mazda 121, kia pride repair manual vol 1

8/20/2019 Mazda 121, Kia Pride Repair Manual Vol 1

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JMO OB1 3 t



Mazda

121

Workshop

Manual

Vofume 1 of

2

FOREWORD

Thisworkshop

manual

s intended

or

use

bv

service technicians

of

Authorized

Mazda

D-ealerso help them serviceMazdavehicles.

It

can also

be uselul

o ownersand

operators

of Mazda

vehicles

in diagnosing

some

problems

and

performing

imited

epair

and

maintenanceon

Mazda

vehicles.

For

proper

repair and

maintenance,

thorough

amiliarization

ith his

manual

s m-

portant,

and

it shouldalways

be kept

n a

han-

dy

place

or

quick

and

easy

reterence.

All

the

contentsof

this manual,

ncluding

drawingsand

specifications,

re he

atest vail-

able

at the time of

printing.

As modifications

affecting

epair

or

maintenance

ccur, elevant

informationupplementary

o

thisvolume

will

be made available

at

Authorized

Mazda

Dealers.This

manual should

be

kept up-

to-date.

Mazda

Motor Corporation

eserves

he right

to alter

he specifications

nd

contentsof

this

manual

withoutobligation

r advance

notice.

All rights

eserved.No

part

of this

book

may

be

reproduced or used

in any

form or

by any

means,electronic

r

mechanical-including

photocopyingand recording and the use of

any kind oJ

nformation

storage and

retrieval

system-without

permission

n writing.

Mazda

Motor

Corporation

HIROSHIMA.

APAN

APPLICATION:

Thismanual

s applicable

o vehicles

eginning

with the

Vehicle dentification

Numbers

(VlN)

shown on the

following

page.

o 1990MazdaMotor

Corporation

ocT.

'90

@)

1249-10-90J

CONTENTS

Tirle

Sect

General

nformation

Pre-Delivery

nspection

and

ScheduledMaintenanceService

Engine

Lubrication

System

Cooling

System

Fuel

ndEmission

,onttolystem EGI-S

Engine

ElectricalSystem

Clutch

ManualTransaxle

Automatic

Transaxle

Front and

Rear Axles

Steering

System

Braking Syslem

Wheels

and Tires

Suspension

Body

Body Electrical System

Heater

and AarConditioner

Systems

Technical

Data

Special

Tools

wiringDiasram

Sili:.|Tj|:'"''""'0"''

The sectionZ is publishedseparate rom this manual.



vEHlcLE

DENTIFICATION

UMBERS

VlN)

JMo

D81031

0 100001



GI

GENERAL

NFORMATION

TMPORTANTNFORMATION.... . . . . . . . . . . . . . . . .

l - 2

BAS|C SSUMPT|ONS.... . . . . . . . . . . . . . . . . . . . . . . . .l - 2

sAFEry

H1SK.... . . . . . . . . . . . . . . Gl- 2

POSSIBLE

OSS FWARRANry... . . , , . . . . . .I- 2

WARNINGN

LUBRICANTS

ANDGREASES. ... . . . . . . . . . . l- 2

HOWTO USETH|S

MANUAL.... . . . . . . . . . . . . . . . .t- 3

PREPARATTON ... . . . . . . . . . . . . . l - 3

REpAtR

ROCEDURE.... . . . . . . . . . . . . . . . . . . . . . . . . .l - 3

SYMBOLS.... . . . .

. . . . . . . . . . . . . . . l- 4

NOTES.

AUTIONS.

NDWARNINGS.... . . .

I- 4

FUNDAMENTALROCEDURES.... . . . . . . . . . . . . .I- 4

PROTECTIONF

THE

VEHICLE

.,.. . . . . . . . . . I- 4

A WORD

BOUT AFETY.... . . . . . . . . . . . . . . . . . . .l - 5

PREPARATIONF

TOOLS

ANDMEASURING

QUIPMENT.... . . . . . . . . .I_ 5

SPEC|ALOO1S.... . . . . . . . .

. . Gl- 5

REMOVALFPARTS.... . . . . . . . . . . . . . . . . . . . . . . . . .l - s

DTSASSEMBLY

.... . . . . . . . . . . . . l -

5

REASSEMBLY ... . . . . . . . . . . . . . .I-

6

ADJUSTMENTS

..,. . . . , . . , , . . . I-

7

RUBBER ARTS

NDTUBING.... . . . . . . . . . , . .I_

7

JACK

ANDSAFETY TAND

POSITIONS....I- 8

VEHICLE IFT

2.SUPPORT

YPE)

postTtoNs.... .

. . . . . . . . . . . . . . . . .

l - I

TOW|NG.... . . . . .

. . . . . . . . . . . . . . . . . . .l - 9

IDENTIFICATION

UMBER OCATIONS.,...I-10

uNtTs. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .l - l 0

ABBREVTATTONS

.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .l - l0

CAUT|ON ....Gl- l l

INSTALLATIONF

A MOBILE

TWO-WAY

AD|O

YSTEM.... . . . . . . . . . . . . . . . .

l - l1

REMOVAL F

GNITIONEYON

AUTOMATIC

RANSAXLEODE1.......... I-11

ELECTRICALROUBLESHOOTING

OOLS I-12

CAUTION

ITHELECTRICAL

ARTS........

I-13

03uGtx-001



GI

IMPORTANT

NFORMATION

IMPORTANT

NFORMATION

BASICASSUMPTIONS

This

workshopmanual ssumes

hat

you

have

certain pecial

ools hatare

necessaryor he safeandetfi-

cient

perlormance

f

service perations

n Mazda

ehicles nd

hat

you

knowhow o

use hem

properly.

It

also

assumeshat

you

are

amiliar ithautomobile

ystems

ndbasic

ervice nd repair

rocedures.

ou

should otattempto use hismanual nlesshese ssumptionsrecorrecl ndyouunderstandheconse-

quences

escribed

elow.

SAFETY

RISK

This

manual ontains ertain

otes,warnings,

ndother

precautionary

nformation

hat

you

should arefully

readand

ollow

o

reduce he

risk

of

personal

njury o

yourself

r others

nd he

risk

of

improper ervice

thatmaydamage he

vehicle r

render t unsafe.

f there

s no

such

nformation

n regard

o

anyspectfic

service

method, his

does not mean

here s no

possibility

hat

personal

afetyor vehicle afety

will

be

jeopardized

y

the useoJ

ncorrectmethods r

tools.

POSSIBLE OSSOF

WARRANTY

Themanufacturer'sarranty

n Mazda ehicles nd

engines

anbe voided f mproper ervice

r repairs

areperformed y persons ther han hoseat an AuthorizedMazdaDealer.

WARNING N

LUBRICANTSND GREASES

Avoidall

prolonged

nd

repeated ontactwith mineral

ils,

especially sedoils.Usedoilscontaminated

during

ervice

e.g.,

ngine ump

ils) remore rritating

nd

more ikelyo cause eriousffects,

ncluding

skincancer, n

the eventof

gross

and

prolonged

kincontact.

Washskin horoughly fter

work nvolving il.

Protective

andcleanersmaybe of

value

provided

heycan be removed

rom he skinwithwater.

Do not

use

gasoline,

araffin,

r

othersolvents

o remove il

from he skin.

Lubricants nd

greases

may be slightly

rritatingo the eyes.

Bepeated r

prolonged

kincontact hould

e avoided

y

wearing rotectivelothingfnecessary.articu-

lar

care

should e taken

withusedoilsand

greases

ontaining

ead.Do notallow

workclothingo be con-

taminated

ithoil. Dry cleanor

launder uchclothing

t

regularntervals.

sMuGrx_oo

Gl-z



HOWTO USE

THISMANUAL

GI

HOW

TO USE

THISMANUAL

F[rtFf#rtifiirointsout heneededpeciat

ervice ool

ssT)

or he erviceperation

att

pro-

ceeds.Gather

ll necessary ST beforebeginning

ork.

Example:

SST

NUMBER

SST NAME SST

ILLUSTRATION

03uGtx-@6

REPAIB ROCEDURE

1.

Most

epair perations eginwith

an overviewllustration.

t identifieshe components,hows

how he

parts

it

together,

nd

visual

parts

nspections.f

a damaged

r

worn

part

s found,

epair

or

replacet

as

necessary.

2. Expendable

arts,

ighteningorques,ndsymbolsoroil,

grease,

ndsealantre

shownn heoverview

illustration.

3. Pages elated

o

service

rocedures

reshownunder

he llustration.efer

o this nformation

hen er-

vicing he

related

art.

Example:

SHOWS TIGHTENING

TOROUE UNIT

sHows

RELATED

PAGEFOR

SERVICE

" 1 :

Thenumbering

ex.@)

hows ervice

rocedure.

Units hown

n Nm

(m-kg,

tJb)unless therwisepecified.

9MUGIX.O34

Gt-3

MANUAL

TEERING

PREPARATION

ssT

490118 50C

Pullef, all

oinl

17

Spacer

18

Drive

pinion

Bemoval

page

M-2'l

rpecl

splines and leelh

fot weat

or

damage



GI

HOW

TO

USE

THIS MANUAL/FUNDAMENTAL

ROCEDURES

SYMBOLS

if,er"

uresi*

symbols

ndicating

il,

grease,

nd

sealant.

hese ymbols

how

he

points

f applying

uch

materials

uring

ervice.

Symbol

Meaning

Kind

g

Apply oil

New engine

oil or

gear

oil as

appropriate

@

Apply

brake

luid

Only

brake luid

E

Apply automatic

ransmission

luid

Only

ATF

€

Apply

grease

Appropriate

rease

(@[

Apply sealant

Appropriate

ealant

e

Apply

petroleum

elly Appropriate

petroleum

ellY

osuctx 05

Note

.

Whenspecial

oil or

grease

s needed, his

is shown

in the

illustration.

NOTES, AUTIONS,

ND

WARNINGS

As

you

ead

hrough

he

procedures,ou

willcomeacross

OTES,

AUTIONS,

nd

WARNINGS.

ach

one

s therefore

ipecific

purpose.

