0.25 - 1.75N-M

FRONT SUSPENSION - Lower Ball Joint Inspection (Cont'd)

Vertical end play "C": 2.5 mm (0.098 in) or less Procedure (1) Jack up front of vehicle and set the stands. (2) Clamp dial indicator onto transverse link and place indicator tip on lower edge of brake caliper. (3) Make sure front wheels are straight and brake pedal is depressed. (4) Place a pry bar between transverse link and stopper road wheel. (5) While raising and releasing pry bar, observe maximum dial indicator value. (6) Replace transverse link or lower ball joint if ball joint movement is beyond specification. Check dust cover for damage. Replace dust cover and dust cover clamp if necessary.

SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications

COIL SPRING
Engine Transaxle Left or right hand side Wire diameter [Left/right] Coil outer diameter [Leftlright] Free length [Lehlright] Spring constant N/mm Identification color
'

CA20E

KA24E

M/T

A/T

M/T

A/T

L/ H mm 12.7

R/H 12.8

L/H 12.8

R/H 12.8

L/H 12.8

R/H 12.8

L/H 12.8

R/H 12.8

mm

130

130

130

130

130

130

130

130

mm

358

363

363

374

363

374

374

38 1

21.6 Red, White

21.6 Red, Yellow

21.6 Red, Yellow

21.6 Red, Green

21.6 Red, Yellow

21.6 Red, Green

21.6 Red, Green

21.6 Red, Blue

SHOCK ABSORBER
Engine CA2OE & KA24E

FRONT STABILIZER BAR

Applied model Bar diameter mm All 22

Strut type Inner cylinder Bore diameter Piston rod Rod diameter Rod stroke Expanded rod Length 'L" Damping force N (kg, Ib) [at 0.3 m (1.O ft)/sec.] Expansion Compression mm

Hydraulic 30.0

DRIVE SHAFT
Engine Joint type Transaxle side Wheel side Diameter mm Transaxle side "D," Wheel side "D2" CA2OE & KA24E DS90 ZFlOO 28 28 Mobil CVJ Grease No. 64925 1 9 170

mm

20.0

143 490k 3

1136(116,255)

Applied grease name Capacity Transaxle side Wheel side

264 (27.59)

Oil capacity

CC

215?5

205-225

Wheel side

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment

WHEEL ALIGNMENT (Unladen*l)
Engine

WHEEL BEARING
-

CAPOE +KA24E

Axial end play

mm (in)

0.05 (0.0020) or less 235 - 314 (24 - 32, 174 - 231 )

Lock nut tightening torque N.m (kg-m, ft-lb) Preload N.m (kg-cm, in-lb) At wheel bolt

Tire Camber Caster degree degree

195/65R14
-025' to 1'05' -0' 25' to 2' 05'

0.3 - 2.5 (3 - 26,2.6 - 22.6)

N (kg, Ib)
At knuckle arm "F" N (kg, Ib)

5.10- 44.62 (0.52 -4.55, 1.15- 10.03)

Kingpin inclination degree Toe-in Total toe-in mm (in) degree

13' 25'

- 15' 05'

2.0 - 17.7 (0.2 - 1.8.0.4- 4.0)

1 - 3 (0.04 - 0.12) 6'

- 18' - 38' - 31'

Front wheel turning angle Full turn degree Inside Outside Toe-out turn degree Insideloutside

34' 27'

2220'/200

*l: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated positions.

LOWER BALL JOINT

Swinging force N At groove between taper and threaded portion New pans Used parts
l

11.O-77.ON 5.5-38.5N

Rotating torque

Vertical end play 'C" mm

2.5 or less

REAR AXLE & REAR SUSPENSION

SECTION

RA!
..

CONTENTS
PRECAUTIONS AND PREPARATION... . .. REAR AXLE AND REAR SUSPENSION . . . CHECK AND ADJUSTMENT . . . . . . . . . .. . REAR AXLE AND REAR SUSPENSION ASSEMBLY REAR AXLE -Wheel Hub. . . . . . . .. . . REAR SUSPENSION .... . . REAR SUSPENSION -Coil and Strut Assembly SERVICE DATA AND SPECIFICATIONS (S.D.S.)
. .... .

..

.. ...

..

RA- 2 RA- 3 RA- 4 RA- 7 RA- 8 RA- 10 RA-? 1 RA- 16

PRECAUTIONS AND PREPARATION Precautions

When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, and mats in designated positions. Always tension brake pipes and fittings to specified torques (refer S.D.S.). When removing each suspension part, check wheel alignment and adjust if necessary. Do not jack up at the parallel links. Where fitted, self locking (nyloc) nuts must not be re-used, they must be renewed.

Preparation
SERVICE TOOLS
Tool supplier: Litchfield Tool number Tool name
E71 13

Description Removing and installing gland packing

Gland packing wrench

Removing and installing coil spring Spring compressor

REAR AXLE AND REAR SUSPENSION

CAUTION: Do not jack up et the parallel links or radius rods. Wheel alignment m Camber cannot be adjusted.

-0'48'

* 0'45'

Vehicle requires only toe-in adjustment. 1 3 mm (0.04 0.12 in)

Wheel bearing m Axial end play: 0.05 m m or less.

(4.3 - 5.5.31

- 40
(6.0 - 8.0, 43 - 58)

Upper spring seat Front

Front parallel link

(0) 41 - 47 (4.2 - 4.8.30

(10 - 12.72 - 87) 88 - 108 (9.0 - 11.0.65 - 80)
'Rear parallel link "Toe-in can be adjusted by varying the length of parallel link.

- 35)

(C1

: N.m (kg-m, ft-lb)

CHECK AND ADJUSTMENT Rear Axle and Rear Suspension Parts

Check axle and suspension parts for looseness, wear or damage. (1) Shake each rear wheel.

(2) Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to RA-16.

Front

(3) Check strut (shock absorber) for oil leakage or other damage.

CHECK AND ADJUSTMENT

Rear Wheel Bearing

Check tightening torque of wheel bearing lock nut. (nl: 186 255 Nom (19 26 kg-m, 137 188 ft-lb) Check that wheel bearings operate smoothly. Check axial end play. Axial end play: 0.05 mm (0.0020 in) or less If there is any axial end play or wheel bearing does not turn smoothly, replace wheel bearing assembly. Refer to REAR AXLE-Wheel Hub

Rear Wheel Alignment

PRELIMINARY INSPECTION
Make following checks. Adjust, repair or replace if necessary. Check tires for wear and for improper inflation. Check rear wheel bearings for looseness. Check wheel runout.

Steel

Check that rear strut (shock absorber) works properly. Check rear axle and rear suspension parts for looseness. a Check vehicle posture (Unladen). "Unladen": Fuel tank, radiator and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

CAMBER
Camber is preset at factory and cannot be adjusted. Camber:

-0'48' + 0'45'

If the camber is not within specification, inspect and replace any damaged or worn rear suspension parts.

CHECK AND ADJUSTMENT

-

Rear Wheel Alignment (Cont'd)

TOE-IN
1. Draw a baseline across the tread. After lowering rear of vehicle, move it up and down to eliminate friction.

2. Measure toe-in. Measure distance "A" and "B" at the same height as hub center. Toe-in: 1 3 mm (0.04 0.12 in) A B 26 -18' to -6'

3. Adjust toe-in by varying the lengths of rear parallel links.

a Adjust left and right rear parallel links to the same length "A". Tighten lock nut while holding rear parallel link with wrench to prevent bushing from twisting. Standard length "A": Black link- 50-55 mm (1.97-2.1 7 in.) Grey link- 55-60 mm (2.1 7-2.36 in.)

REAR AXLE AND REAR SUSPENSION ASSEMBLY Removal and Installation

CAUTION: Do not jack up at the parallel links or radius rods. Disconnect brake hydraulic line and parking brake cable at equalizer.

Remove suspension assembly (one side). 1) Remove parallel link fixing bolt, radius rod fixing bolt, stabilizer fixing bolt, stabilizer connecting rod brackets and parking brake cable fixing bolts.

2) Remove rear seat and parcel shelf. Refer to section BF. 3) Remove strut securing nuts (Upper side). Then pull out strut assembly.

REAR AXLE

- Wheel

Hub

Front

Removal
CAUTION: Wheel hub bearing usually does not require maintenance. If any of the following symptoms are noted, replace wheel hub bearing assembly. Growing noise is emitted from wheel hub bearing during operation. Wheel hub bearing drags or turns roughly when hub is turned with your hand after bearing locknut is tightened tospecified torque. After wheel hub bearing is removed from knuckles spindle. Remove wheel bearing lock nut. Remove brake caliper assembly (disc brake models only). Brake hose does not need to be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted.

REAR AXLE

- Wheel

Hub

Installation
Install wheel hub bearing. Tighten wheel bearing lock nut. 186 255 N-m (19 26 kg-m, 137 188 ft-lb) Check that wheel bearings operate smoothly.

m:

Check wheel bearing axial end play. Axial end play: 0.05 mm (0.0020 In) or less

REAR SUSPENSION

When installing each rubber part, final tightening must be carried out under unladen condition* w i t h tires on ground. Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

CAUTION: Do not jack u p at the parallel links, radius rods.

Strut cover

(ql 59 - 78
(6.0 8.0.43

- 58)
- 40)

Strut mounting tube Spacer

(a) 42-54
(4.3 5.5.31
insulator

Bound bumper Upper rubber seat

Lower rubber seat

(ql 69 - 127 (7.0 - 13.0.51 - 94)

Front parallel link Front

Q
(8.0 - 10.0.58 72)

Rear parallel link

(4.2 - 4.8.30

- 35)

(3.2 43.23

- 31)

REAR SUSPENSION-Coil

Spring and Strut Assembly

Disassembly
1. Set strut assembly on vise with attachment, then loosen piston rod lock nut. Do not remove piston rod lock nut.

2. Compress spring with tool as shown so that the strut mounting insulator can be turned by hand.

3. Remove piston rod lock nu?.

4. Remove gland packing with Tool. Avoid getting dirt and dust into gland packing portion. 5. Retract piston rod by pushing it down until it bottoms. Then, slowly withdraw piston rod from cylinder together with piston guide.

REAR SUSPENSION-Coil

Spring and Strut Assembly

Inspection
Wash all parts, except nonmetallic parts, with solvent; then dry with compressed air. Blow dirt and dust off of nonmetallic parts with compressed air.

STRUT ASSEMBLY If oil IS oozing from the gland packing, the strut need not be replaced. If oil leakage is evident on spring seat, check piston rod gland packing and 0-ring. If oil leakage occurs on welded portion of outer strut casing, replace strut assembly. If the shock absorber is malfunctioning, replace it as a shock absorber kit-cartridge. GLAND PACKING
Check gland packing for oil leakage. Replace gland packing if necessary.

INNER CYLINDER
Check inner cylinder for cracks, deformation or other damage. For inner cylinder damage, replace shock absorber kit-cartridge. lnner diameter: lnner cylinder Refer to S.D.S.

Maximum runout: lnner cylinder 0.2 mm (0.008 in)

PISTON ROD
Check piston rod for cracks, deformation or other damage. Replace shock absorber kit-cartridge, if necessary. Check threads for cracks or other damage. Replace shock absorber kit-cartridge, if necessary. Rod diameter: Refer to S.D.S. Maximum runout: 0.1 mm (0.004 in)

STRUT MOUNTING INSULATOR

Check cemented rubber-to-metal portion for melting or cracks. Check rubber parts for deterioration.

REAR SUSPENSION-Coil

Spring and Strut Assembly

Inspection (Cont'd)
COIL SPRING
Check for cracks, deformation or other damage. Replace if necessary.

Assembly
Before assembly, keep away from dust. Add correct amount of fluid. [Except shock absorber kitcartridge] Use "GENUINE STRUT FLUID" or equivalent. Oil capacity is very important since performance of strut varies with amount of fluid in strut. Capacity: 310 7cc

Lubricate sealing lip of gland packing with multi-purpose grease.

Install gland packing. Cover piston rod with tape to prevent damage to oil seal lip. Tighten gland packing to the specified torque (Refer to the following chart.) with Tool.

REAR SUSPENSION-Coil

Spring and Strut Assembly

Assembly (Cont'd)

(1.0)

(1.5)

(Z.O)(ft)

L: Effective length of torque wrench

Hepeat proceaures (as snown ar IeTrj several rimes so rnat air will be thoroughly bled from strut [Except shock absorber kit-cartridge] .

FA280

Locate upper spring seat as shown.

REAR SUSPENSION-Coil

Spring and Strut Assembly

Assembly (Cont'd)
After placing coil spring in position on lower spring seat, release spring compressor gradually.

Lower spring seat

SERVICE DATA AND SPECIFICATIONS (S.D.S)

General Specifications

COIL SPRING
Model Engine Transaxle Wire diameter Coil diameter Free length Spring constant Identification color mm mm mm N/mm All CA20E & KA24E M/T & A / T 12.0 130 305 21.6 White/Orange

STRUT
Model Engine Strut type Piston rod diameter Inner cylinder bore dia. Stroke 'L" Maximum Length 'L" mm mm mm mm All CA20E & KA24E Hydraulic 22 30 19 1 627

Dampening force N (kg, Ib) [at 0.3 m (1.O ft)/sec.] Expansion Compression Oil capacity ml

735 (75, 165) 245 (25,55) 310+7

SERVICE DATA AND SPECIFICATIONS (S.D.S)

General Specifications (Cont'd) STABILIZER BAR
Eng~ne Bar diameter mm CAPOE 15
KA24E

-- 16

-- -

Inspection and Adjustment

WHEEL ALIGNMENT (Unladen"1)

Engine Camber Toe-in Total toe-in degree mm dearee -0'48' All

+ 0'45'
1-3

-18' to -6'

': Tank full of fuel, radiator coolant engine oil full. Spare tire, jack, hand tools, mats in designated positions

BRAKE SYSTEM I
SECTION

BR1
BR- 2 BR- 3 BR- 4 BR- 6 BR- 8 BR- 10 BR- 12 BR- 13 BR- 16 BR- 19 BR-24 BR-25 BR-27

CONTENTS
PRECAUTIONS AND PREPARATION CHECK AND ADJUSTMENT BRAKE HYDRAULIC LINE BRAKE PEDAL AND BRACKET BRAKE BOOSTER VACUUM PIPING MASTER CYLINDER FRONT DlSC BRAKE (CL25VA) - Caliper FRONT DlSC BRAKE (CL25VA) - Rotor REAR DlSC BRAKE (CL9H) - Caliper REAR DlSC BRAKE (CL9H) - Rotor PARKING BRAKE CONTROL SERVICE DATA AND SPECIFICATIONS (S.D.S.)

PRECAUTIONS AND PREPARATION Precautions

a a a a
Recommended fluid is brake fluid "DOT 4". . Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. a Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.

Use suitable tool when removing and installing brake tube. Always tension brake pipes and fittings to specified torques. WARNING: a Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.

Preparation
SERVICE TOOL
Tool supplier: Litchfield Tool number Tool name

Description

E7 186
Rear brake piston retractor
i

Retracting rear caliper piston

CHECK AND ADJUSTMENT Checking Brake Fluid Level

a Check fluid level in reservoir tank. It should be between Max.
and Min. lines on reservoir tank.
8 If fluid level is extremely low, check brake system for leaks.

Checking Brake System

8 Check brake lines (tubes and hoses) for cracks, deteriora-

tion or other damage. Replace any damaged parts. If leakage occurs around joints, retighten or, if necessary, replace damaged parts. a Check for oil leakage by fully depressing brake pedal.

Changing Brake Fluid .

1. Drain brake fluid from each air bleeder valve. 2. Refill until new brake fluid comes out of each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to Bleeding Procedure. a Refill with recommended brake fluid "DOT 4". a Never reuse drained brake fluid. 8 Be careful not to splash brake fluid on painted areas.

BRAKE HYDRAULIC LINE

Proportioning valve (Do not disassemble.)

: Flarenut15-lS(1.5-1.8,ll-13) : Connecting bolt 17 - 20 (1.7 -2.0, 1 2 - 14)

Primary line Secondary line

(C)1 :

N.rn (kg-m, h-lb)

SBR446A

Bleeding Procedure
CAUTION: Carefully monitor brake fluld level at master cylinder during bleeding operation. Fill reservoir with recommended brake fluld. Make sure it is full at all times while bleeding air out of system. Place a container beneath master cylinder to avoid spillage of brake fluid.

Bleed air according to the following procedure. Left rear + Right front + Right rear + Left front.

BRAKE HYDRAULIC LINE Bleeding Procedure (Cont'd)

1) 2) 3) 4) 5) 6)
To bleed air out of lines, wheel cylinders and calipers, use the following procedure. Connect a transparent vinyl tube to air bleeder valve. Fully depress brake pedal several times. With brake pedal depressed, open air bleeder valve to release air. Close air bleeder valve. Release brake pedal slowly. Repeat steps 2) through 5) until clear brake fluid comes out of air bleeder valve.

Removal and Installation

1. To remove brake hose, first remove flare nut securing brake tube to hose, then withdraw lock spring. 2. Cover openings to prevent entrance of dirt whenever disconnecting hydraulic line. 3. All hoses must be free from excessive bending, twisting and pulling. 4. After installing brake lines, check for oil leakage by fully depressing brake pedal.

Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. If leakage occurs around joints, retighten or, if necessary, replace damaged parts.

BRAKE PEDAL AND BRACKET

Removal and Installation

(1.6-2.2, 1 2 - 16)

Fulcrum shaft

m r 8 - 11 (0.8 - 1.1.5.8 - 8.0) q

(0.8 - 1.1.5.8

- 8.0)

* neplacc r l ~ v i s if plastic stopper, pin

w:r,ch IS located at the end of clevis ;. n, deformed or damaged. ;

([J) :

N.m (kg-m, rr ib)

SBt;c&t3A

Inspection
Check brake pedal for the following items. a Brake pedal bend a Clevis pin deformation Crack of any welded portion

BRAKE PEDAL AND BRACKET

Adjustment
Check brake pedal free height from dash reinforcement panel. Adjust if necessary. H: Free height Refer to S.D.S. D: Depressed height Refer to S.D.S. Under force of 490 N (50 kg, 110 Ib) with engine running C: Clearance between pedal stopper and threaded end of stop lamp switch 0.3 1.0 mm (0.012 0.039 in) A: Pedal free play 1 3 mm (0.04 0.12 in)

-Stays

inside

1. Adjust pedal free height with brake booster input rod. Then tighten lock nut. Make sure that tip of input rod stays inside.

6
Input rod

I?I
Clevis pin

SBR930

2. Adjust clearance "C" with stop lamp switch. Then tighten lock nuts. 3. Check pedal free play. Make sure that stop lamp is off when pedal is released. 4. Check brake pedal's depressed height while engine is running. If depressed height is below specified value, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.); then make necessary repairs.

BRAKE BOOSTER

Removal and Installation

1

(0.8 - 1.1.5.8 - 8.0)

Brake booster

(0.8 1.1.5.8 8.0)

[I)) :

N-m (kgm, ft-lbl

SBR571A

Inspection
OPERATING CHECK a Depress brake pedal several times with engine off, and
check that there is no change in pedal stroke.

a Depress brake pedal, then start engine. If pedal goes down

slightly, operation is normal.

SBROOZA

O.K.

N.G.

AIRTIGHT CHECK a Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. If pedal goes further down the first time and gradually rises after second or third time, booster is airtight. Depress brake pedal while engine is running, and stop engine with pedal depressed. If there is no change in pedal stroke after holding pedal down 30 seconds, brake booster is airtight.

k
SBR365A

OUTPUT ROD LENGTH CHECK

1. Supply brake booster with vacuum of -66.7 kPa (-667 rnbar, -500 mmHg, -19.69 inHg) using a handy vacuum pump. 2. Check output rod length. Specified length: 10.275 10.525 mm (0.4045 0.4144 in)

BRAKE BOOSTER
Inspection (Cont'd)
3. Adjust rod length if necessary. 4. If rod length is without specification, replace brake booster.

VACUUM PIPING
Removal and Installation

h0seT8 >
Vacuum Check valve

e
4

Brake booster

CAUTION: Do not apply any oil or lubricants to vacuum hoses and check valve.

93

Intake man~fold
SB R 4 5 0 A

Insert vacuum tube into vgcuum hose more than 24 mm (0.94 in).

I -- - __ -.-----U

Mora than 24 mm (0.94 in)

SBR004A

Install check valve, paying attention to its direction.