NOTES

giveyou

added

nformation

hat

will help

you

o complete

a

particular rocedrire.

AUTIbNS

are

given

o

pri:vent

ou

rom

making

n error

hatcould

damage

he

vdhicle.

WARNINGS

emind

ou

o beespeciallyareful

n

hose reas

where

arelessness

an

cause

Per'

sonat

niury.

The

ollowingilt contains

ome

eneral

WARNINGS

ou

should

ollow

when

ou

workon

a vehicle

olA.,x-oo2

FUNDAMENTAL

ROCEDURES

PROTECTION

F

THEVEHICLE

Always e

sure o

cover

enders,

eats, nd

loor

areas

be-

fore startino

ork.

Gt-4

9MUGIX.O37



FUNDAMENTAL

ROCEDURES

GI

9MUGtX-003

9[,{UGtX-038

47UOGX-005

47U0GX-006

SMUGIX,O39

A

WORD

ABOUTSAFETY

The

ollowing

recautions

ustbe

ollowed hen

acking

p

thevehicle.

1 Block

he

wheels.

2. Useonly

hespecified

acking

ositions.

3. Support

he

vehicle

with safety tands.

Starthe

engine

nlyafter

making ertain

heengine ompart-

ment s clear

of

ools nd

people.

PREPARATION

F

TOOLSAND

MEASURING

EOUTPMENT

Be

sure

hat

all

necessaryoolsand

measuringquipment

re

available

efore

tarting

ny

work.

SPECIAL

TOOLS

Use special

ools

when hey

are required.

REMOVAL

OF

PARTS

While orrecting

problem,

ry also o

determine

ts

cause.

Beginwork

only

after irst earning

which

parts

and subassem-

b es must

be

removedand disassembled

or replacement

r

repair.

DISASSEMBLY

lf the disassembly

rocedure

s complex,

equiringmany

parts

to be disassembled,

ll

parts

shouldbe

disassembled

n a

way

that

will not affect

heir

performance

r external

appearance

and

dentified o

hat

eassembly an

be

performed

asily nd

efficiently.

Gr-5



FUNDAMENTAL

ROCEDURES

GI

9MUGIX.OOs

ADJUSTMENTS

Usesuitable

auges

nd/oresters

hen

making diustments.

E

RUBBER

ARTS

AND

TUBING

Prevent

asoline

r oil rom

getting

n

rubber

arts

r ubing.

57UoGX-002

Gt-7



Gl

,oo

AND AFEw

srAND

FosmoNsyvEHplE

UFT

25UPP6RT

YPE)

osmoNs

JACK

AND

SAFETY

STAND

POSITIONS

FRONT

ND

Jack

positioni

At

the

rontcrossmember

Satety

stand

positions:

Side

ills

REAR

END

Jack

position:

At he

center f

the

ear rossmember

Safety

stand

positions:

Side

ills

03uGlx'oog

vEHlcLE

LIFT(2-SUPPORTYPE)POSITIONS

FRONT

ND

Frame

Side

ills

9ltlUGlX-010

Gt-8

REAR

END

Frame

Side

ills



TOWING GI

WHEEL

DOLLIES

03uGlx002

TOWING

Properowing quipment

s necessaryo

prevent

amage

o

p

thevehicle.

Lawsand regulationspplicable

o vehiclesn tow must

al

waysbe observed.

As a generalule,owed ehicleshould epulledwith he

driving heels ff he

ground.

f excessiveamage r

other

conditions

revent

owinghe

vehicle ith he

driving heels

off he

ground.

se

wheel

ollies.

Witheitherautomatic

r manualransaxle:

1.Set he

gnitionwitchn

theACC

position:

2. Place he selector

everor shift ever

n N

(Neutral);

3.

Releasehe

parking

rake.

Caution

.

Do not ow he vehiclebackward

with

driving

wheels

on the ground.This may cause nternaldamage o

the transaxles.

.

Do not use

he hook oops under he front and rear

ol the

vehicle tor towing

purposes.

These hook

loops aredesigned

ONLY or transport ie-down. t

tie.down hook

loops

are

used for towing, the

front/rear bumper

will

be damaged.

Gt-9



Gl

rDENTIFrcATroN

UMBERocATroNs/uNtrs/ABBREVtATtoNS

IDENTIFICATION

UMBER

OCATIONS

VEHICLE

DENTIFICATION

NUMBER

(VIN) AUTOMATIC

RANSAXLE

IODEL

AND NUMBER

ENGINE

MODEL

AND NUMBER

,'%

r(g

/tYl

.,,/Pk

UNITS

N.m

m-kg

or cm-kg,

ft lb

or in-lb)..

.. . . . .

orque

rpm...... . . . . .

. . . . . . . . .

evolutions

er

minute

A . . . . . . . . . . . . . .

. . . . . . . . . . .

mpere(s)

V. .

. . . . . . . . . . . . . . . . . . .

Vo l t ( s )

o. .

. . . . . . . . . . . . . . . . . . .

hm(s)

resistance)

kPa

kg/cm2,

si).... .

. Pressure

(usually

Positive)

mmHg(inHg)....

Pressure

(usuallY egative)

W.. . . . . . . . .

. . . .

. . . . . . .Wat t

liters

US

qt,

lmp

qt)

. . Volume

mm

( in )

. . . . . . . . . . . .

. . Length

89U0GX.006

ABBREVIATIONS

EC-AT...... .

.

. . . . . . .Electronically-control led

automatic

ransmission

ECU

.. . . . . . . . . .

. . . . . . . .ng ine

on t ro l n i t

EGI

. ... . . . . . . .

. . . . . .Electronic

asoline

injection

EIL

. . . . . . . . . . . . . . . .. . . .

E lec t r i ca l

oad

EX..

.. . Exhaust

lC...... . .

. . . . . . .

Integrated

ircuit

l G N . . . . .

. . . . . . .

. l g n i t i o n

l N . . . . . . . . . . . . . . . . . . . . . . . . . . .

n t a k e

1NT. . . . . . . .

. . . . . . . . . . . . . . . . . .

n termf tent

ISC

...... . . . . . .

ldle speed

ontrol

LH

. . . . . . . . . . . . . . . . . . . . . . . .

e f t

and

M. . . . . . . . . . . . . . . . . . . . . . . t v lo to r

MIL

. . . . . . . . . .

. . . . . . . . . . . .

\ ra l funct ion ind icator

lamp

MTX...... . . . .

Manual

ransaxle

OD

...... .

. Overdrive

OFF. . . . . . . . . .

. . . . . . . . . . . . . . .

w i tch

f f

ON. .

. . . . . . . . . . . . . . . . . . . . .

w i tch

n

PCV...... .

Posit ive rankcase

ventilatlon

PRC. . . . . . . . .

. . . . . . . . . .

Pressureregula tor

control

P/S.-..... . . . . . . . . . . . .

Power teering

P/ V . . . . . . . . . . .. . . . .

. . . .

. . . Power

indow

RH.. . . .

. . . . . . . . .

. . . . . . . .i gh t

and

SST.,...

.

Special

service ool

S T . . . . . . .. . . . . . . . . . . . . . .t a r t

S W . . . . . .

. . .

. . . . . . . . . . . .w i t c h

TDC...... . . . .

. . . . . . . . . .

Top deadcenter

03uGtx.004

ABDC.......

Atterbottom ead

center

A/C

. . . . . . . . . . . . . . . . . .

A i rcondi t ioner

ACC. . . . . . . . . .

. . . . . . . . . .

ccessor ies

ATX. .... . .

Automatic

ransaxle

ATDC

.....

After op dead center

ATF

Automatrcransmrssion

fluid

BAC...... . . .

Bypass ir control

BBDC... Before ottomdead

center

BTDC .. .. . .

. . . . . . . . .

Beforeop deadcenter

CPU.. . . . . . .

Cent ra lprocess inguni t

Gt-l0



CAUTION

GI

CAUTION

INSTALLATION F

MOBILETWO.WAYRADIOSYSTEM

lf a mobilewo-way

adio ystems nstalled

mproperlyr f a

high-poweredype s used,he

EGI

ystem

and othersystems

may

be affected.

When he vehicle s to be equipped

witha mobile wo-way adio,observe

he ollowlng

recaulions:

1. nstallheantenna l theJarthestointromcontrol nits.

2. nstallheantenna

eeder s aras

possible

rom

hecontrol

nitharnesses

at

east30 cm

[11.8

n]).

3. Ensurehat he antenna nd

feederare

properly

djusted.

4. Do

not nstall high-powered obile

wo-way adiosystem.

05uGlx'013

REMOVAL F

IGNITION EYON

AUTOMATIC

TRANSAXLE

MODEL

Theselector

evermustbe n P

(PARK)

o urn he

gnition ey

to the OFF

position.

f the switch eems

o be off but he

key

cannot e

removed,he switchmay

stillbe n he ACC

posi-

tion,or heselector

evermaynotbe

n P

(PARK).

hift

he

selector

ever o

P

(PARK),

nd urn he

gnitioney o the

LOCK osition.hekeyshould owbe ree or removal.

MOBILE

TWO.WAYRADIO

"'o'"*'*J

Ll lZ'""-rRoLUN,r

r / r l

FARTHESTPOINT

AT LEAST 30 cm

(11.8

n)

EGAT

CONTFOL

UNIT

ENGINE

CONTROLUNIT

R

N

D

s

L

03UGIX.OOs

Gl-11



GI

CAUTION

9MUGIX

O2O

VOLTMETER

GFOUNO

9MUGIX.O21

05uGtx-021

9MUGIX045

ELECTRICAL

ROUBLESHOOTING

OOLS

Test Light

The est-light,

s shown

n he

igure, ses

12Vbulb.

The

two ead

wiresshould

be connected

o

probes.

The est ight

s used

orsimple

oltage

hecks

nd

orcheck-

ing

or

short

ircuits.

Caution

.

Whenchecking

he

control

unit,

never

use a bulb

over 3,4W.

Jumper

Wire

The

umper

wire s used

or esting

y shorting

cross

witch

terminals

nd

ground

onnections.

Caution

.