Brake booster s~de

Intake manifold or vacuum pump side

SBR202A

Inspection
HOSES AND CONNECTORS
Check vacuum lines, connections and check valve for airtightness, chafing and deterioration.

VACUUM PIPING Inspection (Cont'd)

CHECK VALVE

m When pressure is applied to brake booster side of check

valve and valve does not open, replace check valve with a new one

Manifold side

Brake booster side

SBR846

MASTER CYLINDER Removal and Installation

Reservoir

rirnary piston assembly Secondary

/
*:
Dual proportioning valve (Do not disassemble.) Lubricate piston cup with brake fluid or rubber grease when assembling master cylinder.
SBR451A

m Replace stopper cap if claw is damaged or deformed. m Bend claws inward when installing stopper cap.

SBROl l A

Secondary piston

m m

Pay attention to direction of piston cups in figure at left. Check parts for wear or damage. Replace if necessary.

SBROl2A

FRONT DISC BRAKE (CL25VA) -Caliper

Torque member Connecting bolt

[C1 17 -20(1.7- 2.0.12(0.7 - 0.9,5.1

14)

- 6.5)

m@ : P.B.C. (Poly Butyl Cuprysil) grease or silicon-based grease point m @ : Rubber grease point

m: (C1:

Brake f l u i d N.rn ( k g m , ft-lb)

Pad Replacement
1. Remove pin bolt.

SBR453A

2. Swing cylinder body upward. Then remove pad and inner and outer shims. CAUTION: When cylinder body is swung up, do not depress brake pedal because piston will pop out. Be careful not to damage dust seal or get oil on rotor. Always replace shims when replacing pads.

FRONT DISC BRAKE (CL25VA) -Caliper

Removal and Installation
Remove torque member fixing bolts and connecting bolt.

Install brake hose to caliper at protrusions securely.

Disassembly
Push out piston with dust seal using compressed air.

Inspection
INSPECTION OF BRAKE DRAG FORCE
1. Swing cvlinder body upward.

2. Make sure that wheel bearing is operating properly. Refer to

section FA. 3. Measure rotating force (F,).

FRONT DlSC BRAKE (CL25VA) -Caliper

Inspection (Cont'd)
4. 5. 6. 7. 8.

Install caliper with pads to the originai posiiior! Depress brake pedal for 5 seconds. Release brake pedal and rotate disc rotor 13 rc+:c;lc:i,:ns Measure rotating force (F*). Calculate brake drag force by subtracting F. from F . Maximum brake drag force (F2 F,): 114.7 N (11.7 kg, 25.8 Ib) If it is not within specification, check main pins and relaiser boots in caliper.

DlSC PAD
Check disc pad for wear or damage

Pad standard thickness (A): 11.O m m (0.433 in) Pad wear limit (A): 2.0 m m (0.079 in)

CYLINDER BODY

m Check Inside surface of cyllnder for scorlng, rust, wear

damage or fore~gnmater~als Replace ~f any such cor.ditior: ex~sts Ellmlnate mlnor damage from rust or forelgn mater~a'c pollshlng surface with flne emery paper CAUTION: Use brake fluid to clean.

PISTON
Check piston for scoring, rust, wear, damage or foreign niaterials. Replace if any condition exists. CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface.

PIN, PIN BOLT AND PIN BOOT

Check for wear, cracks or other damage. Replace it anv condition exists.

r D ~ sealt ~

Assembly
m Insert piston seal into groove on cylinder body. m With dust seal fitted to piston, install piston into cylinder
body. CAUTION: m Secure dust seal properly.

seal

L Cylinder body
SBR574

FRONT DISC BRAKE (CL25VA) -Caliper

Inspection
RUBBING SURFACE
Check rotor for roughness, cracks or chips.

RUNOUT
Adjust wheel bearing preload. Check runout using a dial indicator. Rotor repair limit: Maximum runout (Total indicator reading at center of rotor pad contact surface) 0.07 mm (0.0028 in)

THICKNESS
Measure thickness of brake disc at least four points to determine maximum worn area. Standard thickness: 22.0 mm (0.866 in) Minimum thickness: 20.0 mm (0.787 in)

FRONT DISC BRAKE (CL25VA) -Caliper

Notes:

REAR DISC BRAKE (CLSH) -Caliper

Notes:

REAR DISC BRAKE (CLSH) - Caliper

Pad re Brake hose connector

Outer

contact area

(q) 22 - 31 (2.2 - 3.2.16

Pad retalner

- 23)

m@

L-

Piston boot

m@P.B.C. (Poly Butyl Cuprys~l)grease or : silicon-based grease point m : Rubber grease point
@ : Brake f l u i d point

[pJ:

N.m ( k g m , f t - l b )

REAR DISC BRAKE (CLSH) - Caliper Pad Replacement

1. Remove parking cable stay fixing bolt, pin bolt and lock spring. Then remove pad retainers, pads and shims. CAUTION: When cylinder body is swung up, do not depress brake pedal because piston will pop out.

2. When installing pads, retract piston into cylinder body by turning piston clockwise with service tool. CAUTION: Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads.

Removal and Installation

Dissconnect parking brake cable and brake hose, then remove caliper assembly.

Disassembly
1. Remove piston by turning it counterclockwise with service tool until tool hits caliper body. Complete the removal using suitable tool.

2. Pry off rlng A from piston w ~ t hsuitable pliers and remove adjusting nut.

REAR DISC BRAKE (CLSH) - Caliper Disassembly (Cont'd)

3. Disassemble cylinder body. (1) Pry off ring B with suitable pliers, then remove spring cover, spring and seat.

(2) Pry off ring C, then remove key plate, push rod and rod

(3) Remove piston seal. Be careful not to damage cylinder body.

4. Remove return spring and lever

Inspection
CAUTION: Use brake fluid to clean cylinder. Never use mineral oil. CYLINDER BODY m Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. m Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

REAR DISC BRAKE (CLSH) - Caliper Inspection (Cont'd)

TORQUE MEMBER
Check for wear, cracks or other damage. Replace if necessary.

PISTON
Check piston for score, rust, wear, damage or presence of foreign materials. Replace ~f any of the above conditions are observed. CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface.

PIN AND PIN BOOT

Check for wear, cracks or other damage.. Replace if any of the above conditions are observed.

Assembly
1. Install cup in the specified direction.

i l

Adlust~ng nut
SBR892
-

I-.
Concave p o r t l o n
\I

2. Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.

3. Install ring C with suitable tool.

i
l

Rod

-4

REAR DISC BRAKE (CLSH) - Caliper Assembly (Cont'd)

Press

4. Install seat, spring, spring cover and ring B with suitable press and drift.

R ~ n -B g

Spr~ng

Seat 4
SBR879

REAR DISC BRAKE (CLSH) - Rotor Inspection

RUBBING SURFACE
Check rotor for roughness, cracks or chips.

RUNOUT
Make sure that axial end play is within the specifications before measuring. Refer to section RA. Then check runout with a dial indicator. Rotor repair limit: Maximum runout (Total indicator reading at center of rotor pad contact surface) 0.07 mm (0.0028 in)

THICKNESS
Rotor repair limit: Minimum thickness 8.0 mm (0.315 in)

PARKING BRAKE CONTROL Removal and Installation

0 Before removing parking brake control, remove console box.

Make sure there is no free play after installing.

Inspection
1. Check control lever for wear or other damage. Replace if necessary. 2. Check parking brake cables and lamp switch. Replace if necessary. 3. Check parts at each connecting portion for deformation or damage, and if found, replace.

PARKING BRAKE CONTROL Adjustment

Before adjusting control lever stroke, ensure the caliper park brake leversare resting against their stops. If they are not, slackenthe cable (using the adjuster) and then depress the brake pedal firmly before carrying out the adjustment.

Adjust control lever by turning adjusting nut.

Pull control lever with specified amount of force. Check lever stroke and ensure smooth operation. Number of notches: 9-1 1

1
/parking brake warning

Bend parking brake warning lamp switchplate so that brake warning lamp comes on when ratchet at parking brake lever is pulled "A" notches and goes out when fully released. . Number of "A" notches: 1-2

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment
Front brake Brake model Cylinder bore diameter mm (in) mm (in) Length X width X thickness 134.1 x45.3 X 11.0 (5.28 X 1.783 CL25VA disc brake

l
I

57.2 (2.252)

Rotor outer diameter thickness

mm (in)

257 X 22 (10.12 X 0.87)

Rear brake Brake model Cylinder bore diameter mm (in) Lining or pad Length X width X thickness mm (in)

CL9H disc brake 33.96 (1.3370)

Rotor outer diameter Master cylinder Cylinder bore diameter

mm (in)

1
I
I
I

75 X 4 0 X 8 (2.95 X 1.575 X 0.31) 258(10.16)

mm (in) Control valve Valve model

23.81 (15116)

Dual proportioning valve (within master cylinder

'

Split point kg/cm2 X reducing ratio Brake booster Diaphragm diameter mm (in) Recommended brake fluid

25 X 0.4

230 (9.06) DOT4

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

Inspection and Adjustment
DISC BRAKE
Brake model Pad wear limit mm (in) Minimum thickness Rotor repair limit mm (in) Minimum thickness Maximum runout 20.0 (0.787) 8.0 (0.3 15) 0.07 (0.0028) CL25VA CL9H

BRAKE PEDAL
Free height "H" M/T 2.0 (0.079) A/T Depressed height "D" mm in) [under force of 490 N (50 kg, 1 10 Ib) with engine running] Clearance between switches and pedal stopper bracket "C" mm (in) Pedal free play "A" mm (in) mm (in) 185-195 (7.28-7.68) 175-185 (6.89-7.28)

75(2.96)

0.3-1 .O (0.012-0.039)

1-3 (0.04-0.12)

PARKING BRAKE
Type Number of notches [under force of 196 N (20 kg, 4 4 Ib)] Number of notches when warning lamp switch comes on Centre lever

9-1 1

1-2

STEERING SYSTEM
I

SECTION

ST'

CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ST- 2 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST- 3 ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST- 5 ON-VEHICLE INSPECTION (Power Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST- 7 STEERING WHEEL AND STEERING COLUMN . . . .......................................... ST- 10 MANUAL STEERING GEAR AND LINKAGE . . . . ......... . . . . . . . . . . . . . . . ST-14 POWER STEERING GEAR AND LINKAGE .. . . . . . . . . . . . . . . . . . . . . . . . ... ST-18 POWER STEERING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-23 SERVICE DATA AND SPECIFICATIONS (S.D.S.) . . . . . . . . . . . ... . . . . . ST-27

PRECAUTIONS

Before disassembly, thoroughly clean the outside of the unit. Disassembly should be done in a clean work area. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. When disassembling parts, be sure to place them in order in a parts rack, so they can be reinstalled in their proper positions. Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might interfere with their operation. Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable solvent. Before assembly, apply a coat of recommended A.T.F." to hydraulic parts. Vaseline may be applied t o 0-rings and seals. Do not use any grease. Replaceall gaskets, seals and 0-rings. Avoid damaging 0-rings, seals and gaskets during installation. Perform functional tests whenever designated. Automatic transmission fluid.

PREPARATION
SERVICE TOOLS
Tool supplier: Litchfield Tool number Tool name

Description

E7 124 Steering wheel puller

E2237 Ball joint remover

+81
oil pump outlet

Removing steering wheel

k!i models

Removing ball joint

AI! modeis

ressure gauge

E9254A-1

Power steering models only

E8802-6 Ball joint wrench

Inner ball joint removal and installatidn

All models

E71 10-1 Pinion plug socket

Pinion plug removal and installation

Manual steering models only

E8802- 1 Yoke plug socket

Yoke plug removal and installation

All models

E8802-2 Lock nut spanner

Yoke plug lock nut All models

E71 15 Angle Torque Gauge

Manual steerlng models on!y

PREPARATION
SERVICE TOOLS
Tool supplier: Litchfield Too1 number Tool name

Description

Application

E1401
Seal Remover

Inner seal remover Removing inner seal

Power steering models only

E7197
Bush key

Rack tube end bush Removing/installing rack tube end bush

Power steering models only

E7000
Seal installer

lnner seal installer

Power steering models only

E1 4 0 4
Protector

Rack protection

Power steering models only

COMMERCIAL SERVICE TOOLS

Tool number Oil pump attachment

Description
R21 (0.831
?lding

'

Disassembling and assembling oil pump

(1.57)

~t: mm ( ~ n )

SST48 1A

ON-VEHICLE INSPECTION
I

Checking Steering Wheel Play

a

With wheels in a straight ahead position, check steering wheel play. Steering wheel play: 35 mm (1.38 in) or less If it is not within specification, check tie-rod outer and inner ball joints andlor pinion & rack assembly.

SST899A

Checking Neutral Position on Steering Wheel

O.K. N.G.

@@
SST9OOA

Check that the steering wheel is in the neutral position when driving straight ahead. Check that rack is centred (i.e.) same number of turns to each side lock. If not, centre steering rack. If it is not in the neutral position, remove the steering wheei and re-install it correctly in the neutral position. If the neutral position is between two serrated teeth, loosen tie-rod lock nut and move tie-rod in the opposite direction by the same amount on both left and right sides to compensate for error in the neutral position.

a a

Checking Front Wheel Turning Angle

a

Rotate steering wheel all the way right and left; measure turning angle. Turning angle: Full turns and toe-out turn Refer to section FA for S.D.S.

If it i s not within specification, check rack stroke. Measure length "P, & P, ": Refer to S.D.S.

(Opposite to Pinion gear side)

(Pinion gear side)

SST793A

ON-VEHICLE INSPECTION Checking Gear Housing Movement

Movement of steering gear housing in stationary steering is attributable t o elastic deformation of mount insulator. The maximum allowable movement is as follows:

Movement of gear housing: 3 mm (0.12 in) (on dry paved surface) or less Note: When a force of 49 N (5 kg, 11 Ib) is applied t o steering wheel. On models equipped with power steering, turn off ignition key while checking. I f movement exceeds the limit, replace mount insulator after confirming proper installation of gear housing clamps.

Checking and Adjusting Drive Belts

Refer to section MA for Drive Belt Inspection.

Checking Fluid Level

Check the level when the fluid is cold.

CAUTION: Do not overfill. Recommended fluid is Automatic "Dexron Type".

Transmission Fluid

Checking Fluid Leakage

Check the lines for improper attachment and for leaks, cracks, damage, loose connections, chafing or deterioration. 1. Run engine at idle speed or 1,000 rpm.

Make sure temperature of fluid in oil tank rises to 60 to 80C (140 to 176OF). 2. Turn steering wheel right-to-left several times. 3. Hold steering wheel at each "lock" position for five seconds and carefully check for fluid leakage. CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. 4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten. Do not overtighten connector as this can damage 0-ring, washer and connector.

ON-VEHICLE INSPECTION (Power Steering)

Bleeding Hydraulic System
1. Raise front end of vehicle until wheels clear ground. 2. Add fluid into oil tank to specified level. Meanwhile quickly turn steering wheel fully to right and left and lightly touch steering stoppers. ~ e p e a tsteering wheel operation until fluid level no longer decreases. 3. Start engine. Repeat step 2 above. Incomplete air bleeding will cause the following to occur. When this happens, bleed air again. Generation of air bubbles in reservoir tank Generation of clicking noise in oil pump @ Excessive buzzing in oil pump ) While the vehicle is stationary orwhile moving the steering wheel slowIy, fluid noise may occur in the valve or oil pump. This noise is inherent in this steering system, and it will not affect performance or durability of the system.

a a

Checking Steering Wheel Turning Force

Park vehicle on a level, dry surface and set parking brake. Start engine. Bring power steering fluid u'p to adequate operating temperature. [Make sure temperature of fluid is approximately 60 to 80C (140 to 176"F).] Tires need to be inflated to normal pressure. 4. Check steering wheel turning force when steering wheel has been turned 360' from neutral position. Steering wheel turning force: 39 N (4 kg, 9 Ib) or less 1. 2. 3.

ON-VEHICLE INSPECTION (Power Steering) Checking Hydraulic System

Before starting, check belt tension, driving pulley and tire pressure. 1. Set Tool. Open shut-off valve. Then bleed air. (See "Bleeding Hydraulic System".) 2. Run engine. Make sure temperature of fluid in tank rises to 100C (212OF).

WARNING: Warm up engine with shut-off valve fully opened. If engine is started with shut-off valve closed, oil pressure in oil pump will increase to relief pressure, resulting in an abnormal rise in oil temperature. 3. Check pressure with steering wheel fully turned to left and right positions at 1,000 rpm. CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. Oil pump maximum standard pressure: 6,669 7,257 kPa (66.7 72.6 bar, 68 - 74 kg/cm2, 967 - 1,052 psi) at idling 4. If oil pressure is below the standard pressure, slowly close shut-off valve and check pressure. When pressure reaches the standard pressure, gear is damaged. When pressure remains below the standard pressure, pump is damaged. 5. If oil pressure is higher than the standard pressure, pump is damaged. Do not close shut-off valve for more than fifteen seconds. 6. After checking hydraulic system, remove Tool and add fluid as necessary, then completely bleed air out of system.

D ~ r e c t ~ o n 011flow of

hose

SST834

STEERING WHEEL AND STEERING COLUMN

( . 4.0, 22 29) 30

13 - 18 (1.3 - 1.8.9 - 13)

[o) 13 - 18 (1.3 - 1.8, 9 - 13)

[o)
(0.35 - 0.45, 2.5 - 3.3)

: N.m (kg-m,ft-lb)

Removal
STEERING WHEEL
1. Pull out horn pad.

2. Remove steering wheel with tool (E7 124)

STEERING WHEEL AND STEERING COLUMN

Installation
STEERING WHEEL
When installing steering wheel, apply multi-purpose grease to entire surface of turn signal cancel pin (both portions) and also to horn contact slip ring.

l
L

-Cutout portion7

SSTl 126

r----

Lowrr ioint

,-- --

SSTBOOA

STEERING COLUMN When installing steering column, fingertighten all lower bracket and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column. When attaching coupling joint, be sure tightening bolt faces cutout portion. CAUTION: After installing steering column, turn steering wheel to make sure it moves smoothly and that the number of turns from the straight forward position to left and right locks are equal. Be sure that the steering wheel is in a neutral position when driving straight ahead.

STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly

bination switch assembly

Steering adjusting circlip bolt

24 - 29 (2.4 - 3.0, 17 - 22

Column shaft assembly

: N.m (kg-m, ft-lb)

SST068B

CAUTION: After installing, turn steering wheel to make sure it moves smoothly and that the number of turns from the straight forward position to left and right locks are equal.

--Upper

shaft

When disassembling and assembling, unlock steering lock with key. Ensure that rounded surface of snap ring faces toward bearing when snap ring is installed. Install snap ring on upper shaft with box wrench.

STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly (Cont'd)

m Adjust tilt lever as follows: (1) When tilt lever contacts stopper, tighten adjusting bolt securely. (2) Turn tilt lever by 90 ( 6 ) in direction "P" to check that steering column moves smoothly without binding. (3) Return tilt lever to position 0 . Make sure there is no free play (=O) of steering column when steering wheel is pushed down by force. (4) Install lock washer and E-ring.

m Steering lock a) Break self-shear type screws with a drill or other appropriate tool.

b) Install self-shear type screws and then cut off self-shear type screw heads.

Joint cover m When assembling, align cutout on joint cover with protrusions on hole cover.

STEERING WHEEL AND STEERING COLUMN Inspection

When steering wheel can not be rotated smoothly, check the steering column for the following matters and replace damaged parts. (1) Check column bearings for damage or unevenness. Lubricate with recommended multi-purpose grease or replace steering column as an assembly, if necessary. (2) Check jacket tube for deformation or breakage. Replace if necessary. When the vehicle is involved in a light collision, check column length. If it is not within specifications, replace steering column as an assembly. Remove column shaft assembly from jacket tube assembly. length = manual 804.0 - 806.2 mm power 763.1 - 765.3 mm Jacket tube assembly length, from upper end to lower pivot centre length = 466.4 - 471.6 mm

MANUAL STEERING GEAR AND LINKAGE (TRW)

Removal and lnstallation

Removal
m

Detach tie-rod ball studs from knuckle arms with Tool.

Installation
Initially, tighten nut on tie-rod outer socket and knuckle arm to 54 to 59 Nm (5.5 to 6.0 kg-m, 40 to 43 ft-lb). Tighten nut further to align nut groove with the first pin hole so cotter pin can be installed. CAUTION : Tightening torque must not exceed 98 N-m (10 kg-m, 72 ft-lb).

MANUAL STEERING GEAR AND LINKAGE (TRW)

Disassembly
Clean all dirt and foreign matter from exterior of steering gear. Clamp steer~ng gear in a soft jawed vice or suitable fixture. Loosen tie rod locknuts and remove outer tie rod ends. Remove clips and boots (discard both). 5. Drill crimping in rack end adjacent to each ball housing with a 4 mm drill to a depth sufficient to break the crimping.
1. 2. 3. 4.

6. Remove inner ball joint assemblies using special tool (Litchfield No 8802-6). CAUTION: When removing ball housings, use an adjustable wrench on the flat teeth of the rack t o prevent rotation and possible damage t o the rack or pinion teeth. Be careful not t o nick or damage rack on yoke side.

7. Using special tools E8802-1 and E8802-2 loosen lock nut and remove yoke plug. Remove yoke and spring.

Note: It may be necessary to file down the cast boss on the rack housing in orderto fit the lock nut spanner (E8802-2) -maximum to be filed -2mm. 8. Remove pinion shaft seal and discard.

MANUAL STEERING GEAR AND LINKAGE (TRW)

9. Using specialtool (LitchfieldNo E7 1 10- 1)remove pinion plug. 10. Remove pinion and rack. 1 1. Invert housing and draw out lower pinion bearing by hand.
12. Remove left hand rack bush from tube and discard.

Inspection
Thoroughly clean and dry all parts. Check rack for signs of tooth wear, tooth contact and signs of irregular wear pattern. Check for scoring at yoke and bush contact areas. Check pinion for signs of tooth wear and irregular contact. Inspect pinion bearing for nicks, scores and signs of brinelling. NOTE: Pinion and bearing should not be separated. Damage or wear to either requires replacement of the assembly. Check steering gear housing for scoring wear and damage.
Assembly

1. Place steering gear in a soft jawed vice or suitable fixture 2. Fit left hand rack bushing with a suitable piece of tube, ensuring tabs on bushing are correctly located in housing grooves.

3. Lubricate the lower bearing assembly with EPLl grease and insert into the housing.
4. Apply approximately 3 0 cc of EPLl grease in the bottom of the pinion bore. 5. Apply approximately 10 cc of EPL1 grease to the rack teeth and insert rack into housing from pinion end, aligning the rack teeth with the pinion bore. Locate rack so that it protrudes an equal amount each side of the housing. 6. Lubricate pinion and pinion bearing and insert pinion into mesh with the rack. 7. Apply Loctite 242 to pinion plug and install into pinion housing. Torque to 40-50Nm several times. Back off and tighten until there is no end play in the pinion, then tighten a further 12-24 degrees.

ST- 16

MANUAL STEERING GEAR AND LINKAGE (TRW)

8. With the rack in the straight ahead position, install yoke and yoke spring. Install yoke plug, and using special tool No. E8802-1 tighten to 4.5 Nm then back off 15-25 degrees. 9. Tighten yoke plug lock nut (using Tool No. E8802-2. Yoke plug must be restrained from turning during this operation. IMPORTANT: Once yoke clearance has been set gear must be racked from lock to lock to ensure wear has not appeciably M e d setting, gear should not bind or appear-tightover any part of the total travel. Should gear bind or excessive free play appear, adjust yoke plug. If this is not the cause, strip gear and examine rack and pinion for wear and damage.

10. Fill the internal lip cavity of the pinion seal with grease and fit the seal over the pinion shaft into the top of the pinion plug. 1 1. Assemble ball housing to rack, then using special tool (Litchfield No. E8802-6) torque to 80-88 Nm. (Using Special Tool, Torque Wrench will read 47.5 Nm.). CAUTION: When torquing use an adjustmentwrenchon the flat teeth of the rack to prevent rack rotation and possible damage to rack or pinion teeth. Be careful not to nick or damage rack on yoke side.

12. Drill a 4 mm dia. X 10 mm deep hole into the rack adjacent to each ball housing at 90" to the rack teeth.

13. Drive a 4 mm dia. X 10 mm long pin into each hole. 14. Smear a small quantity of grease in the groove on each tie rod where the sealing boot seats. Assemble boots and clips ensuring the outer clip is accessible when the steering rack is fitted to the vehicle.

ST- 17

POWER STEERING GEAR AND LINKAGE (TRW)

Removal and Installation

Front suspension member

- 10.0, 40 - 72)
Knuckle arm

Power steerlng gear assembly

Low-pressure s ~ d e

(2.5
H~gh-pressure slde

- 3.0, 18 - 22)

(8.6

- 11.0, 62 - 80)

g
Gear houslng clamp

N-m (kg-m, ft-lb)

A ST-006

Exploded View

ST- 18

POWER STEERING GEAR AND LINKAGE (TRW)

Disassembly
Clean all dirt and foreign matter from exterior of steering gear. Remove pipes, then rack the gear from lock to lock to drain oil. Clamp steering gear in a soft jawed vice or suitable fixture. 4. Loosen tie rod locknuts and remove outer tie rod ends. 5. Remove clips and boots (discardboth). 6. Drill crimping in rack end adjacent to each ball housing with a 4 mm drill to a depth sufficient to break the crimping. 7. Before removing inner ball joint assemblies, remove pinion end cover and loosen pinion lock nut.

8. Remove inner ball joint assemblies using special tool (Litchfield NOE8802-6). CAUTION: When removing ball housings, use an adjustable wrench on the flat teeth of the rack to prevent rotation and possible damage to the rack or pinion teeth. Be careful not to nick or damage rack on yoke side.

9. Using special tool E8802-2 loosen the yoke plug lock nut and unscrew the yoke plug using socket E8802- 1. Remove yokeand yoke spring. 10. Remove pinion lock nut.

ASTOOB

POWER STEERING GEAR AND LINKAGE (TRW)

12.Using a soft faced mallet, carefully knock the pinion/valve
assembly upwards out of the rack housing. Discard the bush bearing and shaft seal from the top of the pinion/valve assembly. 13.Remove teflon sealing rings from valve assembly and discard. 14.Push L/H end of rack in until it is flush with the housing.

15.Rotate L/H end bush with tool (E7 197) locate end of wire clip. to 16.Carefully pry up the end, then rotate the bush in the opposite
direction to feed wire out.

17.Using a soft punch, drive the rack out of the housing toward the
L/H side.

18.Remove and discard bush and seal assembly, remove piston

ring and discard.

19.Using special tool E 1401, tap out the seal and spacer from the
inner end of the rack tube. Discard seal and de-burr the spacer which may have been marked during this removal. 20.Drive out lower pinion bearing using suitable drift.

lnspect rack teeth for wear, burrs, etc.

Inspection
Thoroughly clean and dry the parts which have been removed. lnspect ball housing assemblies and tie rod ends for wear or damage. lnspect yoke and spring for wear and damage. lnspect valve assembly for visible wear or damage and check splines for burrs. lnspect rack teeth for wear, burrs, etc.

NOTE: The input shaft, spool valve, pinion and torsion bar are serviced as a balanced assembly and any of the above parts, if found defective, will require the replacement of the whole assembly. Attempts to dismantle and repair will result in a potentially dangerous unbalanced assembly.

POWER STEERING GEAR AND LINKAGE (TRW) Reassembly

1. Using tool E7000, install a new inner seal, together with the spacer, into the rack housing. Pay attention to the direction of each component as shown. 2. Fit new piston ring t o rack and lubricate ring. 3. Using protective cover (E 1404) to prevent damage to the inner seal, carefully insert the rack into the housing (L/H side). Lightly lubricate the outer surface of the protector. 4. Hold L/H end of rack and carefully draw protector out the R/H end of the housing. 5. Fit the rack end bush/seal assembly over the protective cover (E1404), then slide protective cover over the L/H end of the rack. 6. Whilst holding R/H end of rack, slide rack end bush along the cover until it clears the machined shoulder at the end of the rack. Remove cover. 7. Gently tap end bush home into rack housing. 8. Using tool E7197, rotate bush until the wire locator hole is aligned with the slot in the rack housing. 9. Insert the right angle end of the wire and rotate bush until the wire is drawn completely in. 10. Fit lower pinion bearing using suitable tool. 1 1. Lubricate rack teeth and lower pinion bearing. 12. Fit new seals to pinion valve assembly, then fit assembly t o rack housing together with pinion upper bearing. 13. Using suitable tube, tap upper bearing into housing until bearing and pinion are properly seated, then tap seal into place. 14. Fit circlip and pinion dust cover. 15. Fit yoke and yoke plug assembly and temporarily tighten.

POWER STEERING GEAR AND LINKAGE (TRW)

16. Assemble ball housing to rack, then using special tool (Litchfield No. E8802-6) torque to 80-88 Nm. (Using Special Tool, Torque Wrench will read 47.5 Nm.)

17. Drill a 4 mm dia X 10 mm deep hole into the rack adjacent to each ball housing at 90" to the rack teeth.

18. Drive a 4 mm dia X 10 mm long pin into each hole. 19. Smear a small quantity of grease in the groove on each tie rod where the sealing boot seats. Assemble boots and clips ensuring the outer clip is accessible when the steering rack is fitted to the vehicle. 20. Fit lower pinion nut and tighten (40-45 Nm). Fit lower pinion end cover and tighten.

2 1. Loosen yoke plug. 22. With rack in straight ahead position, tighten yoke plug to 4.5 Nm ten back off 15-25 degrees (using tool E8802-1). 23. Tighten yoke plug lock nut (using Tool No. E8802-2). Yoke plug must be restrained from turning during this operation. IMPORTANT: Once yoke clearance has been set gear must be racked from lock t o lock t o ensure wear has not appreciably affected setting, gear should not bind or appear tight over any part of the total travel. Should gear bind or excessive free play appear, adjust yoke plug. If this is not the cause, strip gear and examine rack and pinion for wear or damage. 24. Refit pipes to assembly.

POWER STEERING OIL PUMP Disassembly and Assembly

Bolt

Suction pipe

(When assembling pulley shaft, be careful not to damage oil seal lip.)

Pay attention to its direction.

R 69 - 78 (7.0 - 8.0,51 - 58)

31 - 4 2 (3.2 -4.3.23 -311

31 - 42 (3.2 - 4.3.23 - 31)

m:

(C1 :

N.m (kg-m, ft-lb) Lubrication points (With automatic transmission fluid "Dexron Type")

R 31 - 42 (3.2 - 4.3.23 - 31)

Pre-disassembly Inspection
Disassemble the power steering oil pump only if the following items are found. Oil leak from any point shown in the figure. Deformed or damaged pulley.

POWER STEERING O L PUMP I Disassembly

CAUTION: a Parts which can be disassembled are strictly limited. Never disassemble parts other than those specified. a Disassemble in as clean a place as possible. a Clean your hands before disassembly. a Do not use rags; use nylon cloths or paper towels. Follow the procedures and cautions in the Service Manual. a When disassembling and reassembling, do not let foreign matter enter or contact the parts.

a Remove snap ring, then draw pulley shaft out. Be careful not to drop pulley shaft.

a Remove oil seal. Be careful not to damage front housing.

Front housing

a Remove connector. Be careful not to drop spool.

SST036A

Inspection
PULLEY AND PULLEY SHAFT

a If pulley is cracked or deformed, replace it. a If an oil leak is found around pulley shaft oil seal, replace the
seal.

a If serration of pulley or pulley shaft is deformed or worn,

replace it.

POWER STEERING OIL PUMP Assembly

Assemble oil pump, noting the following instructions. Before installation, coat the 0-rings and oil seal with A.T.F.* Make sure 0-rings and oil seal are properly installed. m When assembling vanes to rotor, rounded surfaces of vanes must face cam case side. Always install new 0-rings and oil seal. Be careful of oil seal direction. * : Automatic Transmission Fluid

Rear cover side

Front housing side

Pay attention to the direction of rotor.

SST289A

m Install vanes properly.

CAUTION: Do not remove spool valve from connector or connector bolt.

Apply A.T.F.* to 0-ring.

* : Automatic Transmission Fluid

POWER STEERING OIL PUMP

Assembly (Cont'd)
Insert pin @ into pin groove @ of front housing and rotor. Then install cam ring @ as shown at left.

Front housing side Rear housing side

SST497A

Install connector properly.

SST077B

SERVICE DATA AND SPECIFICATIONS General Specifications

Steering gear type Manual Steering Power Steering

Collapsible Steering column Tilt type Turns of steering wheel (Lock to lock)

3.6

2.82

Inspection and Adjustment

GENERAL STEERING GEAR AND LINKAGE
Steering gear type Tie-rod outer ball joint swinging force' N (kg, Ib) 0.3 (0.12) or less Tie-rod inner balljoint swingingforce' N (kg. Ib) Tie-rod outer ball joint rotating torque N-m(kg-cm, in-lb) Tie-rod outer ball joint axial play mm (in) TRW (manual and power)

1-6 (10.2 61.l, 8.853.0)

Movement of gear housing

STEERING COLUMN
Steering column length Refer page ST- 13

0 (0)

(Piniongear and rack gear

Power steering

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd)

TRW Manual TRW Power

POWER STEERING PUMP

Normal operating temperature of fluid "C("F) 60-80
(140- 176)

Steering gear type Measured length mm (~n)

Pinton gear side "Q,
"

65 (2.55)

62 (2.44)
Steering wheel turning force

Opposite pinion gear side " P 2"

(Measuredat one full turn from neutral) Fluid capacity N (kg. Ib) litre

3 9 (4.9) or less

Approximately 1.o 6.669-7.257 (66.7-72.6.68-74. 967-1.052)

Oil pump maximum pressure kPa (bat, kg/crn2, psi)

(Opposite pinion gear side)

(Pinion gear side)

SST507A

Tightening Torque
STEERING COLUMN
Unit Steering wheel nut Lower joint to column Lower joint to gear Hole cover to dash panel Steering column clamp to mounting bracket N.m 29- 39 24-29 24-29 8 - 10 9 - 14 kg-m 3.0-4.0 2.4-3.0 2.4-3.0 0.8 - 1.O 0.9 - 1.4 ft-lb 22 -29 17-22 17-22 5.8 - 7.2 6.5 - 10.1

STEERING GEAR AND LINKAGE Model TRW

Unit Tie-rod to knuckle Tie-rod lock nut Ball housing to rack Gear housing clamp bolt Pinion plug Yoke plug N.m 54 - 98 78-98 80-88 84 - 108 40-50 4.5 kg-m 5.5 - 10.0 8-10 8.1 -9.0 8.6 - 11.0 4.1 -5.1 0.5 ft-lb 40 - 72 58 - 72 59-65 62 - 80 29-37 3

Then back off 15-25 degrees

BODY

SECTION

BF
, , ,

CONTENTS
GENERAL SERVICING (Including all clips & fasteners) . . . . . . . . . . . . . . . . ........................... BODY END . . . . . . . . . . . . . . . ......... . ......... . . ......... .... .................... DOOR (Including "Power Door Lock" & "Power Window" . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT PANEL . . . . ...... ............ .. . ....... ........... .. INTERIOR AND EXTERIOR (in EXTERIOR, Including "Weatherstrips" . . . . . . . . . . . . . . . . . . . . . . . . .. . . ... . SEAT . . . . . . . . . . . . . . . . . . . . .... . .................. ....................... ...... WINDSHIELD AND WINDOWS . . . . . . . . . . . . . . . . . . .. ..................... . MIRROR . . . . ...................... . . . . . . . . . . . . . . . ........ .......... REAR COMBINATION LAMP . . . . ......... . ......... ... . .. ............. BODY ALIGNMENT . . . . . . . . . .............. ......... .................... . BF- 2 BF- 6

When you read wiring diagrams: Read GI section, "HOW TO READ WIRING DIAGRAMS". See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.

GENERAL SERVICING

Precautions
m

m
m

When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent scratches. Handle trim, molding, instruments, grille, etc. carefully during removing or installation. Be careful not to soil or damage them. Apply sealing compound where necessary when installing parts. When applying sealing compound, be careful that the sealing compound does not protrude from parts. When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust prevention measures.

Clip and Fastener

m
m

Clips and fasteners in B F section correspond t o the following numbers and symbols. Replace any clips and/or fasteners which are damaged during removal or installation.
No. Symbol Shape Removal & Installation
Rmnoval: R ~ l n o v r bending u p with by a flat-bladod scrmdrivu.

SBF092B

SBFlO9B

SBF094B
2

- 4
SBF114B

Removal:

Pull up by rotating.
SBF113B SBF137B SBF115B

Removal: Remove with flat-bladed screwdrivers or pliers.

SBFllOB
J

SBFlllB

SBFllZB

GENERAL SERVICING

Clip and Fastener (Cont'd)

No.

Symbol

Shape

Removal & Installation

Removal: Tilt dip m indicated by arrow, then draw out.

Removal: Remove by bending up with flat-bladed screwdrivers

Removal:

Removal:

Push

Removal:

SBF028C

SB F029C

GENERAL SERVICING Clip and Fastener (Cont'd)

No.
Symbol Shape
I

Removal & Installation

Removal: Remove with flat-bladed screwdrivers or pliers.

I
Molded into grille corners

Litchfield tool No. E7184 required for grille removal

Removal: Holdbr portion of clip m u d be spread out to remove rod.

Screw abut with a Phillips iver.

GENERAL SERVICING
NOTE

'

BODY END Body Front End

Hood adjustment: Adjust a t hinge portion. Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease t o hood locks engaging mechanism. Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.

'r

Bumper reinforcement

After removing bumper assembly from body, disassemble fascia and reinforcement.

Reinforcement Fascia

P3) : N.m (kg-m, ft-lb)

t : Bumper assembly mounting bolts, screws & clips

BODY END Body Front End (Cont'd)

Hood lock adjustment Adjust hood so that hood primary lock meshes at a position 1 to 1.5 mm (0.039to 0.059 in) lower than fender. After hood lock adjustment, adjust bumper rubber. When securing hood lock, ensure it does not tilt. Striker must be positioned at the center of hood prlrnary lock. After adjustment, ensure that hood primary and secondary lock operate properly. Hood lock secondary latch hooking length More than 5.0 mm (0.197 in) Bumper rubber adjustment Adjust so that hood i s aligned with fender. At that time deflec. tion is approx. 0 5 mm (0.020in). [Bumper rubber free height i s approx. 22.0 mm (0.866 in)]

\secondary

latch

(2.6 - 3.3. 19 - 24)

sight shield

3k Service

tool E7184 required for removal

BODY END
Body Rear End and Opener
Trunk lid adjustment: Adjust at hinge-trunk lid portion for proper trunk lid fit. Trunk lid lock system adjustment: Adjust striker so that it is in the center of the lock. After adjustment, check trunk lid lock operation. Opener cable: Do not attempt to bend cable using excessive force. After installation, make sure that trunk lid and fuel filler lid open smoothly.

reinforcement

: Bumper assembly mounting bolts & screws : N.m ( k g m , ft-lb)

BODY END Body Rear End and Opener (Cont'd)

Type l

Fuel filler lid opener & control

6.

lid lock

After removing bumper assembly from body, disassemble fascia and reinforcement.

Fascia

SBFlOOE

DOOR Front Door

Inside handle installation

Door glass adjustment

Door glass adjustment Adjust guide rail mounting position by rotating it.

Striker adjustment

Door inner panel

Pawl Inside handle

Escutcheon

(a) :

N.m (kg-m, ft-lb)

SBF~OI E

DOOR
Rear Door

Outside handle lever 7

Door lock release lever Turn adjuster as the clearance between outside handle lever 81adjuster is specified value. A t this time, outside handle play is approx. 2 mm (0.08 in).

Striker adjustment

Door inner panel

I
/

Pawl Inside handle Pawl Escutcheon

L

nm ky
,
l /l'@
--

1-P

urn bell crank-A counterockwise (as white arrow)

"
Turn bell crank-A counterSBF102E

[C1 : N.m (kg-m, ft-lb)

EARTH

(MAIN SWITCH) DOOR LOCK SW

CIRCUIT BREAKER

DOOR LOW SWITCH

(34Ml
SMJ CONNECTOR (SEE LAST PAGE1

(DRIVERS)

yj---R~~ 4
( IFDc)

Iz;"""":~ I
LH REAR
LH FRONT

(9FDL

BATTERY

Power Door Lock Trouble-shooting

PRIORITY 1

SYMPTOM

"HOW TO REPAIR" GOto TROUBLE-SHOOTING PROCEDURE 1. PROCEDURE 2.

(
I

All doors do not operate.

I

Either one or t w o doors do not operate.