Do not connect

a

umper

wire rom

he

power

source

line to a body ground;this maycause burning or

other

damage

to

harnesses

or electronic

com'

ponents.

Voltmeter

The

DC

voltmeter

s used o

measure

f circuit

oltage.

volt-

meter

witha range

of

15Vor

more s used

by

connecting

he

positive

+) probe

red

ead

wire) o

the

point

where

oltage

is to be

mi;asured

nd

the

negative

-) probe

black

ead

wire)o a body

ground.

DiagnosisConnector

Insert

he

probe

nto

heservice

ole

when onnecting

um-

per

wire o the diagnosis

onnector.

Caution

.

Do not insert

the

jumper

wire

probe

nto

the diag'

nosis connector erminal,which maydamage

he

terminal.

Ohmmeter

The

ohmmeter

sused

o

measure

he esistance

etween

wo

ooints

na circuit

nd

also

ocheck

orcontinuity

nddiagno-

sis of short

circuits.

Caution

.

Do not attempt

o

connect

he ohmmeter

o any

cir-

cuit to

which

voltage s applied; his may burn or

otherwise

damage

he

ohmmeter.

9MUGIX.O19

Gl-12



CAUTION

GI

9MUGIX-022

9MUGIX.O23

9MUGIX.O24

9MUGIX-025

03uGtx,011

CAUTION

WITH

ELECTRICAL

ARTS

Battery

Cable

Before

isconnecting

onnectorsr

replacing lectrical

arts,

disconnect

he negative attery

able.

connectors

Removal f connector

Never

pull

on the

wiring

nectors.

harness

when

disconnecting

on-

Connectors

an

be removed y

pressing

r

pulling

he

ock

leveras shown.

Locking

of connector

When

ocking onnectors,

ake ure

o istenor

a

click hat

will ndicate

heyare

securelyocked.

lnspection

1 When

ester

susedocheck

orcontinuityr o measure

voltage,

nserthe

ester

robe

rom hewire arnesside.

Gr-l3



GI

CAUTION

2. Check

he

erminals

f

waterproof

onnectors

rom

he

con-

nector

ide,

as

hey

annot

e accessed

rom he

wire

har-

ness

ide.

Caution

.

Use

ine

wire

to

prevent

damage

o the

terminal.

. Do not damage he terminal when inserting the

tester

lead.

Terminals

lnsoection

putitigntly

n

ndividual

ires

o check

hat

heyare

secured

in he erminal.

ReDlacement

f

terminals

Us6

he

appropriate

ools

o

remove

he

erminal

s

shown'

When nstailind

he erminal,

e sure

o

nsertt until

t

ocks

securery.

<Female)

lnsert thin

piece

ofmetairom he

erminal

ideof

he con-

nector,

nd

hen,

with

he

erminalockingabpressed own,

pull

he

erminal

ut

rom he

connector.

<Male>

Same

as

the

emale

YPe.

Sensors,

Switches,

and

RelaYs

Handle

ensors,

witches,

nd relays

arefully.

o not drop

themor

strike

hem

against

ther

parts.

9MUGIX.O27

9MUGIX-028

9MUGIX-O3O

Gt-l4



CAUTION

GI

M*m

ffifi,.".

MUGIX,O32

BR/Y

olAGtX-001

Fuse

Replacement

1 When eplacing

fuse,be sure

o replacet with

one of

specified apacity.

lf

a

fuseagain

ails

after

t has been eplaced,he circuit

probably

has a short circuitand

the wiring

should

be

checked.

2. Be sure

he negative attery

erminals disconnectede-

fore replacing

main use

80A).

3. Wheneplacing

pullout

use,

se he

use

uller

upplied

in the useboxcover.

Wiring Harness

Wiring color codes

Two-color iresare

ndicated y a

two-color

ode symbol.

The

irst ode

ndicateshebase

olorof hewireand hesec-

ond the color

of the strioe.

9MUGIX.O31

CODE

COLOR

CODE

COLOF

B

Black

o

Orange

BR

Brown

P

Pink

LJ

Green

R

Red

GY

Gray

Violet

L

Blue

White

LB

LightBlue

Y Yellow

LG

Light Green

Gl-15



A

PRE-DELIVERYNSPECTION

AND

SCHEDULED

AINTENANCE

SERVICES

PRE-DEL|VERYNSPECTION

.........,..........

- 2

PRE-DELIVERYNSPECTIONA81E..........

-

2

SCHEDULED

AINTENANCEERVICES.....

- 3



PRE.DELIVEBY

NSPECTION

PFE-DELIVERY

NSPECTION

ABLE

INSPECT nd

ADJUST,

necessary,

he olowing

lemso

Glass

€xterorbight

melal

and

paint

or damage

. Wheel

ug nuls

C Al weathelslf

s

or darnage

r detachrnenl

Operation

l bonnel

elease

nd ock

D Operalion

l tiJnk

id and ue

lid open€r

(l

equipped)

tr

Dooroperaiion nd

ahgnmenl

tr Headlghl

imlng

INSTALLhe

o owrng

arls

Wheel apsor

ngs

f

equ

PPed)

outside

mrro(s)

- Frontlap il equrppeo)

UNDER

BONNET.ENGINE

FF

Headisht

leaner

il

equipped)

Horn,wipers

nd washer

tr Antenna

i

equipped)

tr cigarene

ighter

ndclock

if

equLpp€d)

tr Heater

and defroster

al

variousmode

seleclions

D Canvas

op

(il

equipped)

CHECK

he olow

ng tems:

Presence

l spare

use

upholslery

nd nterlor

inish

CHECK

nd

ADJUST,l necessary,

he ollowing

ems

Operallon

nd

it ol windows

I Pedal

eighl nd

ree

play

ol

blakeand

clutch

pedal

I Parklng

rake

UNDER ONNET-ENGINEUNNING T

OPEFATTNG

EMPEBATUBE

ROAD

TEST

CHECK

he

lollowing lems:

C Operaton

ol

idle_up )€tem or

air cond

toner or

power

seer'

ing

(it

equ

pped)

D

Aulornal transaxle

luid level

I lnitial

gnton

tmrng

- ldle

speed

Operallon

l ihroltle

sensor

Operaton

of dashpot

CHECKhe ollowingems.

u nders

e ue coolarl

nd

hydrallic

ines itlings' onnec'

tons and

components

or

eaks

Tiresor clts

or bruises

D Sleeing

nkage,uspension,

xhausl

yslem nd

alrunder

sde

hardware

or looseness

r oamage

INSPECTand

ADJUST.

r necessary.he

lolowlng

items o

Fuel,coolantand

hydraulc

ines, ll ngs,connecnons

nd

components

or leaks

Englneol evel

Brakemastercylnder

lluid evels

Clutch

mastercyLnder

luid

levels

if

equrpped)

-

Windshied

washer eservo

lluid evel

Radiator

oolanl

eveland spec

ic

graviiy

tr Tlghtness i walerhose clamps

Tghhessol baliery

elminals,

ectro

,'le

eveland specillc

graviry

I l lanual l ransaxe

l

eve

Dflv€ belt(s)

enson

tr

Acceeratorcable

and

linkage

or

iree movemeni

tl

Headlght ceaner

and

lluld level

if

equipped)

CLEAN

he spark

plugs

INSTALL he

lo lowing

parls

C Fubber

slopper or

nside ear

vew mifror

(ii

equ

pped)

tr Fuse or accessones

CHECK

he operation

oi lhe

lolowing tems

- Seatconlrols

slid

ng and

reclning)and head rest

I Seal belts

I lgntion

switchand steer

ng lock

Powerwindow

it

equipp€d)

Door ocks ncluding

hid

prool

door

locks

nhibitor wllch

ATX

only)

n A l l

g lLs Tluo,ng

war119ald

.nd

Lalor

ghts

lgfiton key

rem nder buzzer

f

equlpped)

CHECK

he ollowing

nrs:

Brake peral

n

Clulch

perauon

Steering

ontro

tr op€mtion l meters ndgauges

tr Squeaks,

altes

or unusua

noses

Engine

eneral

eriormance

Emerge^cy

cking

eiiaclors

AFTER

ROAD

TEST

REMOVE

the

seat and

lloor mat

proled ve

covers

CHECK

or the

necessary

wner

nformallon

materias

ools

and spare

ire

n vehicle

A-2



SCHEDULED

MAINTENANCE

ERVICES

SCHEDULED

AINTENANCE

ERVICES

-\.\_{e :Inc€

inrerval

llaintenance

item------\

ilumber ot

months or km. whlchever

comcs lla3l

llonths

1 2

18 24 30 42

48

54

60 6€

x 1000

km t . 5 1 5 22.5 30

{5 60

67.5 42.5 so

ENGINE

Enoine

alve learance

I

Ex. manifold

bolls and nuls

T

T

T

T

Enoine

iminq bell"

Replaco very105,000

kilometels

Dfive belts'"

I

Enoine il'

R R

R B R

B

B

R R

R

Oil ille'"

R

R R

B R

R

COOLING YSTEM

Cooiingsystem

I

Enqine oolanl

With

eservon)

R

F

R

FUELSYSTEM

Arrcleaner lemsnt"

R

R

I R

R

B

R

I

IGNITIONSYSTEM

Initial qnition iminq

I

I

Spark

lugs

I

EVAPOFATIVE

MISSION ONTROL YSTET'

EXHAUST MISSION

ONTROL YSTEM

oashpot

I

I

ELECTRICAL

YSTEM

level and sp€crllc

qravfy

CHASSIS ND

BODY

Clulch

eda

I

Brake llnes.

hoses

and

connections

I

Brakel'rid"

B I

I

Power reenng

lud and ines

ll

oquippeo

Sleerng oporalionand

gear

housing

Steerinainkaoes

ack

qude

and

ie rodends

I R

I

Automatic

ransaxle luid

evel

I

I

Front uspensionall

oir(s

Fronl

wheel bearlng

greases

R

Driveshaft

dust boots

I

8olls,

nuls

on

chassis and body

1

T T

T

T T

T

Exhaugsystemheal shields

I

A-3



SCHEDULED

MAINTENANCE

ERVICES

Chart

symbols:

|:

lsoecl :

V|sua|

xam|nalon

I

iunclona|

measurement

f system's

peration

performance)

A:

,ljust

R:

aedace

or

change

T:

Tighten

L: Lubricate

Note:

.

f -the

resuh

ot

visual

examination

l

tunctlonal

measurement

l

a system's

operation

per-

lolmance),

correct,

clgan

or leplace

as required'

Remarks:

.