I Go t o TROUBLE-SHOOTING

This trouble-shooting must be applied according to priority. Driver's door lock does not operate by this system.

P--

DOOR Power Door Lock Trouble-shooting (Cont'd)

TROUBLE-SHOOTING PROCEDURE 1

For power window main switch, continuity should exist when pushing switch to lock/unlock. Check continuity between terand body ground. minal For auto door lock switch, continuity should exist when

Power window main switch. Check continurty between terminals @ and @, @ and @ and body ground. Auto door lock switch. Check continuity between @ and @ and body

0,

a,

Connect door lock timer conharness

switch.

ta

operation

Check door lock timer. Battery voltage should exist once for 1 second only when grounding. @ and @ terminals are reversed for lock and unlock operations. O.K.

---+ Replace door lock timer.

N.G.

and timer connector.

Go t o @ of TROUBLESHOOTING PROCEDURE 2

DOOR Power Door Lock Trouble-shooting (Cont'd)

TROUBLE-SHOOTING PROCEDURE 2
7

Disconnect door lock timer and actuator connectors.

4

@
N.G.

B
Check continuity between terr g ~@(timer) and n. 1 1 (actuator), and @(timer) and 2 (actuator). O.K. Replace door lock actuator.

Repair harness.

DOOR
Power Window
WIRING DIAGRAM

DOOR
Power Window Trouble-shooting
SYMPTOM All windows do not operate. "HOW TO REPAIR" GO t o TROUBLE-SHOOTING PROCEDURE 1. GO t o TROUBLE-SHOOTING *CEDURE 2. Go t o TROUBLE-SHOOTING PROCEDURE 3. GO t o TROUBLE-SHOOTING PROCEDURE 4.

Driver's window does not operate. Windows except driver's do not operate by sub* switches. Windows except driver's do not operate by mainX*and sub* SWitches.

* : Sub switches mean switches except driver's switch.

* *: Main switch means driver's switch.

TROUBLE-SHOOTING PROCEDURE 1
Disconnect main switch harness connector.

Check harness continuity between terminal @ and body ground. @ - Body ground: OS1

@ and body ground

(mand

O.K.

Melted
I

Not melted

Check harness and eliminate cause o f problem due t o critical short circuit. Replace fusible link.

Check power window relay. Refer t o STANDARDIZED RELAY in E L section.

Replace power window relay.

Repair harness between terminal @ and battery.

1
END

DOOR
Power Window Trouble-shooting (Cont'd)
Power wlndow amp.
IS

located in driver's

TROUBLE-SHOOTING PROCEDURE 2

I Disconnect power window amp. I connector. J 1

I Check power window motor.
1SBF132E

Check continuity. O.K.

Terminal

1 0
(Downward) (Upward)

1 Operation
Downward

I N.G.
ness between terminal @ or @ and motor.

B
I
Check voltase between terminal @ or @ a n i body ground with ignition switch ON. @ - Body ground: 12V @ - Body ground: 12V

p
I
J

lo.K.

Check fuse. Blown

SBF133E

I + O.K.
Disconnect main switch connector.

R
Q Q

Y
I

1I
l
N.G.

Reoai; harness between terminal @ battery.

L m

Check continuity.

2l
and @l.

and

1 1 [

on
051

+ Repair harness between terminals @,@,@,@or@and@, 0 ,@ or body ground (@

@)

and body ground

@ and body ground

02 5

I Connect power window amp.

connector.
I

l + O.K.

1
Check power window amp.
Auto. operation

1
Replace power window amp.

l
Ohmmeter
l

4SBF134E

Operation

and @and

@l Ground 1

(@I

Ground

I Downward
Upward

Manual operation Jumper cable connection down Operation

up

Replace power window main switch.

Manual
SBF135E

DOOR
Power Window Trouble-shooting (Cont'd)
TROUBLE-SHOOTING PROCEDURE 3

I Disconnect inoperative window I

sub switch connector.

m
I I
I

Check voltage terminal @ and body ground with ignition switch ON. @ -Body ground: 12V

II
1

O.K.

t
Replace switch. END

. Y ~ ~ !qnsS M aaeldat]

'~~I!MS qns y3aq3

'3'0

El

A Z L :punofi Apoa - @ 'NO 43l!MS UO!I!U~! ~! IM pun0~6 Apoq pue @

@ (eu!wJai uaawaq ssau

'JO~OW

INSTRUMENT PANEL
When removing instrument panel assembly, remove defroster grille, combination meter, AIC or heater control, cluster lid C and S.M.J. first.

Defroster grille

t:Instrument panel assembly

mounting bolts and nuts

INSTRUMENT PANEL

INSTRUMENT PANEL
Instrument Cluster Removal
lnstrument Case Removal Removal 1. Switch ignition "OFF" and remove key. 2. Remove steering column shroud assembly and cover ignition/ indicator switch assembly with suitable material. 3. Remove ashtray and cigarette lighter to gain access to screws for removal at lower edge of dash support cover. 4. Remove screws directly above heater air/con. panel assembly. 5. Remove bolts from steering column support bracket allowing column to drop. 6. Select and remove screws retaining cluster lid at lower edge. 7. Grasp upper edge of cluster lid and pull firmly towards rear of car (cluster lid is retained by metal spring clips at top edge) to remove. 8. Disconnect cigarette lighter wires and tilt cluster lid bottom edge up to disconnect switch harness plugs. Note: Take note of harness connection plugs and wiring to ensure that hazard warning and fog lamp switch (where fitted) connectors are not reversed on reassembly. 9. Remove upper and lower screws retaining instrument fascia. Carefully pry upper edge above instruments out, grasp and feed out instrument fascia.. Disconnect clock harness connector and slide fascia t o left of vehicle to remove. 10. Remove instrument case retaining screws. Pull bottom edge of case out and tilt up to remove harness connectors. Installation Reverse order of above.

INSTRUMENT PANEL
Instrument Panel Removal
Switch ignition "ON" and list radio presets. Switch ignition "OFF" and remove key. Disconnect battery terminals. 1. Remove lower dash cover. 2. Remove steering column shroud and cover switches. 3. Remove ashtray and screws at lower edge of dash support cover. 4. Remove screws from directly above heater control panel. 5. Remove bolts from steering column support, allow column to drop. 6. Remove screws from lower edge cluster lid, grasp upper edge of cluster lid and pull firmly to release retaining clips. 7. Disconnect cigarette lighter wires, tilt cluster bottom edge up and disconnect switch harness plugs. Note: Take note of harness connection plugs and wiring to ensure that hazard warning and fog lamp (where fitted) connector plugs are not reversed on reassembly. 8. Disconnect SMJ located near fuse holder assembly. 9. Remove glovebox, left hand dash cover and glovebox support bar. 10. Remove radio (with mount bracket), heater control surround and mounting screws for heater control assembly. 1 1. Remove outer lower dash pad retaining nuts. 12. Pry out defroster grille centre cover. SLIDE both defroster grillesTOWARDS centre of car, lift up and remove from recess. Note: Where fitted it will be necessary to locate and disconnect the sun load sensor to enable the left hand defroster grille to be lifted right out. 13. Remove the upper dash and retaining bolts, lift dash assembly partially out to remove both side defroster tubes. Remove dash pad through the left of vehicle. Installation Use reverse order of removal. Reconnect battery terminals. Switch ignition "ON", reset radio presets as previously listed. Ensure all switches/components operate correctly.

INTERIOR AND EXTERIOR Interior

SIDE AND FLOOR TRIM - Passenger room

Metal clip

Metal clip

Garnish

INTERIOR AND EXTERIOR Interior (Cont'd)

1

Type I1

Door trim

and remove it.

screw

-0
[Plug

INTERIOR AND EXTERIOR Interior (Cont'd)

LUGGAGE ROOM TR lM - Trunk space I

INTERIOR AND EXTERIOR Interior (Cont'd)

ROOF TRIM

W ~ n d s h ~ e od rear lr w~ndow glass

garn~sh

Garnish

'

INTERIOR AND EXTERIOR

Exterior
Apply sealing compound where necessary while installing parts. When applying sealing compound, be careful that the sealing compound does not protrude from parts.

INTERIOR AND EXTERIOR Exterior (Cont'd)

@ Front bumper sight shield
Refer to "Body Front End".

@ Windshield upper molding

Method 1
Cut off top portion of molding and clean glass and panel surfaces.

@ @ Hood molding and hood front seal

Apply sealant to top portion of molding.

Cut off lower portion of new molding.

Finish well t o give i t a good appearance.

Method 2

@ 0Cowl top seal and cowl top grille

1 . 'cut off sealant a t glass end. 2. Clean the side on which panel was mounted. 3. Set molding fastener and apply sealant to body panel, and apply primer to molding and body.(

sealant

-I

Apply sealant. ~ p p primer. ~ y

4. Install molding by aligning the molding mark located on center with vehicle center. Be sure to install tightly so that there is no gap around the corner.

@ Windshield lower molding

It is mounted with screws.

INTERIOR AND EXTERIOR

Exterior (Cont'd)
@ Roof side molding

Drip molding It is mounted with screws.

@ Body side welt

SBFl lOE

@ Side guard molding I

Side guard molding i s affixed with doublefaced adhesive tape. Removal: 1. Heat molding portion to 30 to 40C (86 to 104" F ) with a heat gun.

SBFlllE

@ Rear fender air drafter

/'
Heat gun

SBF455A

2. Raise end of molding and, while cutting off bonding agent, detach molding.
Installation: 1. Remove all traces of bonding agent from body panel. Then clean contact face of body. 2. Heat body panel and molding to 30 to 40C (86 to 104F) with a heat gun. Then install rnolding.
SBF742C

INTERIOR AND EXTERIOR

@ Door weatherstrip

Exterior (Cont'd) @ Rear window upper molding

Basically the same as windshield upper molding. Refer to @ Windshield upper molding.

@ Rear window lower molding

I t is mounted with screws.

@ Trunk lid weatherstrip

Vehicle center

@ Door outside rnolding

Front door
There is a marking at vehicle center.

SB F97 1 C

@ Rear bumper sight shield I

Refer to "Body Rear End".

Door outer panel

SBF114E

SEAT BELT

Front Seat Mounting

SEAT Rear Seat

SEAT BELT

r3.i

Front seat belt

Check anchors fo loose mounting.

Rear seat belt

Check retractor Check function o f buckles and tongues when buckled and released.

CAUTION: 1. If the vehicle has been involved in an accident replace the entire belt assembly, regardless of nature of accident.

2.

If the condition of any component of a seat belt is questionable, do not repair seat belt, but replace it as a belt assembly. If webbing is cut, frayed, or damaged, replace belt assembly.

4.

5.

Never oil tongue or buckle. Use only a genuine seat belt assembly. Anchor bolt

3.

(C))

24 31 (2.4 3.2.17

- 23)

WINDSHIELD AND WINDOWS Windshield and Rear Window

REMOVAL After removing moldings, remove glass.
-.
Cutting soslant

INSTALLATION
Use genuine Nissan Sealant k i t or equivalent Fdlow instructions furnished with
it.

Glass

After installation, the vehicle should remain stationary for about 24 hours. Do not use sealant which is more than 12 months past its production date. Do not leave cartridge unattended with i t s cap open. Keep primers and sealant in a cool, dry place. Ideally. they should be stored in a refrigerator. WARNING: Keep heat or open flames away a s primers are flammable.

SBF034B

Glass side

~ o d side y

CAUTION: Be careful not to scratch glass when removing.

SBF413B

Body side

4
-

lass side
L , -

Install molding fastener. When installing it, heat body panel and fastener to approx. 30 t o 40C (86t o 104Fl. Front: U D D ~ ~

Install dam rubber. Windshield

Rear window

Glass

+
Apply primer E.

I
Apply primer A.

CAUTION: Allow primers to dry for 10 to 15 minutes before proceeding to the next step.

CAUTION: Do not apply primer A to windshield opening flanges.

WINDSHIELD AND WINDOWS Windshield and Rear Window (Cont'd)

Install spacers with double-faced adhesive tape. Windshield

+
Apply sealant evenly. Rear window
Windshield

. r

N
C

More than 7 (0.28)

Vehicle center center

X 5 e

C,

m
C

Rear window

Dam rubber

Glass position

l2 (0.47'

Unit: mm (ill)
SBF118E

Spacer

CAUTION: Windshield glass should be installed within 15 minutes of applying sealant: sealant starts to harden 15 minutes after it is applied.

adhesive tape Unit: mm (in)

SBF117E

Set glass in position and press glass lightly and evenly.

Check for water leakage.

l
Install moldings.
L

CAUTION: Molding must be installed securely so that it is in position and leaves no gap.

WINDSHIELD AND WINDOWS Drying Time for Sealant

Reference: Time required f o r sealant t o dry t o desired hardness.
Unit: days Relative humidity

90
Temperature O C
(OF)

50 1.5 1.5 5.0

25
2.5

40 (104) 25 (77) 5 (41)

1.O

1.O 2.0

3.0 8.0

CAUTION: Advise the user o f the fact that vehicle should n o t be driven o n rough roads o r surfaces u n t i l sealant has properly vulcanized.

Repairing Water Leaks for Windshield and Rear Window

Leaks can be repaired without removing and reinstalling glass. If water is leaking between caulking material and body o r between glass and caulking material, determine the extent of the leak b y applying water while pushing glass outward. To stop the leak, apply primer and then sealant t o the leak point.
Flat stick Trimming

Work into joints

Polysulphide or polyurethane sealant

SBF543B

Afterwards, install molding securely.

MIRROR
Door Mirror
WIRING DIAGRAM

REAR COMBINATION LAMP

Rear combination lamps are installed with nuts and butyl sealant.

BODY ALIGNMENT
All dimensions indicated in figures are actual ones. When a tram tracking gauge is used, adjust both pointers to equal length and check the pointers and gauge itself to make sure there is no free play. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. Measurements should be taken a t the center of the mounting holes. An asterisk ( * ) following the value a t the measuring point indicates that the measuring point on the other side is symmetrically the same value. The coordinates of the measurement points are the distances measured from the standard line of "X", IIylf and UZ#l.
"X"

m.
"Y"

"Y"

"X"

: L.H. side : R.H. side

"X" : Vehicle center "Y" : Center line of front axle "2" : Imaginary base line [200 mm (7.87 in) below datum line ("02" at design plan)]

Engine Compartment
MEASUREMENT

Unit: mm (in)

BODY ALIGNMENT

BODY ALIGNMENT
Engine Compartment (Cont'd)
Points Hole d ~ a . mm ( n i) Deta~led points Coordinates mm (in)

"X"

"Y"

"2"

9 (0.35)

Harness clamp mounting hole on front side

-30.0 483.0 438.7 (-1.181) (19.02) (17.27)

SBF083E

Locat~ng hole

16 (0.63)
member

@ -260.0 425.0 459'4 (-10.24) (16.73) ( 8.09) 1

SBF084E

B@ (

16(0.63)

Locat~ng hole on front s~de member

-527.0 465.0 400 0 (18.31) (-20.75) (15.75)

SBF085E

4 (0.16)

Locatlng hole on rad~ator core upper support

-635.0 685 0 00 (0.00) (-25.00)/ 126.97)

I

1 1 (0.43)

Hood lock mount~ng hole on rad~ator core upper support Hood lock stay mountlng hole on rad~ator core lower support Harness clamp mountlng hole on radiator core side support

-681 6 63'3 0 70.0 (2.7561 (-26.83); 124.92)

-l

1 1 (0.43)

0.0 -694.0 (0.00) (-27 32) / 1 490.0 ( 1 9 29)

l

240 0 (945)

8 (0.31)

SBF086E

-606.9 / 515 0 (-23.89) (20.28)

BODY ALIGNMENT
Underbody
MEASUREMENT

a e

111

E
.C"
+

v;
.c
2
U
C

5
,

.E B z m
U .U C .C

"

.L
,

.-

E g

g
E
m w

:
C = .

E .- &
u

St

BODY ALIGNMENT
Underbody (Cont'd)
MEASUREMENT POINTS

BODY ALIGNMENT
Underbody (Cont'd)
Points Hole dia. mm (in) Coordinates mm (in) Detailed points

"X"
Front bumper mounting hole on underside of front side member Locating hole on underside of front side member center extension Locating hole on underside of front side member rear extension Locating hole on underside of rear side member front. portion

"Y"

"2"

($

16 (0.63)

-560.0 517.0 (20.35) (-22.05)

340.0
( 13.39)

14 (0.55)

414.5
( 16.32)

700.0 (27.56)

1 10.0 (4.33)

@ @

16 (0.63)

412.5 (1 6.24)

1,625.0 (63.98)

109.3 (4.30)

16 (0.63)

2,070.0 575.0 (22.64) (81.50)

234.0 (9.21)

16 (0.63)

SBF427B

@ 2,864.0 493'0 (1 12.76) (19.41)

Locating hole on underside of rear side member

328.0 (12.91) 328.0 (12.91)

K '

l6 (0.63)

2,987.0 575.0 (1 17.60) (22.64)

16 (0.63)

570.0 330.0 (22.44) 3,080.0 (12.99) (121.26) 575.0 (22.64) 570.0 330.0 (22.44) 3,330.0 (131.10) (12.99) 575.0 (22.64)

12 (0.47)

Locating hole on underside of rear side member rear portion

BODY ALIGNMENT
Underbody (Cont'd)
Detailed points

on radiator core

Front strut upper

Rear strut upper

17 (0.67)
Front

Transverse link mounting hole on front suspension mounting lower member on front suspensionmounting lower member Transverse link

353.0 (13.90)

106.2 (4.18)

142.7 (5.62)

342.5 (13.48)

139.5 (5.49)

145.6 (5.73)

17 (0.67)
SBF088 E

on dash lower crossmember

402.0 (15.83)

378.9 (14.92)

157.2 (6.19)

0s
SBF089E

Radius rod mounting hole on rear suspension radius rod bracket

496.0 (19.53)

1,969.2 (77.53)

183.9 (7.24)

BODY ALIGNMENT

Underbody (Cont'd)
Points Hole dia. Coordinates mm (in) Detailed points

Rear suspension

HEATER & AIR CONDITIONER

SECTION

HA!
...

CONTENTS
AIR FLOW AND COMPONENT LAYOUT. . . . . . . . . . .. ... . . . .. . . . . ...... .... . DOOR CONTROL HEATER ELECTRICAL CIRCUIT .... . . . ... .. . . . . PREPARATION . . .. . . . ... PRECAUTIONS . . .. . .. PRECAUTIONS FOR REFRIGERANT CONNECTION . . . . ... ... DISCHARGING, EVACUATING, CHARG~NG AND CHECKING . . . . . . SERVICE PROCEDURES. . . ..... .. . . . . . . . .. .. . .... .... A/C PERFORMANCE TEST . . . . . ... .. .. .. .. ELECTRICAL COMPONENTS - Inspection . . . . . . ... .. . . . . .... .... ... TROUBLE DIAGNOSES SERVICE DATA AND SPECIFICATIONS (S.D.S.) . .
. . . ,
, ,

... ... . ...

....
...

. ..
.

.. . . .

.. . .
... .

.. . . ...

HA- 2 HA- 4 HA- 6 HA- 7 HA- 8 HA- 9 HA- 10 HA-16 HA-20 HA-26 HA-28 HA-38

When you read wiring diagrams: Read GI section, "HOW TO READ WIRING DIAGRAMS". a See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.

AIR FLOW AND COMPONENT LAYOUT Air Flow

\ S&L~+ 1

Floor

@ T o defroster

Ventilation

Intake lever Air control lever \.

\. .

A/C switch

Floor and defroster

Temperature control lever

- . ; . I ( [r
L Fan lever

.--

Bi-level

Defroster

m T o ventilator

@ T o defroster

1 Air passed through heater core :

@
: Mixed air (

+@

: Air not passed through heater core

AIR FLOW AND COMPONENT LAYOUT Component Layout

Heater duct (Heater)

Defroster ductC7

Center ventilator duct*

Air conditioner)

Control assembly

Side ventilator ductC A/C switch

L Control finisher

For removal, it is necessary to remove instrument assembly.

DOOR CONTROL Control Cable Adjustment

When disconnecting the control cable, remove the E-ring and take off the cable while pushing the cable outer in the direction of the arrow.

AIR CONTROL CABLE

Clamp the cable while pushing cable outer and side link in direction of arrow. After positioning control cable, check it operates properly.

WATER COCK CONTROL ROD

When adjusting water cock control rod, first disconnect temperature control cable from air mix door lever. Reconnect and readjust temperature control cable.