After 0,OOO

mor

72 months,

onllnue

o ollow

hedescribed

cheduled

aintenance

tems

nd

nter-

vals

periodically.

.

n"lJ-- maite'o

tems

n this

maintenance

hart'

please

ay

attention

o the

ollowing

ollts

- -

ii'

iiin"

".tri"i"

i" op"rated

nder

hsiollowing

onditions'

t s suggested

hat

heengine

ilandoil

ilter

OeCnanged

moieoften

han

at usual

ecommended

ntervals'

a) Driving

n dusly

conditions

Oi extenaeOeriods f idlingor lowspeedoperation'

ij

Oriuinglor'"

prolonged

lrrod n cold emoerature

r

driving

onlyshort

distance

egularly'

.2:

ieolacerient

of he

timing

belt

s

Auned;t;very

1o5,ooo

m'

Failure

o

replace

iming

beltmay

result

n damage

o

the engine.

's,

ir-fr;u.hi"l

i;;p;rated

in-very

usty

r

sandy reas,

nspect

nd'

f necessary'

eplace

more

often

thanat

usual

ecommended

ntervals.

'a,

AJlust

iinip""t

alternator

nd

waGi

pump

drivebelt'

and

power teering

ndairconditioner

rive

beft, f equipped.

'5:

Replace

very

wo

Years

iiiti"i

ta" o6en

ontinuous

ard

dflving,

mountain

rivrng,

r

it the brakes

re

used

extensively

r

the

vehicle

s operated

n

extremely

uriid

climates,

he

brake

luidshould

be changed

nnually'

EmlsgionConiroland RelaledSystems:

il;;;;"

t;Jl;

"i"temJ"*

uitdrrv

mpottanttothe

roper

peration

tthe

emission

ontroland

elated

svste-ms,

s

wellas

tor etflcient

ngine

perations'

ift;;;'g[,"r;;;;JtnJ

dt se"rvicing

eraed

o hese

vstems

e

done

v

vour

uthorized

"oi,?"*fl.

A-4



SCHEDULED

MAINTENANCE

ERVICES

ADJUSTINGCFEW

LOCKNUT

ADJUSTIIENT

OF

ENGINE ALVE

CLEARANCE

Note

.

When

valveclearance

nspection

nd cylindefiead

r

bolts

retightening service

are ai

the

same

nterval,

E

tlEhten

he cylinder

head bolts

tlrst.

I

1. Warmup

the engine

o normal perating

emperature.

2. Withhe

piston

fthe

No.1 ylinderat

DC fcompression,

adjust he

valve learances

llustrated.

valve clearance

(at

valve)

lntake

: 0.30mm

0.012

n)

Exhaust:

0.30mm

0.012

n)

3.

Turn he crankshaft

ne

ull urnso that he

piston

f the

No.4cylinder

s at TDCol compression,

ndadjusl

heclear-

ances

f the

remainingalves.

TIGHTENING

NTAKE

MANIFOLD

OLTSAND NUTS

Tightening

orque:

19-25

N.m

1,9-2.6

m-kg, 14-19

ttlb)

TIGHTENING

XHAUST

MANIFOLD

UTS

Tightening

orque:

16-23

Nm

(1.6-2.3

m-kg, 12-17

ftlb)

REPLACEMENT

IMINGBELT

Refero Section

ot the

Workshop

anualor he replace-

ment

procedure

f the iming

belt.

A-5



SCHEDULED

MAINTENANCE

ERVICES

INSPECTION

ND

ADJUSTI'ENT

OF

DRIVEBELTS

aAlternalot

nd

water

pump

drive

bell'

Power

steering

iump

and

alr condilionel

compressor

drive

belt)

i cfieck he belt

or cracks

r

any other

damage.

2.

Adiustor

rePlace,

l

necessary.

3.

Ch;ckthe

drive

belt

ension

ith

humb

pressuref about

98 N (10 kg, 22 lb) at eacharrowpoints

Belt

detlection

Altemator

drive

belt

New

belt

: 5'5-7.0mm

(0.21-0.27

in)

Used

bell:

6.0-7.5mm

(0.23-0'29 in)

Air conditioner

drive

belt

(if

eqipped)

New bell

: 8-9mm

(0.31-0.35 in)

Used

belt:

9-l0mm

(0.35-0.39

in)

Power

steering

oil

pumP

drive

belt

(if

equipped)

Newbelt:

8-9mm

(0.31-0'35 n)

Used

belt:

9-1omm

(0.35-0.39

in)

Air condltionel

compressor

and

powel

steedng

oil

pump

drive

belt

(it

equiPPed)

-

New belt : 8-9mm

(0'31-0.35

in)

Used

belt: 9-10mm

(0.35-0.39

in)

ALTEFINATOR

P/S

COMPFESSOFI

)X

\euuevi

,a'z \

j

\\

CFANKSHAFT/

\

P U T L E Y 1 " , ^ |

\ -zcoMPREssoF

A-6



SCHEDULED

MAINTENANCEERVICES

Recommended AE

viscosily numbers

Typicalspecitication:API serviceSD, SE or SF

REPLACEMENTF ENGINEOIL

'l.

Warm p heengine.

2. Drain

he oilby removinghe drain

plug

and

oilfiller ap.

Warning

.

Walt a

while fo. the engine s too hot,

And be caretul o drain.

3. Reinstallhe drain

plug

securely.

Tightening orque:

29-41

Nm

(3.0-4.2

m-kg,

22-30 ft-lb)

4. Refillthengine ith hespecified

iltothe

F"

levelmarked

on

he evel

auge.

5. Refithe oil

illercap securely.

Oil

pan

capacity:3.0

iters

(3.2

US

qt,

2.6

lmp

qt)

REPLACEMENTF ENGINEOIL

FILTER

1. Removeheoil ilterwith he SST a

suitable rench.

2. lJse

a clean

ag o wipeoff he

mounting udace n the

engine.

3.

Apply

small

mount f clean ngine

ilio he ubber eal

ol the new

ilter.

4. Installhe oil

ilter

and

ighten t by handuntil he

rubber

sealcontactshe base.

5. Tightenhe llter1 and 1/6 urns

witha filterwrench.

6. Starthe engine nd check

or leaks.

7. Check he oil evelandadd oil

f necessary.

Oil filler capaclty

83:

0.17

iter

0.18

US

ql,

0.15lmp

qt)

(.c)

eF)

-30 -m -10

0 10

20 30 40 50

Engine

il

5W.30

v

30

'

5w-rd->

:

10w-30

A-7



SCHEDULED

AINTENANCE

ERVICES

INSPECTION

F

COOLING

YSTEiI

Warning

.

Nevei

remove

he

radialorcap

while he engine

s

hot.

.

Wrao

a thick cloth

around

he cap

when

removing

t.

. Whdnremovinghe radiatorcap, loosen t slowly

to the

fitst stop

until

he

pressure n the

radialor

s

released.

nd

hen

remove

t.

Coolant

Level

(Engine old)

1.Verifv

hat he

coolanl

evel

s near

he adiator

llel

neck

2. Verilv hat

he coolant

evel n

the coolant

eserviors

be'

tween

he

FULLand

LOW

marks

3. Add coolant

f necessary.

CoolantOuallty

1.Verffyhat

heie

s no buildup

f rust

or scale

round

he

radiator ao or radiatorillerneck

2.

Verily hat coolant

s free of

oi

Replace

he coolant

f

necessarv,

Coolant

Leakage

1.

Connect

radiator

ester

commercially

vailable)

nd he

SST

o the

radiator

illerneck.

2.

Apply 03

kPa

1.05

kg/cmz.

5

psi)

pressure

o the

system.

3. Verify

hat he

pressures held.

It not,check or coolanieakage

Coolanl

Protection

Caution

.

Do

not use

alcohol-

or methanol-based

oolant'

.

Useonly

soft

(deminerallzed)

ater

n

the coolant

mixlure.

1.

Measurehe

coolant

emperature

nd

specific

ravitywith

a

thermometer

nd

a hydrometer'

2. Determine

he

coolant

rotection

y

referring

o he

graph

lrthecoolant

rotectaon

s

not

proper' dd

water rcoolant

Antitreeze olution

mixture

percentage

?_--

-z'-

.- l,'1,/

'

COOLANT

EMPEFATUFE

C

(.F)

Gravily

ai

20"c

(68"F)

coolant

Above

-16"C

(3oF) 65

35

1.054

Above

26oC

(-1soF) 55

Abovea0'C (-40"D 55 1.078

A-8



SCHEDULED

MAINTENANCE

ERVICES

THEDFAIN

HOSE

REPLACEi'ENT F ENGINE

OOLANT

Warning

.

Never pen he radiator apwhile

he

engine

s hot.

.

Wrapa

thick cloth around he cap when oosening.

.

Use caution

when

draining

hqt coolanl.

Caution

.

Do nol

use alcghol.or methanol-basedoolant.

.

Useonly

soft

(demineralized)

ater n the coolanl

mixture.

'1.

Remove

he radiator apand oosenhe drain

plug.

2. Drain he coolant

nto

a suitable

ontarner.

3. Flushhecooling ystem

ithwater ntil ll races f color

are

gone;

hen et he system

raincompletely.

4. Installhe drain

plug.

5.

Fillwith he

proper

mount nd

mixture f

ethylene

lycol

based oolant y referringo the ableabove.

Coolanlcapacity

MTX:5.0 liters

(5.3

US

qt,

4.4 lmp

qt)

ATX: 6.0 liters

(6.3

US

qt,

5.3

lmp

qt)

6.

Run heenginewith he adiator ap

emoved ntilthe p-

per

radiator ose s hot.