1. Push air mix door lever in direction of arrow. 2. Pull control rod of water cock in direction of arrow so as to make clearance of about 2 mm (0.08 in) between ends of rod and link lever and connect the rod to door lever. After connecting control rod, check it operates properly.

TEMPERATURE CONTROL CABLE

Clamp the cable while pushing cable outer and air mix door lever in direction of arrow. After positioning control cable, check it operates properly.

I G N S ON OR START W

F
I G N S ON OR ACC W SMJ CONNECTOR (SEE LAST PAGE1 0 i ' B ~ / c m t 0 ~ / B

RAD FAN RELAY I

RAD FAN RELAY 2

PRESSURE SWITCH

COMPRESSOR AIR CON RELAY

IREF POWER SUPPLY)~ FUSE BLOCK '

I G N I T I O N SWITCH- ON OR ACCESSORY

? l

1
0

BLGWR

RA0 FAN MOTOR #P

RAD FAN MOTOR X I

p,

7
I

I COMPRESSOR

FUSIBLE LINKS

; ; :k[ & A

(ISM)

EARM

0 H
'4M) 0 (90Ml

HEATER SWITCH

BATTERY

RAD FAN RELAY l IGN S ON O START W R

IGN S ON OR ACC W

1
r

FUSE BLOCK

(REF POWER SUPPLY1

'd
R -

SMJ CGWECTOR (REF LAST PAGE)

CIO--

IGNITION

SWITCH-

O OR ACCESSORY N

( I

IM)

RAD FAN MOTOR 12

HEATER
SWITCH

PREPARATION
SERVICE TOOLS
Tool name
1

Description
-3 ' a

Manifold gauge

To discharge and charge refrigerant into system

Charging hose

To discharge and evacuate, charge refrigerant into system

Charge valve

To discharge and charge refrigerant into system

Thermometer

T o check temperature

Vacuum pump

To evacuate refrigerant system

% h

Electric leak-detector

Nominal sensitivity: 15 - 25 g (0.53 - 0.88 oz)lyrar

To locate refrigerant leaks

Note: m State and Federal Regulations may affect any operations involving refrigerant gas. Care should be taken to ensure that these are conformed with. WARNING: Always wear eye protection when working around the system. m Always be careful that refrigerant does not come in contact with your skin. m Keep refrigerant containers stored below 40C (104OF) and never drop from high places. m Work in well-ventilated area because refrigerant gas evaporates quickly and breathing may become difficult due to the lack of oxygen. m Keep refrigerant away from open flames because poisonous gas will be produced if it burns. m Do not increase can temperature beyond 40C (104OF) in charging. m Do not heat refrigerant can with an open flame. There is danger that can will explode. CAUTION: Do not use steam to clean surface of condenser or evaporator. Be sure to use cold water or compressed air. m Compressed air must never be used to clean a dirty line. Clean with refrigerant gas.

Valve press p o i n t

Do not use manifold gauge whose press point shape is different from that shown. Otherwise, insufficient evacuating may occur.

N.G.

sk1~919A

Do not over-tighten service valve cap. Do not allow refrigerant to rush out. Otherwise, compressor oil will be discharged along with refrigerant.

PRECAUTIONS FOR REFRIGERANT CONNECTION

WARNING: Gradually loosen discharge side hose fitting, and remove i t after remaining pressure has been released. CAUTION: When replacing or cleaning refrigerant cycle components, observe the following. Do not leave compressor on its side or upside down for more than 10 minutes, as compressor oil will enter low pressure chamber. When connecting tubes, always use a torque wrench. After disconnecting tubes, plug all openings immediately to prevent entrance of dirt and moisture.

Always replace used 0-rings. When connecting tube, apply compressor oil to portions shown in illustration. Be careful not to apply oil to threaded portion. 0-ring must be closely attached to inflated portion of tube.

Inflated portion

un'On&

m'cizZz3
-'F

@ fps3

After inserting tube into union until 0-ring is no longer visible, tighten nut to specified torque. After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the 0-ring. Then tighten connections of seal seat to the specified torque.

SH A898A
+

DISCHARGING, EVACUATING, CHARGING AND CHECKING

Discharge refrigerant system.

Discharging

Run pump for 5 minutes

Evacuating the System

Charging

Charge refrigerant into system.' When low-pressure gauge reading is 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi), completely close high-pressure valve of rnanifold gauge and stop charging.

1 1 /
Run pump for 20 minutes.

Evacuating the System

Charge the specified amount of refrigerant into system

Charging

DISCHARGING, EVACUATING, CHARGING AND CHECKING

T o low-pressure servtce valve T o htgh-pressure serv~ce valve

Slowly open the valves to discharge only refrigerant. If they are opened quickly, compressor oil will also be discharged.
C

Slowl

open

SHA240B

T o low-pressure service valve

T o htgh-pressure servtce valve

Evacuating the S se - y t m11

1. Start pump, then open both valves and run pump for about 5 minutes. 2. When low gauge has reached approx. 101.3 kPa (1,013 mbar, 760 mmHg, 29.92 inHg), completely close both valves of gauge and stop vacuum pump. Let it stand for 5 to 10 minutes in this state and confirm that the reading does not rise. a. The low-pressure gauge reads lower by 3.3 kPa (33 mbar, 25 mmHg, 0.98 inHg) per 300 m (1,000 ft) elevation. Perform evacuation according to the following table. b. The rate of ascension of the low-pressure gauge should be less than 3.3 kPa (33 mbar, 25 mmHg, 0.98 inHg) in 5 minutes.

Vacuum p u m p Elevation m (ft)

SHA241B

Vacuum of system* kPa (mbar, mmHg, inHg)

* : Values show reading o f the low-pressure gauge.

1. Evacuate refrigerant system. Refer to 1. "2. Close manifold gauge valves securely and disconnect charging hose from vacuum pump. 3. Purge air from center charging hose. 1) Connect center charging hose to refrigerant can through charge valve. 2) Break seal of refrigerant can and purge alr.

4. Charge refrigerant into system. WARNING: Ensure that engine is off. 1) Open high-pressure valve of manifold gauge and charge refrigerant into system.

DISCHARGING, EVACUATING. CHARGING AND CHECKING

-

C h a r g i n g - m ] (Cont'd)
T o low-pressure service valve T o high-pressure service valve

CAUTION: If charging liquefied refrigerant into system with the can turned upside down to reduce charging time, charge it only through high-pressure (discharge) service valve. After charging, the compressor should always be turned several times manually.

2) When low-pressure gauge reading is 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi), completely close high-pressure valve of manifold gauge and stop charging.
SHA244B

T o low pressure service valve

To h~gh-pressure service valve

Evacuating the ~ ~ s t e r n - m
1. Close manifold gauge valve securely and disconnect charging hose from refrigerant can. 2. Connect center charging hose to vacuum pump. 3. Start pump, then open both valves and run pump for about 20 minutes.

Vacuum pump

1 J Ltql tr+;
Low

$i ,$

High

Open

Open

*+.( I
6

SHA241B

(Below 1,500 rpm T o low-pressure service valve

T o high-pressure

1. Charge refrigerant into system Refer to " 1 ". WARNING:

SHA245B

Max~murn cold and s ~ e e d

4

Ensure that engine is off. 1) Open low-pressure valve of manifold gauge and charge refrigerant into system. 2) When refrigerant charging speed slows down, close highpressure valve of manifold gauge and open low-pressure valve of manifold gauge and charge refrigerant while running the compressor for ease of charging. 3) Start engine - Air conditioning system ON, maximum temperature set, maximum blower speed. Open lowpressure valve on gauge set, with can in upright position, and monitor sight glass. Charge is complete when sight glass is clear.

DISCHARGING, EVACUATING, CHARGING AND CHECKING

Charging -[Point-51 (Cont'd)
Cycling clutch systems will produce bubbles in sight glass when clutch engages. Therefore, allow 5 seconds after clutch engages to determine if bubbles continue, and, if so, add refrigerant to clear sight glass. WARNING: Never charge refrigerant through high-pressure side (discharge side) of system since this will force refrigerant back into refrigerant can and can may explode. 4. Charge refrigerant while controlling low-pressure gauge reading at 275 kPa (2.75 bar, 2.8 kg/cm2, 40 psi) or less by turning in or out low-pressure valve of manifold gauge. a Be sure to purge air from charging hose when replacing can with a new one.

5. Charge the specified amount of refrigerant into system by weighing charged refrigerant with scale. Overcharging will cause discharge pressure to rise. Refrigerant amount: 0.8 0.9 kg (1.8 - 2.0 Ib) The state of the bubbles in sight glass should only be used for checking whether the amount of charged refrigerant is small or not. The amount of charged refrigerant can be correctly judged by means of discharge pressure. 6. After charging, be sure to install valve cap on service valve. 7. Confirm that there are no leaks in system by checking with a leak detector. a When refrigerant charging is performed with a charging cylinder, charging station, or automatic charging equipment, engine off, charge only through high side, after specified refrigerant amount has entered the system, close high pressure valve on gauge set. Start engine return to idle speed, operate AIC at maximum temperature setting, high blower. Observe sight glass to confirm complete charge. Overcharging will result in increased high pressures, and reduced performance.

DISCHARGING, EVACUATING, CHARGING AND CHECKING Checking Refrigerant Level

CONDITION Door window: A/C switch: TEMP. lever position: FAN lever position: Check sight glass after a minutes.
Open ON Max. COLD 4 lapse of about five

Almost n o refrigerant Check item Temperature of highpressure and l o w pressure lines. Almost n o difference between high-pressure and low-pressure side temperature. Bubbles f l o w continuously. Bubbles w i l l disappear and something like mist w i l l f l o w when refrigerant is nearly gone.

lnsuff icient

Suitable

T o o much refrigerant

is High-pressure s ~ d e warm is and low-pressure s ~ d e fairly cold.

High-pressure side is h o t and low-pressure side is cold.

High-pressure side is abnormally hot.

State i n sight glass.

The bubbles are seen at intervals o f 1 - 2 seconds.

Almost transparent. Bubbles may appear when engine speed is raised and lowered.

N o bubbles can be seen.

N o clear difference exists between these t w o conditions.

AC256

AC257 B o t h pressures o n hlgh and low-pressure sides are slightly low. Check for gas leakage, repair as required, replenish and charge system. B o t h pressures o n high and low-pressure sides are normal.

AC258

Pressure of system.

High-pressure side 1 abs normally low.

B o t h pressures o n high and low-pressure sides are abnormally high. Discharge refrigerant f r o m service valve of l o w pressure side.

Repair.

Stop compressor !mmediately and conduct an overall check.

a.

The bubbles seen through the sight glass are influenced by the ambient temperature. Since the bubbles are hard t o show u p in comparatively l o w temperatures below 20C (68"F), it is possible that a slightly larger amount o f refrigerant would be filled, i f supplied according t o the sight glass. Recheck the amount when it

I exceeds 20C (68F). n higher temperature the bubbles are easy t o show up. b. When the screen i n the receiver drier is clogged, the bubbles w i l l appear even if the amount or refrigerant is normal. I n this case, the outlet side pipe o f the receiver drier becomes considerably cold.

DISCHARGING, EVACUATING, CHARGING AND CHECKING

Checking Refrigerant Leaks
ELECTRIC LEAK DETECTOR
The leak detector is a delicate device that detects small amounts of halogen. To use the device properly, read the manufacturer's manuals. Also perform the specified maintenance and inspections.

UNION TYPE

GENERAL PRECAUTIONS FOR HANDLING LEAK DETECTOR

Place the probe on connection fitting and wait for 5 seconds or more. To check cooling unit, wait for 10 seconds or more. Keep the probe as still as possible for one more minute.

RHA279

PLATE TYPE

When testing single-bolt flange, place the probe on the opposite side of the fitting.

R HA280

MEASUREMENT STANDARD
If any leak is noted with a detector having a nominal sensitivity of 15 to 25 g (0.53 to 0.88 oz)/year, that leak must be repaired. The nominal sensitivity of the detector is determined under the assumption that all the leaking gas is collected by the detector. Accordingly, the quantity of gas actually leaking can amount to five to ten times the indicated value. Generally speaking, leakage of 150 to 200 g (5.29 to 7.05 oz) of refrigerant can cause insufficient cooling. Oil deposited during assembling must be wiped off before inspection. Refrigerant easily dissolves in oil, and the presence of oil can cause an error in measurement. This precaution is important when checking a used car for refrigerant leakage. If oil is noted at or around connections, it indicates that refrigerant is leaking.

SERVICE PROCEDURES Refrigeration Cycle

REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the receiver drier, through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case.

FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the compressor operation. When the evaporator coil temperature rises above the specification, the thermo control amplifier allows compressor operation.

REFRIGERANT SYSTEM PROTECTION

Dual-pressure switch The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch, located on the receiver drier. If the system pressure rises above, or falls below the specifications, the dual-pressure switch opens to interrupt the compressor operation. Pressure Relief valve Opens at a pressure above 3.3 Mpa thereby discharging refrigerant t o the atmosphere. If this valve has opened, check the refrigerant system for faults and rectify before recharging.

Receiver drier Fusible plug Dual-pressure switch

SERVICE PROCEDURES Refrigerant Lines

Cooling u n i t High-pressure (Discharge) service valve

: N m (kg-m, f t - l b )
RHA296A

SERVICE PROCEDURES
Compressor Oil Checking and Adjusting
The oil used to lubricatethe compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. OIL CAPACITY
Unit: ml

3. Check the purity of the oil and then adjust oil level following the procedure below. (a) When oil is clean;
Unit: m1 Amount of oil drained Adjusting procedure Oil level is right Pour in same amount of oil as was drained out. Oil level may be low Below 7 0 Pour in 70 ml of oil

Above 70'

Applied model Caoacitv Total in system

All models

200

": If amount of oil drained is much greater than under normal circum-

stances, flush air conditioner system with refrigerant. Then pour in 200ml of oil into air conditioner system

Amount of oil which can be drained

Approx. 100'

Compressor (Service parts) charging amount

200

*: All oil cannot be drained from system

(b) When oil contains chips or other foreign material; After air conditioner system has been flushed with refrigerant, replace receiver drier. Then pour in 200 m of oil into air conditioner system. 1

OIL RETURN OPERATION Before checking and adjusting oil level, operate compressor at engine idling speed, with controls set for maximum cooling and high blower speed, for 20 to 3 0 minutes in order to return oil to compressor.

CHECKING AND ADJUSTING FOR COMPRESSOR REPLACEMENT

200 ml of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from new compressor. Follow the procedure below. 1. After oil return operation, drain compressor oil from used compressor and measure the amount. (It is the same procedure as CHECKING AND ADJUSTING FOR USED COMPRESSOR.)

CHECKING AND ADJUSTING FOR USED COMPRESSOR 1. After oil return operation, stop the engine and discharge refrigerant and then remove compressor from the vehicle. 2. Drain compressor oil from compressor discharge port and measure the amount. Oil is sometimes hard to extract when compressor is cooled. Remove oil while compressor is warm [maintained to 4 0 to 50C (10 4 to 122"F)I.

SERVICE PROCEDURES
Compressor Oil Checking and Adjusting (Cont'd)
2. Check the purity of the oil and then adjust oil level following the procedure below. (a) when oil is clean;
Unit: ml Amount of oil drained from used compressor Above 70" Below 9 0 Draining amount of oil from new compressor 200 - [Amount of oil drained 201

70

*: If amount of oil drained is much greater than under normal circumstances, flush air conditioner system with refrigerant. Then install

new compressor [200 ml of oil is charged compressor service parts].

Example:
Unit: ml Amount of oil drained from used compressor 100 60 Draining amount of oil from new compressor 80 70

L l

1
E I

(b) When oil contains chips or foreign material; After air conditioner system has been flushed with refrigerant, replace receiver drier. Then install new compressor [200 ml of oil is charged in compressor service parts].

A/C PERFORMANCE TEST Performance Chart

TEST CONDITION
Testing must be performed as follows: Vehicle location: Indoors or in the shade (in a well ventilated place) Doors: Closed Door window: Open Hood: Open TEMP. lever position: Max. COLD Air control lever position: a * (Ventilation) # (Recirculation) INTAKE lever position: FAN lever position: Max. position Engine speed: 1,500 rpm Time required before starting testing after air conditioner starts operating: More than 10 minutes

TEST READING
Recirculating-to-discharge air temperature table

Inside air (Recirculating air) at blower assembly inlet Relative humidity % Air temperature "C ("F) 25 (77)

Discharge air temperature at center ventilator "C ( O F )

7.0 - 10.0 (45 - 50) 12.0 - 16.0 ( 5 4 - 6 1 ) 17.0 - 2 1.O (63 - 70) 9.0 - 12.0 (48 - 54) 14.0 - 18.0 (57 - 64) 19.0 - 23.0 (66 - 73)

55 - 60

30 (86) 35 (95) 25 (77)

60 - 65

30 (86) 35 (95)

Ambient air temperature-to-compressor pressure table

I

Ambient air Relative humidity % Air temperature "C ("F) High-pressure (Discharge side) kPa (bar, kg/cm2, psi) Low-pressure (Suction side) kPa (bar, kg/cm2, psi)

A/C PERFORMANCE TEST

Performance Test Diagnoses
Characteristics revealed by the manifold gauge readings for the air conditioning system are shown in the following. For how to do the performance test, refer to the item "Performance Chart".

In the following table, the portion smeared with ink on each gauge scale indicates the range showing that the air conditioning system is in good order. This range is described in Performance Chart.

Condition INSUFFICIENT REFRIGERANT CHARGE Insufficient cooling. Bubbles appear in sight glass.

Probable cause

Corrective action

Refrigerant is low, or leaking slightly.

1 . Leak test. 2. Repair leak. 3. Charge system.

Evacuate, a necessary, and s recharge system.

ALMOST NO REFRIGERANT No cooling action. Serious refrigerant leak.

Stop compressor immediately.

A lot of bubbles or something like mist appears in sight glass.

1. 2. 3. 4.

Leak test. Discharge system. Repair leak(s). Replace receiver drier if necessary. 5. Check oil level. 6. Evacuate and recharge system.

AC353A

FAULTY EXPANSION VALVE Slight cooling. Sweat or frosting on expansion valve inlet. Expansion valve restricts refrigerant flow. Expansion valve is clogged. Expansion valve is inoperative. Valve stuck closed. Thermal bulb has lost charge. If valve inlet reveals sweat or frost: 1. Discharge system. 2. Remove valve and clean it. Replace i t if necessary. 3. Evacuate system. 4. Charge system. I f valve does not operate: 1. Discharge system. 2. Replace valve. 3. Evacuate and charge system.

AC354A

A/C PERFORMANCE TEST Performance Test Diagnoses (Cont'd)

Condition lnsufficient cooling. Sweat on suction line.

Probable cause Expansion valve allows too much refrigerant through evaporator.

Corrective action Check valve for operation. If suction side does not show a pressure decrease, replace valve.

No cooling. Sweat or frosting on suction line.

Faulty expansion valve.

1. Discharge system. 2. Replace valve. 3. Evacuate and charge system.

AIR IN SYSTEM

I Insufficient cooling.
Sight glass shows occasional bubbles.

( Air mixed with refrigerant

in system.

1. Discharge system. 2. Replace receiver drier. 3. Evacuate and charge system.

1 MOISTURE

IN SYSTEM

1
After short operation, suction side may show vacuum pressure reading. During this condition, discharge air will be warm. As a warning of this, reading vibrates around 39 kPa (0.39 bar, 0.4 Drier is saturated with moisture. Moisture has frozen in expansion valve. Refrigerant flow is restricted.
1. Discharge system. 2. Replace receiver drier (twice if necessary). 3. Evacuate system completely. (Repeat 30minutes evacuating three times.) 4. Recharge system.

A/C PERFORMANCE TEST Performance Test Diagnoses (Cont'd)

Condition

I
No cooling action: engine may overheat. Bubbles appear in sight glass of drier. Suction line is very hot.

Probable cause

Corrective action

FAULTY CONDENSER Usually a malfunctioning condenser. Check radiator fan motors. Check condenser for dirt accumulation. Check engine cooling system for overheating. Check for refrigerant overcharging. I f pressure remains high i n spite of all above actions taken, remove and inspect the condenser for possible oil clogging.

l HIGH PRESSURE LINE

BLOCKED

l
Drier clogged, or restriction in high pressure line.

I Insufficient cooling.
Frosted high pressure liquid line.

1. Discharge system.

2. Remove receiver drier

or strainer and replace it. 3. Evacuate and charge system.

FAULTY COMPRESSOR

lnsufficient cooling.

Internal problem in compressor, or damaged gasket and valve.

1. Discharge system. 2. Remove and check compressor. 3. Repair or replacecompressor. 4. Check oil level. 5. Replace receiver drier. 6. Evacuate and charge system.

A/C PERFORMANCE TEST Performance Test Diagnoses (Cont'd)

Condition Insufficient cooling. Probable cause Too much oil circulates with refrigerant, causing the cooling capacity o f the system to be reduced. Corrective action

Refer to COMPRESSOR O I L
for correcting oil level.

SYSTEM (Excessive)

AC364A

A/C PERFORMANCE TEST

Notes:

ELECTRICAL COMPONENTS

Inspection
BLOWER RESISTOR
Check continuity between terminals.

FAN SWITCH
Check continuity between terminals at each lever position shown in the table.

AIC SWITCH
Check continuity between terminals at each switch position.

ELECTRICAL COMPONENTS Inspection (Cont'd)

THERM0 CONTROL AMP.
1. Run engine, and operate A/C system. 2. Connect the voltmeter from harness side. 3. Check thermo control amp. operation shown in the table.
Evaporator outlet air temperature Thermo amp. operation Turn OFF Turn ON Tester Approx. 12V Approx. OV

"c
Decreasing t o 1.5 k 0.7 Increasing t o 2.8 k 0 . 3

THERMAL PROTECTOR
Temperature of compressor

"c
Increasing t o approx. 135- 145 Decreasing t o approx. 120- 130

Operation Turn OFF Turn ON

TROUBLE DIAGNOSES

CONTENTS
HOW TO READ SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-28 INSPECTION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HA-29 PRELIMINARY CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-29 . CIRCUIT FOR TROUBLE DIAGNOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer HA-6 & 7 TROUBLE SHOOTING PROCEDURE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-3 1 (INCIDENT: Blower motor does not rotate.) TROUBLE SHOOTING PROCEDURE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-33 (INCIDENT: A/C does not blow cold air.) TROUBLE SHOOTING PROCEDURE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-34 (INCIDENT: Magnet clutch does not operate.)

HOW TO READ SYMBOLS

Symbols are shown in the illustrations to clarify the checking conditions. The checking conditions indicated by each symbol are as follows:

Ignition switch is ON.

1
/El
X or-

: :

A/C switch is ON.

A/C switch is OF F.
:

Ignition switch i s OFF.

Fan switch is ON. ( A t any position except for OFF position) Fan switch is OFF.

*a-

1 1 l=!

: : :

VENT switch is ON. VENT switch is OFF. REC switch is ON. REC switch is OFF.

TROUBLE DIAGNOSES Trouble-shooting (Cont'd)

INSPECTION TABLE
INSPECTION PORTION

Th~s table ~ n d i c a t the mnrpstoon portion for each lyp. of incklant. r For locatoon, refer ro PRELIMINARY CHECK '1

PRELIMINARY CHECK
Compressor belt tension check Check compressor belt deflection. Adjust if belt deflection exceeds the limit. Refer to "Checking Drive Belts" in MA section. Power supply circuit check for air conditioning system Check power supply circuit for air conditioning system. Refer to "Power Supply Routing" in EL section and A/C ELECTRICAL CIRCUIT.

TROUBLE DIAGNOSES
-

Trou ble-shooting (Cont'd)

Thermo control amp.

connector

a m
Voltmeter

Thermo control amp. check Check power supply circuit for thermo control amp. with ignition switch ON. 1. Disconnect thermo control amp. harness connector. 2. Connect voltmeter from harness side. 3. Measure voltage across terminal No. @ and body ground.
Voltmeter terminal Voltage
Body ground

Approx.

12V

Thermo control amp. connector

Ohmmeter

Check body ground circuit for therm0 control amp. with ignition switch OFF, AIC switch ON and fan switch ON. 1. Disconnect thermo control amp. harness connector. 2. Connect ohmmeter from harness side. 3 Check for continuity between terminal N o @and body ground. Ohmmeter terminal

I
Continuity exists: O.K.

-l

Continuity Yes

Body ground

TROUBLE DIAGNOSES Trouble-shooting (Cont'd)

INCIDENT Flowchart No.
7

TROUBLE-SHOOTING PROCEDURE 1
INCIDENT: Blower motor does not rotate. Perform preliminary check before referring to the following flowchart.
Check if blower motor rotates properly at each fan speed. Conduct check a per flowchart s at left.

Fan falls to rotate. Fan does not rotate at

r
l2

I speed.
Fan does not rotate at 2-speed. Fan does not rotate at 3-speed. Fan does not rotate at 4-speed.

3!

, ! !L
r-

2 A Q x r F

B
voltmeter Blower motor connector @

Check power supply for blower motor. Disconnect blower motor harness connector. Do approx. 12 volts exist between blower motor harness terminal No. @ and body ground?

(Refer to Preliminary Check.)

B
RHA30,A

O.K.

Check circuit continuity between blower motor harness terminal No. ground.

Reconnect blower motor harness connector.

'

El
Ohmmeter Blower motor connector @

@ and body
0.K.

Continuity

exists O.K.

B
RHA310A

v
Disconnect blower motor and resistor harness connectors.

Check blower motor circuit between blower motor and resistor. Do approx. 12 volts exist between resistor harness terminal No. @ and body ground?

O.K.

tween blower motor harness terminal No. @ and resistor harness terminal No. @ .

Mote: If the result is N.G. after checking circuit continuity, repair harness or connector.

TROUBLE DIAGNOSES
Trou ble-shooting (Cont'd)
Fan w i t c h connector

I Check resistor after discon(Refer to HEATER ELECTRICAL CIRCUIT.)

L k

1 O.K.
RHA312A

I N.G.
Replace resistor.

Fan switch connector

Reconnect resistor harness connector.

Ohmmeter

1 L

I-,

&

Continuity exists: O . K .

RHA313A

tween each fan switch harness terminal and body ground?

Flowchart

Voltage

'a
3
4,

O.K.

N.G.

Note

7-

Check circuit continuity between fan switch and resistor.

Check fan switch after disconnecting it. Refer to A/C ELECTRICAL COMPONENTS.

Re~lace switch. fan

O.K.

Note

Check circuit continuity between fan switch harness terminal No. @and body ground.

/ Replace blower motor

Note: I f the result is N.G. after checking circuit continuity, repair harness or connector.

TROUBLE DIAGNOSES Trouble-shooting (Cont'd)

TROUBLE-SHOOTING PROCEDURE 2
INCIDENT: AIC does not blow cold air. a Perform preliminary check before referring to the following flowchart.

I Does air flow from vents?

Condition Ignition switch, A/C switch, and fan switch are ON. Mode lever is in vent mode and temperature lever is in full cold position. O.K. Does radiator fan motor rotate? circuit. Refer to COOLING FAN CONTROL in section ES Condition Ignition switch, A/C switch and fan switch are ON. O.K. Check for refrigerant leaks.

N.G.

Is blower motor operating normally?

( yes

I Check blowzr motor

operation. Go t o TROUBLESHOOTING PRO-

I No

r?-?

Check for evaporator coil freeze-

Remove intake unit. Check if evaporator freezes. N.G. O.K.

+--

N.G.

Check refrigerant. Connect manifold gauge, then check system pressures. Measure temperature of discharge air. (Refer to A/C PERFORMANCE TEST.)

for air leaks.

Check thermo control amp. operation. Refer to AIC ELECTRICAL COMPONENTS.

Go t o TROUBLE-SHOOTING PROCEDURE 3.

N.G.

1 O.K.

I I

Check compressor operation.

Check air mix door adjustment. Refer to Door Control.

J

1 O.K.
]

Check evaporator outlet air t e m perature.

Check refrigeration cycle Go to PERFORMANCE TEST DIAGNOSES. Refer t o Performance Chart.

Check thermo control amp. operation.

-

Refer to AIC ELECTRICAL COMPONENTS.

TROUBLE DIAGNOSES
Trouble-shooting (Cont'd)
compressor connector

TROUBLE-SHOOTING PROCEDURE 3
INCIDENT: Magnet clutch does not operate. m Perform preliminary check before referring to the following flowchart.

Voltmeter

Check power supply for compressor. Disconnect compressor harness connector. Do approx. 12 volts exist between compressor harness terminal No. @ and body ground?

N.G.
b

R H A ~ I ~ A

connector.

O.K.

Check thermal protector.

N.G. + Replace thermal protector.

Ohmmeter Continuity exists: O.K.

R A l A

l
l

Disconnect thermal protector harness connector. Does continuity exist between thermal protector harness terminal No. @ and body ground?
I

O.K. Check magnet clutch coil. O.K. Replace magnet clutch.

TROUBLE DIAGNOSES Trouble-shooting (Cont'd)

1
Check A/C relay operation. Do approx. 12 volts exist between A/C relay harness terminal No. @ and body ground?

---+ Check power supply for A/C

relay. Disconnect A/C relay. Do approx. 12 volts exist between A/C relay harness terminals No. @ , and body ground?

N .G.

El

A/C relay connector

O.K.
Disconnect A/C relay harness connector.

O.K.

N.G.

Check power supply and 10A fuse at fuse block.

RHA460A

tween A/C relay harness terminal No. @ and compressor harness terminal No. @ .

Refer t o Preliminary Check.

El

A/C relay
connector

I Check A/C relay after discon- 1 necting it.

Replace A/C relay.

I
Voltmeter
RHA461A

Reconnect A/C relay.

Note: If the result is N.G. after checking circuit continuity, repair harness or connector.

TROUBLE DIAGNOSES Trouble-shooting (Cont'd)

Dual-pressure swltch connector

'Q l
Check coil side circuit of A/C relay. Do approx. 12 volts exist between dual-pressure switch harness terminal No. @ and body ground?
I

N.G.

O.K.
~ual-pressure switch connector

Check voltage for thermo control amp. Do approx. 12 volts exist between thermo control amp. body ground? N .G.

Disconnect dual-pressureswitch harness connector.

Ohmmeter

O.K.
Check power supply for thermo

B
Therrno control amp. connector

O.K.

Go to Preliminary Check. Check dual-pressure switch. O.K. Does continuity exist between

Voltmeter

N.G. O.K. Replace thermo control amp. Check refrigerant. Connect manifold gauge, then check system pressure. (Refer to AIC performance test.)

0 .K.

N .G.

leaks.
I
I

r
Replace dual-pressureswitch.

Disconnect thermo control amp. and dual-pressure switch harness connectors.

Note: I f the result i s N.G. after checking circuit continuity, repair harness or connector.

TROUBLE DIAGNOSES Trouble-shooting (Cont'd)

Note Check circuit continuity be. tween thermo control amp. harness terminal No. @ and dual-pressure switch harness terminal No.

m.

Disconnect A/C switch.

L
m.
Check circuit continuity between thermo control amp. harness terminal No. and A/C switch harness terminal No.

10.".
1
1

Disconnect fan switch harness connector. Note

Check circuit continuity between AICswitch harness terminal No. @ and fan switch harness terminal No. @ .

1O.K.
Check circuit continuity between fan switch harness terminal N o . a a n d body ground. O.K.

Note

r
Check fan switch. Refer to A/C ELECTRICAL COMPONENTS.

l
(

Replace fan switch.

Check A/C switch. Refer to A/C ELECTRICAL COMPONENTS.

Replace A/C switch.

Note: If the result is N.G. after checking circuit continuity, repair harness or connector.

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
COMPRESSOR
Model Type Displacement cm3 (cu in)/Rev. Direction of rotation Drive belt DIESEL KlKl DKV 14C Vane rotary 140 (8.54) Clockwise (Viewed from drive end) Poly V

LUBRICATION OIL
Model TYpe Capacity ml (Imp fl oz) Total in system Amount of oil which can be drained Compressor (Service parts) charging amount DIESEL KlKl DKV 14C FREOL D-9OPX

200 (7 .O) Approx. 100 (3.5)

200 (7.0)

REFRIGERANT
Type Capacity kg R-12 1.2

Inspection and Adjustment

ENGINE IDLING SPEED (When A/C is ON.) Refer to ES section. BELT TENSION
Refer to Checking Drive Belts (MA section).

COMPRESSOR
Model Clutch disc-pulley clearance mm (in) DKV 14C 0.3 - 0.6 (0.012 -0.024)

ELECTRICAL SYSTEM SECTION

ELl
EL- 2 EL- 3 EL- 5 EL- 7 EL- 8 EL-13 e1-22 e1-23 e1-28 e1-35 e1-37 e1-4 1 e1-44 e1-49 e1-55 e1-58 e1-59 EL-6 1 e1-63 e1-65 e1-83

CONTENTS
HARNESS CONNECTOR STANDARDIZED RELAY POWER SUPPLY ROUTING STARTING SYSTEM STARTING SYSTEM - Starter - CA20E STARTING SYSTEM - Starter - KA24E CHARGING SYSTEM CHARGING SYSTEM - Alternator -CA20E CHARGING SYSTEM - Alternator - KA24E COMBINATION SWITCH HEADLAMP EXTERIOR LAMP INTERIOR LAMP METER AND GAUGES WIPER AND WASHER HORN, CIGARETTE LIGHTER AND REAR WINDOW DEMISTER REAR WINDOW DEMISTER AUDIO LOCATION OF ELECTRICAL UNITS HARNESS LAYOUT SUPER MULTIPLE JUNCTION (S.M.J.)

WIRING DIAGRAM REFERENCE CHART ENGINE COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITIONSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/TELECTRlCALSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIRROR, WINDOW AND DOOR LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEATER AND AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES SECTION ES SECTION ESSECTION ATSECTION BF SECTION HA SECTION

HARNESS CONNECTOR
Description
HARNESS CONNECTOR

All harness connectors have been modified to prevent accidental looseness or disconnection.
The connector can be disconnected by pushing or lifting the locking section.

CAUTION: Do not pull the harness when disconnecting the connector.

[Example]
PUSH Terrn~nal retalner

(Waterproof type) Term~nal retalner

LIFT

PUSH PUSH

@
PUSH

PUSH (For comb~rutlon motorl

(For relay)

STANDARDIZED RELAY Normal Open, Normal Closed and Mixed Type Relays
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.
NORMAL OPEN RELAY NORMAL CLOSED RELAY
Flows

Does not

MIXED TYPE RELAY

Flows

Does not flow

SW l
Flows

BATTERY

SW 1

BATTERY

1
Does not flow

BATTERY

Does not

0
Flows

SW 1

BATTERY

8%
SW 1 BATTERY SW l BATTERY
SEL881H

Type of Standardized Relays

1M .......... 1 Make I T .......... 1 Transfer 2M .......... 2 Make 1M.1B .......... 1 Make 1 Break 1M

I-

1M

STANDARDIZED RELAY

POWER SUPPLY ROUTING

Wiring Diagram

POWER SUPPLY ROUTING Fuse

If fuse is blown, be sure to eliminate cause of problem before installing new fuse. b. Use fuse of specified rating. Never use fuse of more than specified rating. c. Do not install fuse in oblique direction; always insert it into fuse holder properly. b. Remove fuse for clock if vehicle is not used for a long period of time. a.

Fusible Link
A melted fusible link can be detected either by visual inspection or by feeling with finger tip. If its condition is questionable, use circuit tester or test lamp. CAUTION: If fusible link should melt, it is possible that critical circuit (power supply or large current carrying circuit) is shorted. In such a case, carefully check and eliminate cause of problem.

Engine does not start.

/
\
Nr r

Check Fuse and Fusible Does starter motor turn? Yes Does gear shaft turn?

1
Check battery.for charging condition and battery terminals for connections and corrosion.
/

2
Charge or replace battery. battery terminals.

z
L

'< 1
Check pinion roller clutch for damage. Replace if necessary. Check reduction gear, armature and gear 4 shaft for damage. Replace if necessary.

? !
,

O.K.
N.G.

S
C Z 0

Check wiring of starting system. Yes

Repair wiring or replace electrical units.

a a

Clutch interlock switch or Inhibitor Ignition switch switch Starter relay Connections

r
V)

Can you hear magnetic switch of starter motor operating?

Repair or replace magnetic switch.

1 Z

'
X

?'

t)
Adjust dimension P. Check shift lever for deformation, return spring for fatigue and pinion for sliding condition. Correct meshing condition of pinion and ring gear. Replace if necessary.

Remove starter motor from engine.

terminal of starter motor and battery @ terminal t o starter motor body?

*
O.K.

N.G. (Turns slowly)

for charging conditio and battery terminals for connections
O.K.

Y er

Check armature assembly, field coil, and brush. Replace if necessary.

Does engine turn normally?

+ 'l

r
b

Check magnetic switch contacts. Replace if necessary.

Check ignition system and fuel system.

L

Does engine turn by replacing starte motor with a new one?

Repair or replace starter motor.

No
Check inside of engine. Starter motor does no stop if ignition switch is turned off.

Repair or replace ignition switch, starter relay or magnetic switch.

b

10 i

l
Problem or corrective action

Check item

I-

i f m y abnormality is found. immediately dironn.ct h t t e r y negative terminal.

STARTING SYSTEM
IGNITION SWITCH-ON OR START
I

SMJ CONNECTORS (SEE LAST PAGE)

(REF POWER SUPPLY1

EARTH

y:::::

G/OW

B/R

FUSIBLE

E
(MANUAL)

LINKS

g-q
128) (1281

P(5z1
GBRG G
(

U INHIBIT SWITCH (NEUTRAL/Pr\RKl

STARTER MOTOR

STARTING SYSTEM S t a r t e r -

I CA20E I

Disassembly
1. Clamp starter motor with "mounting lug" of drive-end bearing housing into vice facing away. Note: Mounting by other than this location may cause damage to the permanent magnet. 2. Unscrew nut of main positive cable at solenoid and remove cable. 3. Remove solenoid fastening screws and remove complete solenoid noting its position. 4. Re-position starter motor in vice, now facing operator and only loosen philip head screws. Undo through bolts and remove. 5. Keep sealing rubber at fork lever in place and remove stator housing with armature and end shield as a unit. Now take out rubber piece, carefully noting its position. 6. Remove cover plate on ring gear and remove planetary gear train together with over-running clutch and fork lever from housing by gently tapping end of output-shaft with soft mallet. Inspect and put aside. 7. To disassemble motor section, carefully press armature with end shield still attached and cable grommet out of housing. Unscrew cap from end shield and remove horse-shoe clip and shims from shaft end, remove end-shield. 8. To remove brush holder, place suitable sleeve with 32 mm O.D. and 10 mm I.D. at end of commutator and slide brush-holderand brushes off commutator. Should visual inspection of gear train necessitate disassembly, proceed as follows: Place planetary gear vertically onto suitable support in centre of satellite gears. Using sleeve, knock stop ring back, remove retainer and clutch-drive. To separate drive-shaft from ring-gear, remove circlip with washer and push through ring-gear.

STARTING SYSTEM S t a r t e r Assembly

Before commencing assembly, note should be taken of the following points: 8 Lubricate only sparingly, as per S.D.S. 8 Ensure that drive shaft is free of burrs. Always renew all bushings (sintered bushings should be soaked in oil before fitting). Armature length play can only be adjusted before stator frame is fitted. 8 Any numbers only to be stamped on side of drive end housing. 8 Do not connect starter motor incorrectly, as permanent magnets will be damaged. 8 New brush holder assembly with one directional brushes. Please read following carefully. The brush holder consists of a thermo-set plastic with the detachable brush cages. The brushes are manufactured from two (2) carbon compounds with the leading edge being of a harder brush compound. Special attention must be paid when installing the brushes. The brush, when viewed from top, displays two (2) noses with the central nose positioning the brush spring. The second nose is indicating the installation position. The starter motor "rotation indicating nose" faces toward the thermo-set plastic brush holder plate.

Difficulties may be experienced when replacing brushes due to the shorter length of the brush leads and soldering the leads to the brush plate assembly (stiffening of the leads and poor solder joints). It is therefore recommended that during normal overhaul the complete brush plate assembly be replaced.