7.With he engine

dling, dd coolanto the radiator

ntil

t

reacheshe bottom l

the illerneck.

8.

Installhe radialor ap.

A-9



SCHEDULED

MAINTENANCE

ERVICES

ADJUSTMENT

F

IDLE SPEED

Preparalion

'1.

Warmup the

engine

o normal

peratlng

emperaure.

2. Verity

hat he

wat rod

e)dends

utward

ully

and he

dle

cam separates

rom

he roller'

3. Turnall electric

oadsOFF.

. Blower an

.

Headlight

.

Rear

Window

Delroster

4. Makesure

hat

he engine

peed

does

notchange

wnen

disconnecting

he

alr btpass

solenoid

alve

@

connector.

Note

.

lf lhe engine

Peed ecleases.

he engine

s still un-

der the

warm-up

condition'

5.

ftheelectfic

ooling

an soperating,

ait illthefan

lops

6.

Verifyhat he

engine

s running

t

dle n

good

condition-

7. Connecthe SST o the diagnosisonnector'

8. Connect

tachometer

o thediagnosis

onnector

G-

ter-

minal

as shown.

L Selswitch

6)

to

Position

.

10 SetTESTSW

10SELF-TEST.

Note

.

lf the SST

s

not used,

ump

across

he TEN

elmi'

nal and

the GND

telminal

ot

the diagnosis

con'

nector.

ldle Speed

1. Check

he

idle speed

with a

tachometer.

ldle speed:

MTX

Neutral) 750

T

ATX

P

range)

,100

't

rpm

rpm

2.

f notwithinhe

specifacalion,

djust

he dle

by urning

he

throttle

djusting

crew

OAS).

t-\*l

A-10



SCHEDULEDMAINTENANCEERVICES

REPLACEMENTF AIF CLEANEF LEMENT

Visuallyheckthe ircleaner lementforxcessive

irt,dam,

age or oil,replacef necessary.

REPLACEMENTF

FUEL

FILTER

Warning

.

Keepsparksand

open

lamesaway rom

lhe tuel

area.

.

After

replacing he

tuel

filter,

check hat the filler

iointsare nol leaking.

To reolacehe uel ilter,

roceed

s ollows:

1.

Disconnect

he uelhoses.

2.

Removehe uel i/ ter irh he

brackel

3. lnstall new

ilter n

the

reverse

rderol removal.

Note

.

When nstalling he fillter make

sure

he hoses

are

pushed

gn

as tal

as

possiblg.

Secure he hoses with

clips.

INSPECTION FFUELLINESANOHOSES

Checkhe uel ine

ittings,

onnectionsndcomponentsor

|eaKs,

There hould e nowetness r stalned reashatmioht ndi-

cate

eaks-

Replace ny detective

oses

r clips.

A-1

1



SCHEDULED

MAINTENANCE

ERVICES

GND

/1.,"_(V

.:TS

r ,<--

ATUUSTMENT

F

IGNITION

IMING

Preparation

1. Warmup

the engine

o normal

perating

emperature.

2. Verily hat

hewax

odextends utward

ully

and

he dle

cam

separates

rom he

roller.

3. Turnall

electric

oadsOFF.

. Blower an

.

Headlight

.

RearWindow

Defroster

4. lvlake ure hat

he engine

peeddoes

notchange

when

disconnecting

heairbypass

olenoid

alve

@

connector'

Note

.

I the engine

peed

decreases,

he engine

s still u]}

der

the

warm-upcondition.

5. lf heelectric

ooling

an soperating,

aittillthe

anstops.

6. Verifyhal

he engine

s running

t dle

n

good

condition.

7.Connecthe SST o the diagnosisonnector.

8. Connect

timing

ight.

9. Connect

tachometer

o

hediagnosis

onnectorG-

ter'

minalas

shown.

10.Setswitch

@

to

Position

.

11.SetTEST W

o SELF

EST.

Note

.

lf the

SST s

not used,

ump

across

he TEN ermi'

nal and

the GND

erminal

gl

the

diagnosiscon'

nector.

lgnition Timing

Inspeclion Adiustment

1.

Check

hat he

dlespeed

s within

he specification.

ldle speed:

MTX

Neutral) ?50

:l rPm

ATX

(P

range)1,100

'

rpm

2. Check

he gnjtion

iming

witha timing

ight

lgnition

timing:

BTDC16

+

|

"

3.

lf the gnition

iming

s notwithinhe

specification,

oosen

the

distributor

ockbolts

and urn he

distributor

o make

the adiustment-

4. Tiqhten

he distributor

ockbolts o

the speciliedorque.

Tiohteninq

oloue:

ie-zsI{m

(i.6-2.3

m-kg,12-16

ft lb)

5.

Puta sealon

the distributor

ock bolt

ACHOMETEF

. - -

|N

re

G-

GNO

_ - - \

.?-.:f-

\r:1

\

- = \ , ( ' _ _ ' ,

A-12



SCHEDULED

MAINTENANCEEFVICES

USECONNECTOR

INSPECTION F SPARK

PLUGS

'1.

Checkhe

plugs

or burned r eroded lectrodes,ouling

or cracked

orcelain.

2. lvleasureheelectrode

ap.

f necessary,djusthe

gap

o

specificationsr replacehe spark

plugs.

Pluggap:1.0-l.1mm (0.039-0.043n)

(0.75-0.85mm

10.029-0.033

nl)

-Bl

Carburetor

Cauiion

.

when nslalling new

plug

or reinstalling

ld

plugs,

use a

small

amount

of anti-seizecgmDound

or

Bolybdenum-bas€dhread lubricar on the filst few

threads.

.

Do not

pull

the

spark

plug

cables

lo remove

them,

pull

on the spark

plug

boots.

INSPECTION F THROTTLE ENSOR

1.Warm p the engineo normal peralingemperature.

2. Verifyhat hewax odexpands utwardullyand hecam

separates

rom he roller.

3. Stop he

engine

nd

urn he gnition witch

ON.

4. Connectthe

STS

Engine

Signal

Monilor

and Adapter

Harness)

o the ECU

as shown.

5. Set he SST(EnglneSignelMonitor) o terminal M.

6.

Rotate

he hrottleinkby

handand verify

hat he voltage

is within he

specification.

Speciticalion

7. It nol

as

specilied, 4ust the throttlesensor.

ENGINE B1 B3

NGK BPBsES, PBoES BKRsE.11,KN6E.]

NIPPONDENSO

W16EXF.U, 2OEXR.UK16PR-U11,2OPR-IJ11

ECUTerminal

Throtle valvecondilion

2M 0.41-062V

A-13



SCHEDULED

'AINTENANCE

ERVICES

INSPECTION

F DASHPOT

Inapection

1. ODenhe hrottle

alve

ully.Push he

dashpot od witha

fingerandverity

hat t

goes

nto he dashpot

lowly.

2. Releasehe rodand

check hat

t comes

out

quickly

3.

Replacehe dashpot

f notas specified.

4. Warmup the engine

nd run

t

at

idle.

5. Connect

tachometer

o the diagnosis

onnector

G-

terminal nd

ncrease ngine

peed.

6. Slowly ecrease

he engine

peedand

check hat he

e-

ver ouches

he dashpot

od at the specified

peed.

Specitication: ,500+ 100 rpm

7. f not

as

specilied,

oosenhe ocknut

nd urn he

dashpot

to adjust.

ADJUSTING

CFEW

A-14



SCHEDULED

AINTENANCE ERVICES

INSPECTION F EVAPORATIVE

YSTEM

1 Warm p heengineo normal peratang

emperaturend

.un t at idle.

2. Disconneclhe vacuum

ose rom he solenoid alveas

shownn he igure, ndverity

hatnovacuums eltatthe

solenoid

alve.

3. f notas specified,heck he solenoidalve.

INSPECTION F

BATTERY

Check he electrolyte

evel.

The evelshoulde betweenhe

upper nd owerines.l the

level s low.add distilled ater.

Check he specific

ravity.

Speciticgravity:1.27

1.29

INSPECTION F ALL ELECTRICAL

YSTEM

Check

he all electricalystems.

lf he mulfuncton

sfound,eiero Section

or wiring

iagrams

tor reparr.

A-15



SCHEDULED

ATNTENANCE

ERVICES

INSPECTION

F CLUTCH

PEDAL

'1.

Check

he

pedal

or

smooth peration

2. Checkthe

edal

eight.

f necessary'

djudthe

edalheight

by

oosening

ocknut

@

and

urning

heclutch

wltch

q).

retighlen

he ocknut

4).

3.

Ch;ck

he

pedal

ree

play.

f

necessary,

diust

he

pedal

freeplay.Refer o H-4.

Pedal

heiqht:

196-207mm

(7.72-8.15 in)

Pedal

reC

play:

0.7-3.3mm

(0.03-0.13 In)

Diaenqagement

eight:

4lmm

(1.61

n)

mlnimum

With carPet)

INSPECTION

F

BFAKE

LINES,

HOSES

AND

CONNECTIONS

Check

he

points

elow,

eplace

arts

f

necessary.

1. Crackind,

amage

r

corrosion

l

the brake

hose

2.

Damaoe

o the brake

hose hreads.

3. Scars.lracks

r swelling

f the

lexible ose.

4. All ines or luid eakage.

INSPECTION

F

BRAKE

FLUID

Checklluid

evel

n reservoir.

he

evelshould

ebetween

he

lvax.

and Min.

ineson

the

reservoir.

lf the luid

evel

s extremelv

ow,

check

he brake

ystem

or

€aKs.

A-16



SCHEDULED

AINTENANCE

ERVICES

REPLACEMENT

F BRAKE

FLUID

AIR

BLEEDING

1. Remove

he brake

luidkom he

reservoiry using

suc-

lon

pump.

2. Fill he

reservoir

ithnewbrake

luid.

Fluidapecllication:FMVSS116: DOT-3

SAE:J1703

3. Attach

vinyltubeto

hebleeder

crew nd

place

heoth-

er end

ol the

vinyl ube n a containel.

4. Pumpout

he old brake

luidby loosening

ach

bleeder

screw

one

by one)and

pumping

he brake

pedal.

5. Bleed

ir as described

elow.

Cautlon

.

The tluid

in the reservolr

must be

maintalnedal

the

Z4 l€velor higherdurlngair bleeding.

.

Be caretul

nol to spill

brake lluid onto

Painted

surtaces.

'1.

Jack

up the

vehicle nd

supportt withsalety

tands

2.

Removehe

bleeder ap

and attach

vinylhose o the

bleeder

lug.

3. Place

he otherend

of the

vinyl ube n a container.

4. Slowly

ump

he brake

pedal

severalimes.

5.

Whilethe

rake

edal

s

pressed,

oosenthe leeder

crew

to let luidand a'rescape.

6. Repeat

teps and

5 until here

re no air bubbles

n he

fluid.

7. Check or

cotrectbrake

operation.

8.

Checko

be sure hat here

s no luid

eakage. esure

o

clean

awayany

spilled

luidwith ags.

9. After

bleedinghe

air,add brake

luid o he

reservoirp

to the

sDeciiied

evel.

INSPECTION

F

PARKING

RAKE

1. Pullthe

brake

everwith98

N

(10

kg, 22

b) ol forceand

measure

he ever

stroke.

2. f necessary,djusthe ever troke y

urninghe

adjust-

Ingnut.

Stroke: 6-8

noiches

INSPECTION

F POWER

RAKEUNIT

AND

HOSES

1. Check

he vacuum

ose, onnectors

nd

check-valve

or

cracks,

hafing, eterioration

tc.

2.

With he engine

topped, epress

he

pedal

a few imes

3.

With he

pedal

depressed,tart

he engine.

4. lf,

mmediatelyfter

heengine tarts,

he

pedal

moves own

slightly,

he unit s

good.

@ @

w w

A-17



SCHEDULED

'AINTENANCE

SERVICES

INSPECTION

F

DISC

BRAKE

Check

he ollowing

iscbrake

omponents.

1. Check

he caliper

peration

nd

nspect

or eaks

2. Check

he

Pads

ot wear.

3 Check he condition

nd

hickness

l the disc

plate

Minimum:BrakePad2.0mm(0.08 n)

Dlsc

plate

thicknesa

l6.0mm

(0.63

n) ATX

models

lomm

(0.39 n) MTX

mod€ls

INSPECTION

F

DRUMBBAKE

'1

.

Check

he

wheel ylinder

peration

nd

nspector

eaks.

2. Check

he

in'ngs

or wearor damage

3. Checkhe

condition

f he

nner urface

nd he

nner l-

ameter f

the drum.

Limli:

Brake1in1n9...........

l.omm

(0.04

n)

lnner

dlamater

f drum

..'.,....

81.smm

7.15

n)

INSPECTION

FSTEERING

ND

FRONTSUSPENSION

1. Check he

steering

heel

ree

play

Free

play:

0-30mm

(0-1.18 in)

2. Checkthe

teering

or

proper

peration

nd

or ooseness

of the steering ouslng.

3.

Check he

steering

ear

housing

or lluid

leakageor

seepage.

4. Check or exoessive

lay

on he

ie rodends

and rack

guide

5.

Check or damage

l the dust

boots.

6.

Checklor

ooseness

r

grease

eakage

fthetie od

ends

INSPECTION

F

POWER TEERING

LUID

AND LINES

(if

equipped)

i- Check he

fluidhoses,

inesand

connections

or cracks,

chaf

ng,deterioration,

tc.

2. Check

he

luid evelon

he reservolr.

The evel hould

e between

he

"F"

and

"L"

level

Add

fluid f necessary.

Fluld soecificalion:

ATF

Dexronoll

or M-m

A-18



SCHEDULED

MAINTENANCE

ERVICES

HOT

BANGE

REPLACEi'ENT

F MANUAL

RANSAXLE

IL

1.

Visually heck

he manual

ransaxle

or

oil

eakage.

lf

leakage

s

found, heck

or he cause,

nd repair.

2.

Removehe

speedometer

ableand driven

gear.

3.

Removehe drain

plug

and

drain he oil.

4. Reinstall

he drain

plug

securely.

Tlghtening

orque:

24-35

Nm

(2.4-3.6

m-kg,

17-26 ftJb)

5.

Fillwith

hespecifiedil

rom hespeedometer

riven

ear

hoie o the

F markon he

speedometer

riven

ear.

Specilledoil

Grade:

API service

GL-4

Viscoslly:

All-season

Dexron@tr l

M2C33F

Above

-l8cc

(0"F)

SAE

75W'80

Capacity:

2.5

litets

(2.64

US

qt,

2.2

lmp

qt)

INSPECTION

FAUTOMATIC

MNSAXLE

FLUIDLEVEL

Caulion

.

Place he

vehlcleon

a flat,

level surtace.

1

Apply he

parking

rake

nd

position

heel hocks

ecurely

lo preventhevehicleromrolling.

2.

Warm-uphe

engineuntil

he

ATF .eaches 0-70oC

(140-rs8oq.

3. While

epressing

he brake

pedal,

hift he

selectorever

to each

ange

P-L)

nd eave

t a iew seconds

n each

range.

4. Shiftback

o

P.

Nole

.

Only use

the COOL

(20oC) range as a

rough

tetetence.

5.

Ensurehatthe

ATF evel

s n he

HOT

65oC)

ange. dd

ATF o soecffication,

f necessary.

ATF ype:

oexron@tr r

M-Itr

Capacity:

6.3

literc

(6.7

US

qt,

5'5 lmp

qt)

BEPLACEMENT

F

FRONTWHEEL

EARING

REASES

Completely

ill heshaded rea

shown

n he igure

with ithi'

um

grease.

Note

.

Reler

to

page

M-8 for

disassembly

assembly

procedure.

A-19



SCHEDULED

MAINTENANCE

ERVICES

INSPECTION F

DRIVESHAFT

DUSTBOOTS

Check

he dustboot

on he drive

shaft or cracks, amage,

grease

eakage, nd

a loosebootband.

TIGHTENING F

BOLTSANDNUTS

ON CHASSIS ND

BODY

'1.

Tighten ll seat

mounting olts.

2. Retightenny

oose uts nd

bofts n hechassisand

ody

to the specified

orque.

Refer

o Section

D.)

TNSPECTIONF

EXHAUST YSTEM

HEATSHIELD

Check

heclearance

etweenhe

nsulator nd bodyandalso

between

he nsulator

nd he exhaust

ystem.

A-20



tNDEX. . . . . . . . . . . . . , . . . . .

ourLrNE.. . . . . . . . . . . . . .

SPECTFTCATIONS

...

TROUBLESHOOTINGUIDE..,........,

ENGINE UNE-UP ROCEDURE.....,

Pt rFPAHATI . ) I \ I

ENGTNE

r1. . . . . - . . . . .

ENGINE OOLANT

VALVECLEARANCE

IGNITION

IIVIING,DLESPEED.....

coMPRESStON......

TNSPECTTON

.........

ON.VEHICLEAINTENANCE............

PREPARATION

T||VltNGE1T ........

CYLINDEH

EADGASKET.....,.......

FRON'T ILSEAL....

t rFAA AI I qFAI

REMOVAL............

ENGINE TANOMOUNTING.............

PREPARATION

DrsAssEMBLY.......

PREPARAIION......

AUX|LIARYARTS........................

T IMING E1T. . . . . . . . .

cYLtNDER

EAD. . . . . . . . . . . . . . . . . . . . . . - . - .

CYLINDER

LOCK

(EXTERNALARTS).....................

CYLINDER

LOCK

{tNTERNALARTS)......................

tNSPECT|ONREPA|R.....................

-48

pREpARATtON

.....,...................,..-48

cYLtNDER

EAD..........................-48

VALVE

VIECHANtSM....................

-49

cAt\,4sHAFT..................................

-52

cYLtNDEB1OCK........................-54

PISTON,ISTON ING, ND

PtsToN

PrN................................-56

coNNECT|NG

OD.......................-57

CRANKSHAFT.............................

-s8

BEARlNG.........-.-.........................

-58

TTMtNGE1T......,........................

-59

TENSTONER,

DLER.......................-sg

TENSTONEBPRrNG.....................

-sg

pu11EY.................-..-..-...............

-59

ASSEI'BLY.....................................

-60

pREPARATTON

.........,..................

-60

CYLINDER

LOCK

flNTERNALARTS)......................-61

CYLINDEHLOCK

(EXTERNAL

ARTS)........-............-67

cYLtNDER

EAD..........................-72

TIMINGE1T. . . . , . . . . . . . . . . . . . . . . . . . . . . . . . .

-76

AUXtLtARYARTS........................

-79

ENGINE TAND

DISMOUNTING........-82

pRocEDURE

..............................

-42

rNST4LLAT|ON...............................

-84

pRocEDURE...............................

-84

01a08x.001

ENGINE

B - 2

B - 3

B - 3

B - 3

B - 5

B - 5

B - 5

B - 5

B - 5

B - 7

B - 8

B-10

9-10

B-11

B- l1

B-12

B-17

B-21

B-23

8-26

8-26

B-33

B-33

B-34

B-36

B-36

a-37

B-38

B-40

B'42

B-45



INDEX

INDEX

INTAKE

MANIFOLO

19-25

rktr

(1,$-2,6

n-*t,

la-19ll-rb)

lN: 0.3omm

0.012

n)

E* 0.30mm

0.012

n)

INSPECTION

ADJUSTMENT

ENGINE @OIAMI,

SEFIVICE

SECTION

E

ENGINE IL

INSPECTION

IEPLACEMENT,

SECTION

EXHAUSTMANIFOLD

rr-23 l&n

{r.9-2.3

f-*9,

DEFLECTION

AT

{98

N, 10 kg, 22 lb)

MPRESSION NSPECTION

AGE

B-12

6.0-7.5

{0.23-0.29}

.0-7-0

(o.1

1412

14.4,

O4l30O

1.Timing

elt

Removal

Insta||ation..................

age

B-12

2. Cylinder

ead

gasket

Bep|acement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .age -1

3. Frontoil seal

Replacement . . . . . . . . . . . . . . - . . . . . . . . . . . . . . .

age

21

4-

Rearoil seal

Replacement . . . . . . . . . . - . . . . . . . . . . . . . . . . . . .

age

-23

B-2

5.