STARTING SYSTEM S t a r t e r Assembly (Cont'd)

1. Push drive shaft through ring gear and secure with washer and circlip. Fit clutch drive and stop ring on shaft. Clamp retainer ring into groove and caulk stopring. Test over-running torque. 2. Push shaftlgear assembly with fork attached into drive end housing by positioning flat side of ring gear towards solenoid opening. Fit gear cover plate and fork lever sealing rubber. 3. To assemble motor section slide brush plate over commutator, (check proper seat of brush holders in anchor points) lightly oil felt ring and insert in recess on commutator end/of armature. Place end shield on shaft and set armature length play with shim and fit clip. Lightly grease end of commutator shaft, fit seal and end cap, insert screws but do not tighten. 4. Slide stator frame over armature until rubber cable grommet and end shield fit neatly into their positions and join with previously assembled drive unit by slowly turning drive until gears engage. Do not use force. 5. Insert through bolts and tighten by checking on proper fit of end shield. Now tighten hexagon screws of end cap. 6. Fit solenoid in position and connect cable, tighten screws to prescribed torque.

STARTING SYSTEM S t a r t e r Service Data and Specifications (S.D.S.)

General Data
Type Applied Model System voltage No-load Terminal voltage Current Revolution Automotive Length Play Overrunning Torque (clutch) Bosch Reduction Gear Type

CA2OE
12V 12v Less than 75A More than 3000 rpm 0.05 to 0.4 mm

0.12-0.18 Nm

Tightening Torque
I

Solenoid Screws Through Bolts Rear Cap Screws Positive Cable Nut

7.6-1 l.O Nm 4.5-7.0 hrn 1.4-2.4 Nm

6.0-8.0 Nm

Lubrication Specifications Coarse thread of armature shaft Bosch Grease - Part Number Helix of drive assembly

5 932 240 150 5 932 240 150

0.8 grams 0.5 grams

Securing and adjustment washers and inside of cover cap 5 700 082 005 Bosch Grease - Part number or Shell Grease MDL 2 Bushes, sealing washer and pinion running track of armature shaft 5 962 260 605 Bosch Oil - Part number or Shell Tellus Oil

0.5 glams

0.15 ml

STARTING SYSTEM
Wiring Diagram

1-

STARTING SYSTEM S t a r t e r Construction

STARTING SYSTEM S t a r t e r Construction (Cont'd)

STARTING SYSTEM -StarterRemoval and Installation

REMOVAL
1.
Remove air duct.

2. Remove harness clamps. For A/T model, remove harness

3.
connectors from harness connector bracket. Remove starter cable from starter.

4.

Remove starter fixing bolts.

INSTALLATION
a Installation is in reverse order of removal. Starter upper fixing bolt is shorter than lower bolt.

STARTING SYSTEM S t a r t e r Magnetic Switch Check

Before starting to check, disconnect battery ground cable. Disconnect "M" terminal of starter motor. 1. Continuity test (between "S" terminal and switch body). No continuity ... Replace.

SEL035H

2. Continuity test (between "S" terminal and "M" terminal). No continuity ... Replace.

PinionIClutch Check
1. lnspect pinion teeth. Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) 2. Check to see if pinion locks in one direction and rotates smoothly in the opposite direction. If it does not lock (or locks) in either direction or unusual resistance is evident ... Replace. 3. lnspect reduction gear teeth. Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.)

Brush Check
BRUSH
Check brush for wear. Wear limit length: Refer to S.D.S. Excessive wear ... Replace.

Brush

Lsh
spring
SEL656M

BRUSH SPRING PRESSURE

Check brush spring pressure with brush spring detached from brush. Spring pressure (with new brush): Refer to S.D.S. Not within the specified values ... Replace.

STARTING SYSTEM -StarterBrush Check (Cont'd)

BRUSH HOLDER

1 KA24E I

1. Perform insulation test between brush holder (positive side) and its base (negative side). Continuity exists. ... Replace. 2. Check brush to see if it moves smoothly. If brush holder is bent, replace it; if sliding surface is dirty, clean.

Pole Piece Check (Mitsubishi type)

Pole piece is secured to yoke by bonding agent. Check pole piece to see that it is secured to yoke and for any cracks. Replace malfunctioning parts as an assembly. Holder may move slightly as it is only inserted and not bonded.

Yoke Assembly Check (Hitachi type)

Check magnet for cracks. If there is any crack, replace malfunctioning parts as an assembly.

Armature Check
1. Continuity test (between two segments side by side). No continuity ... Replace.

STARTING SYSTEM S t a r t e r Armature Check (Cont'd)

K A ~ ~ E

2. Insulation test (between each commutator bar and shaft). Continuity exists. ... Replace.

3. Check commutator surface. Rough ... Sand lightly with No. 500

- 600 sandpaper.

4. Check diameter of commutator. Commutator minimum diameter: Refer to S.D.S. Less than specified value ... Replace.

Undercut procedures

5. Check depth of insulating mold from commutator surface. Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in)

Round

(0.020 - 0.031 in)

W
Correct ile

Commutator

Incorrect

EEOZl

STARTING SYSTEM -StarterAssembly

KA24E J

Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the starter. Carefully observe the following instructions.

Switch

Pinion stopper

PINION PROTRUSION LENGTH ADJUSTMENT

Hitachi With pinion driven out by magnetic switch, push pinion back to remove slack and measure clearance " Q " between the front edge of the pinion and the pinion stopper. Clearance " Q ": Refer to S.D.S.

Clearance "P" Adjusting plate Plate thicknon 0.5 m m (0.020 in) 0.8 mm (0.031 in)

--tt

Not in the specified value ... Adjust with adjusting plate.

Mitsubishi Compare movement " Q " in height of pinion when it is pushed out with magnetic switch energized and when it is pulled out by hand until it touches stopper. Movement " Q ": Refer to S.D.S.

Not in the specified value ... Adjust by adjusting plate.

STARTING SYSTEM S t a r t e r Service Data and Specifications (S.D.S.)

STARTER
Type MlTSUBlSHl make

I
Reduction gear 12 11.0

HlTACHl make

System voltage Terminal voltage No-load Current Revolution Minimum length of brush Brush spring tension (With new brush) Minimum diameter of commutator Clearance "Q" between pinion front edge and pinion stopper Movement "Q" in height of pinion assembly Maximum thrust gap of pinion shaft

V V
A rpm mm (in) N (kg, Ib) mm (in) mm (in) 0.5 50 - 75 3,000 - 4,000 12.0 (0.472) 13.7 - 25.5 (1.4 - 2.6, 3.1 - 5.7) 28.8 (1.134)

Less than 90 More than 2,950

ll.O (0.433)
17.7 - 21.6 (1.8 - 2.2.4.0 - 4.9) 32.0 ( 1.260)

- 2.0 (0.020 - 0.079) -

0.3 - 1.5 (0.012 - 0.059) 0.5 (0.020)

mm (in) mm (in)

CHARGING SYSTEM
Wiring Diagram

ICAZOE

&~ ~ 2 4 ~

CHARGING SYSTEM A l t e r n a t o r -

[CAZOEI

c .-

a
a!

m m t?
.a, a ,

S --

' C 'C 0

am a 3 rnrnco~coa

cca, $, m m m c % 2 ?

CHARGING SYSTEM -Alternator-

pzq
Connect~on

ALTERNATOR B O S CK1-80 ~
DESCRIPTION
The 3 phase BOSCH alternator is a 12 pole machine equipped with silicon diodes for rectification and a built-in electronic regulator. Cooling is by an external fan located behind the pulley. The six diodes are arranged in a 3 phase bridge connection whereby 3 diodes have anodes at the connection (normal polarity) and 3 diodes have anodes at the housing (reverse polarity). See Figure 2. The alternator is designed for negative ground operation. When an indicator lamp is used in the system a further 3 smaller diodes are fitted into the rectifier assembly. The stntor winding has :I star connection - see Figure i - with three outlets which are connected to the rectifier assembly. The rotor comprises the slip rings and exciter winding and is constructed of imbricated poles which form alternator north and south poles. The exciter winding is wound concentric with the shaft inside the claw poles and has its ends connected t o the slip rings.
Current (Anode)

I
D~ode

ked

;*l

<

Housing (Anode) Current flow

Housing (Cathode)

Connection ( ~ a i h o d e )
X092

Fig. .? Dioclc, c.or~nrc.tiot~.c-

ALTERNATOR OPERATION
(See Figure 1 for wiring diagram.) When the ignition switch is turned to the 'ON' position, battery current is supplied to the exciter winding through the warning lamp. If we look Bt one pair of rotor poles, it will be seen that the magnetic field of the rotor will be broken by one loop of the stator winding as the rotor is turned. A voltage will be induced in t h s conductor and because of the closed circuit a current will flow away from the wire connection through a phase winding. Since the phase is connected t o both a positive and a negative diode, the current will flow thorugh the positive diode, which is open to current flow in this direction. The, negative diode of this phase obstructs current flow. From the positive diode the current passes into the heat sink, which is conimon t o the B+ terminal, and then t o the battery.

r----

I I

- ----0, REGULATOR
OF

l
I

I
l
SUPPRC SSOR

I
1
I

X09 1

Fig. I . 9-diode alternator with built-in regulator

CHARGING SYSTEM A l t e r n a t o r T o complete the clrcult a return path from the negatlve battery terminal t o the alternator stator star point must be found. The negarive heat s ~ n k is directly connected to the alternator housing, therefore, the return circutt is firstly througli the negative diodes. However, the negative diode, which 1s connected at the b r ~ d g e connection, is open t o current tlow 111 this d~rection but is opposed by the equal potential of the phase. The remaining negative diodes are free at this period and the circuit back t o the star point can be c o m pleted through either of these diodes and associated phases. The interconnected positive diodes also have the phase potential and resist the direct flow of current across the bridge connection. If the rotor is now moved until the other loop of the phase winding 1s affected, a current will flow in the opposite direction and s o c o m plete the other half of the sine wave. Actually, t h s cycle takes place very quickly in the phases and the o u t p u t is a continuous current flow. the collapse of the excitation the output voltage decreases until the zener diode blocks positive potential from reachng the base of T 3 . T I and T 2 now become conductive again and the output voltage will rise until the switching cycle 1s repeated. Diode D1 IS for the protection o f transistor T I . Condenser C1 is a stabil~singcondenser t o reduce any instab ~ l ~ o y the zener diode arrangement. tf ammeter in the cable t o B+. If the test bench is not fitted with a battery load resistor, a load resistor rated at 40A must be connected in parallel with the battery. Start test b e n c h , a n d increase speed but maintain a maximum of 14V by adjusting the load resistor. With a warm alternator i.e. after S minutes operation at maximum o u t put values as per test instruction should be obtained.

ALTERNATOR TERMINALS
D+ Exciter diode junction-connection
for indicator lamp B+ Battery c o n n e c t ~ o n( d ~ r e c tt o battery).

TESTING ON T H E CAR
a) Ignition switch off. b) Connzct ampmeter between B+ connector and B+ lead at rear of alternator. c) Connect voltmeter between B+ connector and earth. d) Brldge B+ and D+ with a 2 watt globe. e) Connect tachometer. f) Run engine a t 900 RPM. g) Switch o n consumers t o achieve an output o f 2 6 a m p s f 2 a m p s and check that voltage is within specifications 13.6 t o 14.4 volts.

TESTING ON T H E T E S T BENCH
T h e alternator may only be run on a test bench when the fan is fitted. Use only correct sockets and cable ends for the various alterantor connections. D o n o t use temporary connection clips. A 12 volt battery must always be connected in parallel with the machine when it is being tested. T h e battery acts as a buffer and eliminates voltage peaks which occur when a load is switched o n and off. When voltage peaks exceed safe limits, the rectifier action of the diodes will be destroyed. Set u p the alternator on an approved test bench. As the construction of the alternator does not readily lend itself t o clamp type mounting, a suitable adapter should be used. Connect a I?V warning lamp of at least 2 watts between terminals D+ and B+. Connect the test bench voltmeter between terminals D arid B+ and the

VOLTAGE REGULATOR OPERATION

Voltage from D+ is supplied t o voltage dividers RS, R 6 and R 7 , whereby R 7 is adjusted t o the correct value during production. T h e centre tapping of the voltage divider is taken t o a zener diode through diode D2 w h c h provides the necessary temperature compensation. The zener diode controls the base of T 3 w h c h opens t o ground when set voltage is exceeded. This renders T 3 conductive, thereby switctung off T 2 and T 1 w h c h are arranged In a Darlington pair. With tlus s w ~ t c h n gaction the current flow through the exclter winding and T I to ground is interrupted. With

Note: If consumers a r e unable t o supply required load, connect additional load in parallel.

DISASSEMBLY
1. Mark relative positions of stator @ and e n d plates @ and with centre punch. 2. Loosen brush holder and regulators @ by unscrewing 2 screws @ l 3. Extract brush holderlregulator. U n solder wire connection linking it t o the rectifier. 4. Remove 2 nuts and lower rear mounting bracket. Unscrew 4 through bolts. 5. Withdraw e n d plate together with rectifier @ a n d stator @ .

CHARGING SYSTEM -Alternator6. Unsolder the 3 stator connections from rectifier assembly and remove stator. 7. Remove screws @ and terminal nuts (B*). Withdraw rectifier assembly. 8. Hold rotor @ in vice (soft jaws!) and unscrew pulley retaining nut
sinks is essential for maximum efficlency, therefore dirt and oil traces must be cleaned from and around the rectif~erassembly. Exciter diodes

l CA2OE l
Apply test probes between points A and B , C , I). By reversing to probes it can be established ~f one or several of the exclter diodes failed due to an open or short circuit.

0.
9. Remove pulley @ fan Q and 2 spacers. 10. Drive end plate can now be supported on a press and the rotor @ pressed out. 11. Remove ball bearing in drive end plate by unscrewing two screws @ and remove ball bearing @. 12. Remove ball bearing @ on slip ring end of rotor with a suitable puller.

TEST1 NG INDIVIDUAL PARTS S t a t o r winding Rectifier assembly

CLEANING

Thoroughly clean all parts with compressed air, d o not immerse windings and bearings in solvents. The free passage of cooling air around the heat

The rectifier assembly is not repairable and should, in case of diode failure, be replaced. In order to establish whether the diodes are functioning properly observe the following points: Use only test lamps up to 24V. With diodes of normal (t) polarity the test lamp must light up if the positive probe of the test lamp is connected to the anode and the negative probe to the cathode (housing). This process has to be reversed for negative diodes. (See Figure 1.) There are two main possibilities w h c h can destroy a diode during service, either breakdown in resistance to current flow caused by h g h current and high temperature, or open circuit in both directions. This is almost always the consequence of excess voltage.

Test stator for short circuit to ground with a test lamp of up to 40V. Test winding resistance between phases according to the values given. Refer to Service Data and Specifications. Insulation and short circuit tests on windings should only be carried out with the diodes disconnected.
T e s t i n g of exciter winding

Test for short circuit to ground with a test lamp of up t o 40V. Measure the resistance of the exciter winding between the slip rings. Resistance should be according to the values gven. Refer to Service Data and Specifications.
Regulator and brush assembly

Take special care of these solder connections Positwe heat s ~ n k

The regulator is not serviceable and should be replaced as an assembly. If the brushes are worn, new brushes should be soldered into the brush holder allowing 0 . 4 3 to 0.47" ( l l to 12 mm) of brush to protrude from holder. Worn slip rlngs can be turned in a lathe In the usual manner.
Ball bearings

Negative heat sink

Check ball bearings for wear and roughness. Renew defective bearings with approved bearings only hnd lubricate wlth BOSCH Grease Etlv34.
X094

Fig 3 Rectifier connections

ASSEMBLY
(Reverse disassembly procedure) a) Tlghten the through bolts evenly. The air gap between rotor and stator must be equal at all polnts If the alr gap I S not even, loosen the through bolts and reposltlon the end plates on the stator b) T ~ g h t e n pulley nut to 40 to 50 ft-lb (S S3 to 6 9 1 kg-m) torque

Power diodes
Apply test probes as described above to points B, C, D o r E, F , G (see Figure 3) a n d t h e a p p r o p r i a t e h e a t s i n k . Establish by reversing the

test probes (polarity) whether the diodes are functioning properly. If diodes C-B, F-C or E-D are short circuited. all 6 power diodes will show a short clrcult when tested with the testlamp.

CHARGI NG SYSTEM AlternatorService Data and Specifications (S.D.S.)

pk6q

ALTERNATOR
Type Applied Model Nominal rating
!
BOSC~

CA2OE V-A 12-70 Negative More than 1611300 More than 4012200 More than 6016000 14.3-14.7 54-68 (40-50) 3.8 to5.5 ( 3 4 t o 4 9 )

Ground polarity

Hot output current

Alalternator rpm

Regulated output voltage Torque pulley nut

V Nm (ft-lb)

Through bolts Nm (in.-lb)

CHARGING SYSTEM A l t e r n a t o r Construction

Pulley assembly

Bearing retainer

(4.0 - 6.0.29 - 43)

Diode assembly

Front beer~ng

Q Q

(0.32 0.40.2.3
Brush assembly

- 2.9)
SEL936J

(q) : N.m (kg-m, ft-lb)

+Rear bearing CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. Be careful not to lose this ring during removal.

CHARGING SYSTEM A l t e r n a t o r Disassembly

REAR COVER REMOVAL CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facilitate removal of rear cover, heat just bearing box section with a 200W soldering iron. Do not use a heat gun, a it can damage diode assembly. s

Rotor Slip Ring Check

1. Continuity test No continuity

... Replace rotor.

2. l nsulator test m Continuity exists ... Replace rotor. 3. Check slip ring for wear. Slip ring minimum outer diameter: Refer to S.D.S.

Brush Check
1. Check smooth movement of brush. m Not smooth ... Check brush holder and clean. 2. Check brush for wear. m Replace brush if it is worn down to the limit line.

3. Check brush lead wire for damage.

Damaged ... Replace. 4. Check brush spring pressure. Measure brush spring pressure with brush projected approximately 2 mm (0.08 in) from brush holder. Spring pressure: Refer to S.D.S. m Not within the specified values ... Replace.
m

CHARGING SYSTEM -Alternator-

Stator Check
To test the stator or diode, separate them by unsoldering the connecting wires. CAUTION: Use only as much heat as required to melt solder. Otherwise, diodes will be damaged by excessive heat.

1. Continuity test No continuity

... Replace stator

2. Ground test m Continuity exists ... Replace stator.

CHARGING SYSTEM AlternatorDiode Check

MAIN DIODES Use an ohmmeter to check condition of diodes as indicated in chart below. If any of the test results is not satisfactory, replace diode assembly.
Ohmmeter probes Positive Diodes check (Positive side) Diode terminals Negative diode plate Diodes check (Negative side) Diode terminals Negative diode plate Positive diode plate Diode terminals No No

p%q

Continuity Negative @ Diode terminals Yes

Positive diode plate

Yes

l Positive diode

plate

SE L768D

SUB-DIODES Attach ohmmeter's probe to each end of diode to check for continuity. Continuity is N.G. ... Replace diode assembly.

CHARGING SYSTEM A l t e r n a t o r Assembly

I KA24E (

Carefully observe the following instructions. When soldering each stator coil lead wire to diode assembly terminal, carry out the operation as fast as possible.

WHEN SOLDERING BRUSH LEAD WIRE (1) Position brush so that it extends 10.5 to 11.5 mm (0.413 to 0.453 in) from brush holder.

10.5 - l (0.413 SEL595A

(2) Coil lead wire 1.5 times around terminal groove. Solder outside of terminal. When soldering, be careful not to let solder adhere to insulating tube a it will weaken the tube and cause it to break. s

place insulating tube on terminal.

RING FITTING IN REAR BEARING Fix ring into groove in rear bearing so that it is as close to the adjacent area as possible.

CHARGl NG SYSTEM -AlternatorAssembly (Cont'd)

REAR COVER INSTALLATION
(1) Before installing front cover with pulley and rotor with rear cover, push brush up with fingers and retain brush by inserting brush lift wire into brush lift hole from outside. (2) After installing front and rear sides of alternator, pull brush lift wire by pushing toward the center.
Do not pull brush lift wire by pushing toward outside of rear cover as it will damage slip ring sliding surface.

CHARGING SYSTEM A l t e r n a t o r Service Data and Specifications (S.D.S.)

ALTERNATOR
LR 180-719 Type HlTACHl Nominal rating Ground polarity Minimum revolution under no-load (When 13.5 volts i s applied) rpm Hot output current Regulated output voltage Minimum length of brush Brush spring pressure Slip ring minimum outer diameter mm (in) Alrpm
V
V -A

12-80

Negative Less than 950 More than 5012,500 More than 6715.000 14.1 - 14.7
7 (0.28)

mm (in) N (g, 0 2 )

2.746 - 3.923 (280 - 400,9.88 - 14.1 1) 30.6 ( 1.205)

COMBINATION SWITCH

WIPER HI

Check

TURN SIGNAL

For lighting switch and turn signal switch

L I G H T I N G SWITCH

For wiper switch

WIPER SWITCH

TURN SIGNAL SWITCH

VARIABLE INTERMITTENT WIPER VOLUME (where fitted)

H O R N SWITCH

NOTE: Pin numbers are only for reference to switching diagrams. They do not relate to pin numbers on the relevant wiring diagrams.