Engine

Remova| . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

Engine tand

mounung

.............

age

Disassemb|y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age

InspecUon

F]epair................-.....

age

Assemb|y . . . . . . . . . . . . . . . . . . . . . - - . . . . . . . . . . . . .

age

Engine tand

ismounting

........

age

1nsta | Ia t ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

P-26

B-33

B-36

8,48

B-60

8,82

8 8 4



OUTLINE.

ROUBLESHOOTING

UIDE

B

OUTLINE

SPECIFICATIONS

Engine

Item

a3

Cylinder

nangementnd number

Combusrion

hamber

OHC, belt-driven

6 va ves

Displacemenl cc

(c'r

in)

1323

80.7)

Boreandstroke

mm

(in) 7 1 . 0 x 8 3 . 6 ( 2 . 8 0 x 3 . 2 9 )

9.4

Compression

ressure

kPa

kg/cm'. si)'rpm

1373

14.4,

99)300

IN

Open BTDC

ABDC

EX

Open BBDC

404

Close ATDC

Vaiv€

learance

mm

(in)

N

0.30

0.012)

EX 0.30

0.012)

ldle sp€ed rpm

[/TX

750

i

ATX

1100

"3

lgnition iming BTDC

1 6

1-3-4-2

TBOUBLESHOOTING

UIDE

Posslble Cause

eemedy

Page

Dif ii cu li start lng Mal lunction ol eng ine relaied componen ls

Wom

piston,pislon

ing or

cylinder

Faled cylinder

head

gasket

B-49

8,54,56

B-17

Mallunclion ol tuol system

Mallunclion ol igrltion system

Refer o SectionG

Poor

dling uallunclion

of

engine-rslated components

Poorvalvelo-valve eatconlact

Failed

ylinder

ead

gasket

B-49

B-17

Maltunction ol tuel system

Mallunctlon l

ign[ion

system

Reler to Section G

Oil workingup

Worn

pjston

ing

groove

r sticking

iston

ng

Worn

pision

r cylinder

8 5 6

B 54,56

Oil working

down

Worn alve tem r

guide

8-61,72

B-50

Oll leakage Retero Section

B-3



B

TROUBLESHOOTING

UIDE

Remedy

Ps9e

Insulticient

compaession

Compresson

eakage

rom valve seat

Weak or broken

valvespfing

Faiiedcylinderheadgasket

Crackedor d'slorred

ylinder

heao

Sticking damaged,

or wom

plslon

ng

Crackedor wofi

pislon

B-51

B

-49

B-52

B-17

B-48

B-56

B-56

Mallunction ot luel

system

Mallunction ot ignition

system

Relero Secnon

Othera

Slipping

lutch

Draggng brakes

lklfunction of enginerelaled

components

Siicking r burned

alve

weak or broken alve pnng

Carbon

ccumulalon

n combustionhamb€r

B-49

B-52

itallunclion ol

tuel system

lraltunctionof

lgnllionsystem

Enginsnois€

Crsnkshaft- or bearing-rolated

p.tls

Excessive nainbearing

oil clearance

Main bearingseized

or healdamag€d

Excessive rankshait

nd

Dlav

Excessive onnecting

od bearingoii

clearance

Connecting

od bearing

seizedor

heat_damaged

B-64

B-58

B-65

B-65

B-58

PBton-related

parls

Wom

piston

r

pislon

Pn

Damaged

ston rng

8 5 5

8 5 6

8 5 6

8 5 6

valves or timing-related

Parls

Broken alve ping

Excessve

alve

ude

clearance

B-52

B

-49

Malfunctlon

f coolingsystem

Refor o Secton

E

llralluncllon of

tuel sFtem

others

lvlaLfunctionl water

ump

bearing

lmproper

rive

beLl

enslon

Malfunctioni

aternalor eanng

Exhaustas eakage

N,4afunctioni I ming

beli ensioner

Befer to seci

on E

Reler o Section

G

B-13

B-4



ENGINE

UNE-UP ROCEDURE

ENGINE

UNE.UP ROCEDURE

PBEPARATION

ssr

49 9200 020

Tension

auge,

49 8019 9A0

ignilion

iming

ENGINEOIL

Inspection

1. Be sure he vehicles on

level

ground.

2. Warm p heengineto ormaloperating

emperature

nd

stop

rI.

3. Wait

or fiveminutes.

4. Removeheoildipsticknd heckheoil evelandondition.

5. Add or

replace il f necessary.

Note

.

Thedislance

elween he Land

F

markson he dip.

stick repressnts .8

iter

(0.85

US

qt,

0.70 mp

qt).

ENGINE OOLANT

Inspectign

Coolant

evel

(englne

cold)

Warning

.

Never emove he radiatorcap whlle he engine s

hot.

.

Wlapa thlckclotharound

he capwhen emovingl.

1.Verilyhat

hecoolantevel s near

he radiatoriller

eck.

2. Check hat hecoolant

evel n hecoolant eservoirs be'

tween he

FULL

and LOW

marks.

3. Add coolanl

l

necessary.

Coolanl

quality

1. Verifyhat

here s no buildup i

rust

or

scale

around he

radiator ap or

radiatorillerneck.

2. Verifyhat he coolant

s freeof oil.

3. Fleplacehe coolanl

i necessary.

ORIVEBELT

Inspection

1. Checkthe

rive eltsorwear, racks, nd

raying. eplace

if necessary.

2. Verity hat

he drivebeltsare correctly

mounted

n the

puleys.

V.RIBEEDELT

M t w J t M

o

x

B-5



ENGINE

UNE-UP

ROCEDURE

!.t- 2",.r

\

q/lotL puMp

Y/

\

cutteY

" fi.i sp,an'//

l,.PULrEV

ALTERNATOF

\ ,

-

P / s \

r^A /orr

pui,rp

Y

\"ut""\

.4.'

'--

'/

\\

CFANKSHAFT/

\

"y . . . "J \ " " J

CAANKSHAFI

/.A/C\

PULLEYCO

' .-agy'

3. Checkhedrive

eltdeflection

y applying

oderate

res-

sure

98

N,

l0 kg, 22

b) midway etween

he

pulleys,

s

shown.

Adjust

l necessary.

Dellection

trnn

n/

4.

Checkthe

rive

elttension

ith heSST

tension

auge).

Note

. Belt tensioncan be measuredbetweenany two

pulleys,

Tension

N

(kg,

b)

Adiusiment

Caution

.

It a new

bett s used,

adiusi

he bell dellection

at

the midpoint

ot

new belt specification.

Alternatorelt

1. f necessary,

oosenhe alternator

ounting olts

@and

adruslrno

olt

G)

z Lever h-e lternitor utwald ndapplyensiono thebeh

Tightening

orque

i&

:

37-51

N.m

3.8-5.3

m-kg, 27-38

ft-lb)

\t:

18-25 N.m

l'9-2'6 m-kg,13-18

ft'lb)

3. Becheckhe belt

ension

r deflection.

P/Sbelt.P/S +

tuC belt

It necessary,oosen

he

P/Soil

pump

mounting

@,

@

and

O

and

adjusthebelt

deflection

y utning

headjustingolt

@)

Tighlening

orque

@:

19-25

Nfl

(1.9-2.6

m-kg'

4-19

ft-lb)

!E,

36-54

Nm

(3.7-5.5

m'kg' 27-40

ft-lb)

G

:

36-54

N.m

3.7-5'5 m-kg, 27-40

flnb)

Drive bet

5 0

7 0

(019

0.27)

6.0-7.5

(o.23-O.29)

P/S, P/S

+

A/C

8 0 9 . 0

(0.31-0

35)

9.0-100

(0.35-0.39)

pJc

8 0 - 9 0

(0.31-0

5)

9.0-10.0

(0.3s

0.39)

Drive bell

451-785

(46

80.

101-176)

392 588

(40-60,

88

132)

P/S, PiS + A/C

491

589

(50-60, 110 132)

422-491

(43-50,95-110)

A/C

491-589

(50-60,

1r0-132)

422-491

(43

50,95-110)

5. lnstall he alr

intake

PiPe.

B-6



ENGINETUNE-UP

PROCEDURE

AJCbelt

lf

necessary,

oosenhe ocknut

@

andadjusthebeltdeflec-

tion by turning

he adjusting olt

@.

Tlghlening orque:

37-51

Ntn

(3.8-5.3

m-kg,

27-38 fl-lb)

:i\\

a.\.\

VALVECLEARANCE

Inspecilon Adiustment

1. Warmup the engine o normal

peratingemperature.

2. Removehe aircleaner.

3. Remove

he acceleratorable-

4. Remove

he cylinder eadcover.

5. Turn he crankshaftndalign he imingmarkso hat he

piston

fthe

No.1 r No.4 ylinder

s

atTDC f

compression-

6. Measurehevalve learances

with heNo.'lcylinder t

TDC

of compression,

nd hose

f

@

with he No.4 ylin-

der at TDCof compression.

Valve

clearanae

valve

slde)

lN : 0.30mm

0.012

n)

EX: 0.30mm 0.012 n)

7. lf il is not

within

pecification,

djustand

recheckthe alve

clearance.

B. Turn he crankshaft ne

Lrllurn and measure

he remain-

ing valve clearances.

diust f necessary.

9.

Installhe cylinder eadcover.

Tightening

orque

Bolt

@:

4.9-9.8 Nm

(50-90 cm-lq, 43-78 In-lb)

Bolt

@r

7.8-11

Nm

(80-110

cm-l€, 69-95

inlb)

Caution

.

It

the

headcover

gasket

s reused,applysealant

n

the

groove

as shown.

10. nstallhe accelerator

able.

'11.

lnstallhe air cleaner.

12.

Start

he engine nd check

or excessiveappet

noise.