@--E%

COMBINATION SWITCH Replacement

Each switch can be replaced without removing combination switch base.

Switch base Lighting switch

SEL967K

To remove combination switch base, remove base attaching screw and turn after pushing on it.

rotrusion guide

SEL989C

HEADLAMPWiring Diagram

HEADLAMP Bulb Replacement

The headlamp is a semi-sealed beam type which uses a replaceable halogen bulb. The bulb can be replaced from the engine compartment side without removing the headlamp body. Grasp only the plastic base when handling the bulb. Never touch the glass envelope. 1. Disconnect the battery cable. 2. Turn the bulb retaining ring counterclockwise until it is free from the headlamp reflector, and then remove it. 3. Disconnect the harness connector from the back side of the bulb. 4. Remove the headlamp bulb carefully. Do not shake or rotate the bulb when removing it. 5. Install in the reverse order of removal. CAUTION: Do not leave the bulb out of the headlamp reflector for a long period of time as dust, moisture, smoke, etc. may enter the headlamp body and affect the performance of the headlamp. Thus, the headlamp bulb should not be removed from the headlamp reflector until just before a replacement bulb is to be installed.

PUSH
to remove

Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming machine, aiming wall screen or headlamp tester. For operating instructions of any aimer, it should be in good repair, calibrated and used according to respective operation manuals supplied with the unit. If any aimer is not available, aiming adjustment can be done as follows : For details, refer to the regulations in your own country. CAUTION: a. Keep all tires inflated to correct pressures. b. Place vehicle and tester on one and same flat surface. c. See that there is no load in vehicle (coolant, engine oil filled up to correct level and full fuel tank) other than the driver (or equivalent weight placed in driver's position).

HEADLAMP Aiming Adjustment (Cont'd)

LOW BEAM
1. Turn headlamp low beam on.

2. Use adjusting screws to perform aiming adjustment. First tighten the adjusting screw all the way and then make adjustment by loosening the screw.

"H":

Horizontal center line of headlamps

0
0

a. Adjust headlamps so that main axis of light is parallel to center line of body and is aligned with point P shown in illustration. b. Dotted lines i n illustration show centre of headlamp. "H": Horizontal center line of headlamps "WL": Distance between each headlamp center "L": 5,000 mm (196.85 in) rrC!r: 50 mm (1.97 in)

Vertical centerline

&

= ACCEPTABLE RANGE

Intermittent Amp. Check

Connect as shown in the figure at left. If test lamp blinks when connecting terminal @ to battery @ terminal and disconnecting terminal @ from battery @ terminal, intermittent amp. is normal.

STOP L A W SWITCH

RH COMBINATION LAW

n
I - A I T I O N SWITCH-ON OR S T M T
I

n
STOP/TAIL LAMP

STDP/TAIL LAMP

@ -'

REVERS L A W

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring Diagram

EXTERIOR LAMP
1

Test lamp (27W)

I

Combination Flasher Unit Check

Before checking, ensure that bulbs meet specifications. Connect a battery and test lamp to the combination flasher unit, as shown. Combination flasher unit is properly functioning if it blinks when power is supplied to the circuit.

Battery

SEL122E

Bulb Specifications

INTERIOR LAMP
IIlumination/Wiring Diagram (GL Models)

FRONT RH

AUTO TRANSMISSION

HEATER CONTROL

A/C SWITCH

SHJ

CONNCTOR SEE LAST PAGE

aU Z N 4 E C T C n

SEE

LAST PAGE

U O V E BOX IUUMINATION

CLOCK ILLUMINATICN

HAZARD WITCH ILLUMINATION

RR DEFDG SWITCH IUUMINAT ICN

ILLWINATION C O N T R ~ SWITCH

ETER ILLUMINATION

INTERIOR LAMP
-

q L T h i w8Test,lamp (3

;; ;
\
Dark Test lamp Bright

Illumination Control Unit Check (GHIA Model)

Connect as shown in figure at left. If test lamp darkens when connecting terminal @ to battery 0 terminal, and if test lamp brightens when connecting terminal, illumination control unit is terminal @ to battery normal.

4 1 2 5

(38W)

H
\"l',

SE L987K

INTERIOR LAMP
Interior, Spot and Trunk Room LampsIWiring Diagram (GL Model)

T
3g
W
Q .

8gl
2g
"'L
U

REAR CMPARTPENT

REAR LH W W SWITCH O

HEADLAMPS

FRONT LH DOOR SWITCH

REAR RH WoR SWITCH

l - - - !
SPOT LAMP FRONT STEP L A W LH FRONT STEP L A W RH REM) STEP L W LH

REAR STEP LAMP RH

METER AND GAUGES

Combination Meter
Rear View of Combination Meter

Plug 1

Plug 2

Plug 3

METER AND GAUGES

Wiring Circuit -Speedometer, Tachometer, Water Temp, Clock, Fuel Level, Low Fuel, ECM Lamp

NOTE: The circuit shown covers all models. Ignore the circuits which do not
apply to the model in question

M P S M M RELAY

COMBINATION METER
3K
IB ILLUM GLOBES 1 OXE

IC

D R I E R S DOOR W I T C H

O----#~&,l

r
OILP

FR(WT LH W D R % I T C H

BRAKE PRESSWE
DIFFERW I T W

PARK BRAKE

SWITCH

(8DO

e
CHIME

METER AND GAUGES

Meter & Gauge Checking Procedure. Ignition Switch "OFF". 1. Remove fuse cover. 2. Remove S.M.J. harness connector, located above fuse/relay assembly and pull harness down through fuse cover opening. 3. Connect instrument tester E71 14 t o dash harness plug using adapter harness E7 1 14-3. Plug power lead into cigarette lighter socket and turn ignition switch t o "ACC" position. 4. Ensure speedometer and tachometer (where fitted) indicate the readings in each switch position as detailed on the tester. 5. The fuel, water temperature and oil pressure (where fitted) can be tested by connecting the gauge tester (E7 126) between the colored wires provided on tester E7 1 14, and body ground. Refer ES-54 for specified values. 6. Switch ignition "OFF", remove tester and adaptor harness. 7. Guide S.M.J. connector onto locater guides of S.M.J. plug and push firmly. Caution: Take care t o align connector and plug correctly. 8. Tighten connector bolt and replace fuse cover. Note: The gaue checker (E7 126) can be used by itself t o test fuel, water temperature and oil pressure (where fitted) gauges. The checker should be connected in place of the relevant sender unit (ie) Temperature gauge: Connect checker t o sender unit wire. Fuel gauge: Connect checker t o yellow/black wire (fuel pump harness connector beneath rear seat). Oil pressure guage (where fitted): Connect checker between oil pressure harness (red/yellow wire) and ground. Meter & Gauge Assembly Removal -Refer BF-23 Meter & Gauge Disassembly.
1. Remove trip meter knob, depress front cover retaining clips and remove front cover. 2. Locate and unplug printed circuit connecting plugs from bottom edge of instrument case. 3. Remove screws from rear of case and lift out gauges one at a time. Caution: Do notcontact gaugefacesastheyareeasilymarked.

Meter & Gauge Assembly.

Use reverse order of disassembly instructions.

METER AND GAUGES

Fuel Tank Gauge and Check

Low fuel sender unit

Sender position - 15 1.9 m m Sender resistance - Dry = low resistance Submecged = high resistance
Float position Resistance value

162.6

282

Thermal Transmitter Check

Check the resistance between the terminals of thermal transmitter and body ground.
Water temperature 60C (140F) 100C ( 2 1 2 ' ~ ) Resistance Approx. 70 - 90C2 Approx. 21 - 24C2

Ohmmeter cz==r

Oil Pressure Switch Check

Check the continuity between the terminals of oil pressure switch and body ground.
Oil pressure kPa (bar, kg/cm2, psi)

Continuity

Engine s t a r t Engine stop

More than 10 - 20 (0.10 -0.20, 0.1 - 0.2, 1.4 - 2.8) Less than 10 - 20 (0.10- 0.20, 0.1 - 0.2, 1.4 - 2.8)

NO

YES

METER AND GAUGES

Vehicle Speed Sensor (V.S.S.)
To fault diagnose the vehicle speed sensor or sensor circuit, refer section ES.

WIPER AND WASHER

Wiper and WasherIWiring Diagram

mONT WIPER SWITCH

GHlA ONLY
FUSE BLOCK (REF POYER SLPPLY)

4
LG

145E) l33El
EARTH

I I ~ I I I I I ~ ~
I
IGNITION SWITWLlN 5
4CC

0
BA
FROG

(W)

FRT WASEARTH

MOTCR

WIPER AND WASHER Installation

1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it "OFF" (Auto Stop). 2. Lift the blade up and then set it down onto glass surface to set the blade center to clearance "C" or "D" immediately before tightening nut. 3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it "OFF". 4. Ensure that wiper blades stop within clearance "C" or "D". Clearance "C": 20 - 35 mm (0.79 1.38 in) Clearance "D": 25 35 mm (0.98 1.38 in) Tighten windshield wiper arm nuts to specified torque. Front wiper: [nJ: 17 23 Nom (1.7 2.3 kg-m, 12 17 ft-lb) Rear wiper: [nJ: 13 18 Nom (1.3 1.8 kg-m, 9 13 ft-lb)

-Clearance "C"
,--?I
i /A

i t

t f 9
Unit: mm (in) A l l the d~ameters these circles are of less than 80 (3.15). Lower windshield molding

1,'

SEL217K

Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness.

WIPER AND WASHER Washer Nozzle Adjustment

Adjust washer nozzle with suitable tool as shown in the figure below. Details of tool are shown below.
Adjusting hole: 0.9 (0.03510 X 1.O (0.039)
'5 (0.059)

l.5 (0.059)

0.85 (0.0335)
Nozzle holes
SEL2451

Unit: m m (in) 0.85 (0.0335)

SEL0881

Check Valve
From reservol r Check valve

&D+

To nozzle

A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong direction.

SEL411H

Wiper Amplifier Check

1. Connect as shown in the figure at left. 2. If test lamp comes on when connected to terminal @ and battery ground, wiper amplifier is normal.

NOTE: Pin 8, shown as a blank, will be used on models with variable intermittent wipers.

HORN, CIGARETTE LIGHTER AND REAR WINDOW DEMISTER

Wiring Diagram

REAR WINDOW DEMISTER

I+l
[-l

Filament Check
1. Attach probe circuit tester (in volt range) to middle portion

of each filament.

6 volts (normal filament)

SE~263

Burned-out point

2. If a filament is burned out, circuit tester registers 0 or 12 volts.

[v]
12 volts

SE L264

[+l

[-l

urned-out point

[V1

0 volts

SE L265

3. To locate burned out point, move probe to left and right along filament to determine point where tester needle swings abruptly.

SE L266

Filament Repair
REPAIR EQUIPMENT
1. Conductive silver composition (Dupont No. 4817 or equivalent) 2. Ruler 30 cm (11.8 in) long 3. Drawing pen 4. Heat gun 5. Alcohol 6. Cloth

-8 8
0

REPAIRING PROCEDURE

Heat wlre

%iq-

,
Break

l !/

1/r

Drawing pen

Unit: mm (in)
BE540

1. Wipe broken heat wire and its surrounding area clean with a cloth dampened in alcohol. 2. Apply a small amount of conductive silver composition to tip of drawing pen. Shake silver composition container before use. 3. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap existing heat wire on both sides [preferably 5 mm (0.20 in)] of the break.

4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver composition is deposited. Do not touch repaired area while test is being conducted.

5. Apply a constant stream of hot air directly to the repaired area for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area and hot air outlet. If a heat gun is not available, let the repaired area dry for 24 hours.

SE L013D

AUDIO
Wiring Diagram (GL Model)

IIGNITION SWITCH-ACCESSW

OR ON

RH FRONT SPEAKER

FUSE BLOW IREF POWER SUPPLY)

WA
R/G

EARTH

BR

I
B A m Y

ANXW

BR CASSETTE

L
R/G

G
IGNITION SWITCH-ACCESSORY OR ON

EARTH EARTH

99

(2T)

RH FRONl SPEAKER

LH FRONT SPEAKER

SPEAKER RH REAR

e
SPEAKER

LH REAR

/
Fuel pump relay (Green) Horn relay (Grey) Radiator fan relay(Blue) (Low speed

Inhibitor relay (Brown: CA2OE engine) (Grey : K A 2 4 E engine)

Bulb check relay (Blue) iator fan relay-2 (Brown)

(High speed)

ECCS relay ( K A 2 4 E ) (Green)

Distributor

LOCATION OF ELECTRICAL UNITS

Passenger Compartment

HARNESS LAYOUT
Main Harness -GL Models

For harness plug description refer page EL-69

EL 65

HARNESS LAYOUT
Main Harness -GL Models (Cont'd)

For harness plug description refer page EL-69

HARNESS LAYOUT
Main Harness

-GHlA Models

For harness plug description refer page EL-69

EL-67

HARNESS LAYOUT
Main Harness -GHlA Models (Cont'd)

For harness plug description refer page EL-69

EL-68

HARNESS LAYOUT
Main Harness
Plug Descriptions

49M 50M 5 1M 52M 53M

AIR CONDITIONING UNlT RADIO FRONT DOOR HARNESS R.H. ILLUMINATIONCONTROL UNlT E.C.C.S. HARNESS

80M 8 1M 82M 84M 85M 86M' 87M 88M 89M 90M 9 1M 92M

AUTOMATIC TRANSMISSION DEVICE MODE SWITCH HANDBRAKE SWITCH FRONT DOOR SWITCH L.H. REAR DOOR HARNESS L.H. FRONT DOOR SWITCH R.H. REAR DOOR HARNESS R.H. FUEL GAUGE REAR DOOR SWITCH R.H. BODY EARTH R.H. REAR DEFOG TAIL HARNESS

HARNESS LAYOUT
E.C.C.S. Harness -CA20E Engine

1G 2G 3G 4G 5G 6G 7G 8G 9G 10G
1 1G

Main Harness ECM ECM ECM Diagnostic Connector Air Flow Meter Radio Condenser Ignition Coil Engine Room Harness Engine Room Harness Oxygen Sensor Distributor Earth Engine Earth Distributor IAC Valve Throttle Switch Injector 4 Injector 3 lnjector 2 lnjector 1 Air Regulator Water Temperature Sensor

12G 13G 14G 15G 16G 17G 18G 19G 20G 21 G 22G

HARNESS LAYOUT
E.C.C.S. Harness - KA24E Engine

Manual Variant

HARNESS LAYOUT
E.C.C.S. Harness - KA24E Engine (Cont'd)
Automatic Variant

38G 39G 40G

THROTTLE VALVE SENSOR ENGINE EARTH ENGINE EARTH IDLE SPEED CONTROL SOLENOID CRANK ANGLE SENSOR THERMAL TRANSMITTER SPEED SENSOR (AUTO.) AUTO. TRANS. SOLENOID (AUTO.) CANISTER CUT SOLENOID PRESSURE RELIEF VALVE REGULATOR SOLENOID SWIRL CONTROL VALVE SOLENOID AIR TEMPERATURE SENSOR AIR FLOW METER

28G 29G 30G

3 1G

50G IGNITION COlL IGNITION TRIGGER IGNITION COlL EARTH RESISTOR & CONDENSOR DROP RESISTOR (AUTO.) 5 1G 52G 53G 54G 55G 56G ENGINE HARNESS (AUTO.) ENGINE HARNESS (MAN.) 57G 58G 59G

32G

37G

I THROTTLE VALVE SENSOR

HARNESS LAYOUT
Engine Harness -CA20E Engine (Manual & Auto Transaxle)

58 78 128 138 148 15B 16B 178 188 19B 208 2 1B 22M 23M

TO SPEED SENDER TO OIL PRESSURE SWITCH TO ENGINE ROOM HARNESS TO ENGINE ROOM HARNESS TO ALTERNATOR TO ALTERNATOR TO THERMAL TRANSMITTER TO STARTER MOTOR TO INHIBITOR SWITCH (AUTO) TO LOCK UP & O.D. SOLENOID (AUTO) TO ENGINE ROOM HARNESS TO FUSIBLE LINK TO POSITION SWITCH (MAN.) TO STARTER MOTOR

HARNESS LAYOUT
Engine Harness - KA24E Engine
Manual Transaxle

1B 28 38 48 58 68 78 88 9B 100
l lB

TO E.C.C.S. HARNESS TO E.C.C.S. HARNESS TO E.C.C.S. HARNESS TO STARTER MOTOR TO SPEED SENDER TO OIL PRESSURE SWITCH TO OIL PRESSURE SWITCH TO INHIBIT SWITCH TO POSITION SWITCH TO INHIBIT SWITCH TO ENGINE ROOM HARNESS TO STARTER MOTOR

Automatic Transaxle

238

HARNESS LAYOUT
Engine Room Harness -CA20E Engine

HARNESS LAYOUT
Engine Room Harness

-KA24E Engine

For harness plug description refer page EL-77

EL-76

47E

FRONT TURN LAMP, L.H.

lI

INSTRUMENT HARNESS ILLUMINATION CONTROL SWITCH G.L. ILLUMINATION CONTROL SWITCH GHlA REAR DEFOG SWITCH HAZARD SWITCH GLOVE BOX SWITCH CLOCK (EXCEPT GL) METER l METER 2 METER 3

21 31 51 71 81 91 101 111 121

HARNESS LAYOUT
Front Door Harnesses
lFDR

TO MAlN HARNESS TO MAlN HARNESS TO MAlN HARNESS TO SPEAKER TO MIRROR TO POWER WINDOW MOTOR

2FDR 3FDR 4FDR 5FDR 6FDR

7FDR TO POWER WINDOW (ONE TOUCH) 8FDR 9FDR

lOFDR 1 IFDR

TO POWER WINDOW SWITCH AUTO TO STEP LAMP TO STEP LAMP TO DOOR UNLOCK SWITCH

R/H Front Door

lFDL 2FDL 3FDL 4FDL 5FDL 6FDL 7FDL 8FDL 9FDL

TO MAlN HARNESS TO MAlN HARNESS TO SPEAKER TO MIRROR TO POWER WINDOW SWITCH TO POWER WINDOW MOTOR TO STEP LAMP TO STEP LAMP TO DOOR LOCK ACTUATOR

\\\\

L/H Front Door GHlA Model

Front Door (GL Model)

Note: Left & right doors are the same.

12FD 13FD

TO MAlN HARNESS TO SPEAKER

HARNESS LAYOUT
Rear Door Harness (GHIA Model)

1RD

TO MAIN HARNESS TO POWER WINDOW MOTOR, RR TO POWER WINDOW SWITCH, RR TO STEP LAMP TO STEP LAMP TO DOOR LOCK ACTUATOR, RR

2RD 3RD 4RD 5RD 6RD

Left hand shown, right hand is the same.

HARNESS LAYOUT
Room Lamp Harness

I i:: 1
I
1RL

MAIN HARNESS ROOM LAMP MAP LAMP (GHIA ONLY)

HARNESS LAYOUT
Tail Lamp Harness

IT 2T

TO MAIN HARNESS EARTH TRUNK ROOM LAMP SWITCH REAR SPEAKER, RH (EXCEPT GL) TRUNK ROOM LAMP HIGH-MOUNTING STOP LAMP REAR SPEAKER, LH (EXCEPT GL) REAR DOOR SWITCH, LH TRUNK ROOM LAMP SWITCH REAR COMBINATION LAMP, RH REAR COMBINATION LAMP, LH LICENCE LAMP

3T
4T 5T 6T 7T 8T 9T 12T 16T 17T

SUPER MULTIPLE JUNCTION (S.M.J.)

INSTALLATION
To install S.M.J., tighten bolts until orange "full-tight" mark appears and then retighten to specified torque as required. tn):3-5N.m (0.3 - 0.5 kg-m, 2.2 3.6 ft-lb) CAUTION: Do not overtighten bolts, otherwise, they may be damaged.

Terminal Arrangement

MAIN HARNESS

INSTRUMENT HARNESS

l ENGINE ROOM HARNESS