B-7



ENGINE

UNE-UP

PROCEDURE

IGNITION

IMING,

DLE

SPEED

Prsparalion

1.Warm

up the engine

o

normal perating

emperature

2. Verity

hat he

wax odextends

utward

ullyand he dle

cam separates

rom he

roller'

3. Turnall electric

oads

OFF.

. Blower an

.

Headlight

.

RearWindow

Defroster

4. MakesLrre

hat he

engine peed

does

notchange

when

disconnecting

heair

bypass

olenoid

alve

@

connector'

5. l theeleckic

ooling

an

soperating,

aittillthe

anstops

6. Verifyhat

he engine

s running

t

dle n

good

condition

7. Connecthe

ssT to

the diagnosis

onnector'

8. Connect

tlming

ight.

9. Connecta

tachoheter

o the diagnosis

onnector

G- ter-

minalas shown.

Note

.

ll the engine speed

decreases,

hs englne

a atlll un-

der

the warm-up

condition.

'10.

Setswitch

@

to

position

1'1. et

TESTSW o

SELF-TEST.

Note

.

It the SST

s not used,

ump

across

he TEN ermi-

nal and the

GND erminal

ol

the diagnoals

con-

nedor.

lgnition

Timing

Inspection

Adius|ment

1.

Check

hat ne

dlespeed

s wiihrn

he specification

ldle speed:

MTX

Neutral) 750

i:!

rym

ATx

(P

range)

,100

:1

rpm

2. Check he

gnitioniming

witha

timing

ight

lgnit ion iming:

BTDC

6

+

l"

3. t the onition

r|nino

s not

within he specilication.

oosen

the disiflbutorocLbohs

nd urn

he distributor

o

make

the adiustment.

4.Tighte; he distributor

ockbofts o

the specified

orque

Tiohteninq orque:

is-zs-Nm

(i.9-2.6

m-ks,

14-19

ftlb)

5. Puta seal

on the

distributor

ockbolt.

)

B-8



ENGINE

UNE-UPPROCEDUFE

oreeos'6 o"G66alj

ldle Speed

'1.

Perform

Preparaljon"-

(Refer

o

page

B-8.)

2.

Check

he dlespeed

witha tachometer.

ldle speed:

MTx

(Neutral)

750

it

rpm

ATX

P

range) ,100:1 rpm

3. lf notwithin

pecification,djust

he dleby urning he hrottle

adjusting crew.

B-9



COMPRESSION

COMPRESSION

ll

rheenoine

xnibits

ow

power.poor ueleconomy

or

poor

dle check

he

ollowing:

1.

gnrtro;

ystem

Beler o Sectron

G.)

2.Compressron

3. Fuel

svstem

Fefer

o Section

.)

INSPECTION

1 Verifv

hat hebattery

s ully harged

Recharge

t f

neces-

sarv.

Refer

o

Section

G.)

2. Warm

up the engine

o normal

perating

emperature'

3. Turn he

engine

OFF.

4. Bemove ll

spark

plugs.

5. Disconnecthe gnition oilconnector'

6. Connect

compression

augetothe o

spark

lughole

7.

Fr.rllyepress

he acceleiator

edal

nd

crank he

engine'

8.

Recordhe

maxrmum

auge

eaolng

9. Check

ach

cylinder.

Compression

kPa

kg/cm', silrpm

B3

Siandard

1412 t4.4, O4!3OO

1030

00.5,

149)-300

't96

(2.O,

26)

10.

f thecompression

n oneor

more yllnders

rcw'

pour

a

small

amount

f engine

il

nto he

cylinder

nd

recheck

the

compressrcn.

(1)

lt thecompression

ncreases,

he

piston,

iston

ings'

or cvlinder

wall

mavbe

worn

(2)

lf the compression

tays

ow, he

valve

maybe

stuck

or seatingmProperly.

{3)

lt

he

comoression

n adjacent

ylinders

tays

ow, he

'

'

cvlinder

ead

gaskel

maybe

delective

r

he cylinder

head distorted.

11 Connect

he

ignition

coil connector.

12.Apply ntiseize

ompound

r molybdenum-based

ubricant

to

the spark

Plug

hreads.

13. nsiallthe

park

Plugs.

Tidhlenino oroue:

is-zsi{.m

(i.5-2.3

m'ks'

11-17

finb)

B-10



ON-VEHICLE

AINTENANCE

ON-VEHICLE

AINTENANCE

PREPARATION

ssT

49

G0175A0

Engine

uppod

49 D011102

inslallation

f

timing

belt

puley

49 E301060

Brake,ing

gear

49

E301 61

Sody

(Pan

of

49

E301

60)

49 E301

062

Collar

(Part

of

49 E301 60)

43 SE01 10

Centeingool,

installation

t

B-11



ON.VEHICLE

l|AINTENANCE

TIMING

BELT

Femoval

lnstallalign

'1.

Drsconnect

he negative

attery able.

2. Lilt up

the vehicle.

3.

Remove

n the order

shown n the igure,

eferringo Removal

Nole.

4.

Install

n

the

reverse rderof

removal,elerringo

Installalion

Note

1r-25

O,r-2.6,

1a-19)

7€-rr

rlo

(30-110

.eks, 6e-e5 In{b)

p0-rr0

*rs,

ca-es .-rb)

12-17

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

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

1.Splashhield

2.

P/Sand/or

A,/C

rive

belt

Insp€ct ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

3-

Alternatorrivebelt

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . .

age

Adjus tment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

4. Water

ump pulley

5.

Plate

Removal

ote. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

Installat ionote..........................age

6.

Pulleyock bolt

Removalote. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

lnstallat ion

ote........

...............-.

age

7.

Crankshatt

ulley

and

pulley

boss

B-12

L Timingbelt

cover,upper

L Timing elt

cover, ower

10.High-tensron

eads

11.Spark

lugs

12.Timing

elt

Removal

ote. . . . . . . .

. . . . . . . . . . . . . . . . . . . .

age

-14

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

'14

Installalion

ote....

.....................

age

B-1

'13.

Tensioner

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-14

Installat ionote..........................ageB-1

14.Tensioner

pring

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-14

Installat ion

ote..........................

age

B-'1

B - 5

8 , 6

B-16

8,13

B

1 5



ON-VEHICLE

AINTENANCE

Removalnote

Plate

1.Removehe rightstabilizer

ounting olts.

2. Suspendhe

enginewith he SST.

5. Removehe

plate

mountingbolts, nd hen he

plate.

Removeheenginemounl

No.3mounting olts nd urn

over he enginemount

No.3.

Lowerheengine

pproximately0mm

1.97

n)

gradually.

3

4

Pulley

ock

bolt

1.Hold he oullev

osswith he SST.

2. Using he SST,

oosenhe

pulley

ock bolt.

3. Remove

he

pulley

ockbolt

and

pulley.

i.- i\\

z

B-13



ON-VEHICLE

IAINTENANCE

Tlming

belt

i. lnstiiltneouttev

oct boll

and

urn

hecrankshaft

the

pin

on the oullev

oss

aces

up-right)

Caution

.

Donot

turn the

crankshaft

while

removing

he

pul'

ley lock bolt.

2.

Remove

he

iming

belt.

Note

.

Ma*

the liming

belt

rotallon

latlon.

lor

proper

leinslal-

PEELIN6

lnsoeclion

Refb.ring

o

page

B

69,

nspecthe

ollowing

arts:

1.

Timing elt

2.

Timing elt

engoner

nd spnng

3. Timing

elt

pulley

4. Camshaft

LrlleY

lnslallation

nole

Tensioner,

ensioner

sP.ing

1. nstall

he ensioner

nd

he ensioner

pring

2. Temoorarilv

ecllre

he ensioner

ith

he

spring

ullyex-

tenoeo.

Timinq

belt

1.Verii

lhal

he rming

ell

pulley

mark

s

alQned

ith

he im-

Ing

marK.

B-14



ON.VEHICLEMAINTENANCE

2. Installhe imingbeltso that here

s no looseness

t the

tension ide.

Caution

.

Do not tum the crankahaft ounterqlockwbe.

3. Installhe

pulley

bossand

pulley

ock

bolt.

4. Turn he crankshaft

wo urns lockwise,nd ace he

pin

on the

pulley

ossuPright.

5. Verifyhat hecamshaft

ulley

marks realigned ith he

cylinder eadcovermarks.

lf notaligned,emovehe iming

elt

and

repeatrom en'

sioner nstallation.

6. Loosenhe ensionerockbolt o

apply ensiono

he

im-

ing

belt.

Caution

.

Be sure

not to apply ensionother han hat of the

ienslonerspring.

7.Tightenhe

ensionerook

bolt.

Tighlening orque:

19-25

N.m

1.9-2,6

m-kg, 14-19 ft-lb)

8.Turn he crankshaft turnsclockwise nd verify hat

he

marks

re

correctly ligned.

9. Checkthetimingeltdeflection

y applying oderate

ree

sure

98

N,

l0 kg,

22 b)

midway etweenhecrankshaft

pulley

nd he camshaft

ulley.

ll

the iming

beltdellections notcorrect,emporarilye

cure ensionerockboltsothesprings ullyextendednd

repeat teps

-8

aboveor

replacehe ensionerpring.

Deflection:

11.0-13.0mm

0.43-0.st

In)at 98 N

(10

kg, 22 lb)

10.Removethe

ulley

ockboft nd

pulley

oss

sing

heSST.

Pulley

ock bolt

lnstallhe crankshaft

ulley

and ighten

he

pulley

ockboll

using

he SST.

Tightening orque:

157-167N.m 16-17 m-kg,116-123 t-lb)

9 a N

(10

kg, 22 lb)

B-15



ON.VEHICLE

MAINTENANCE

Plate

1. nstallhe

plate.

Tlghtening

orque:

iz-tz

Nrn

(1.25-1.7s

m-kE,

109-152

in'lb)

2.

Litt he engine

nd

nstallhe engine

mountNo3.

Tiohtenino orque:

ss-r

l i H..

(g.s-t1.9

m-kg,8.2-10.3

n-lb)

3. lnstallhe stabilizer.

Tiohteninq orque:

!l-sz

itm

(5.s-5.9

m-ks,

4.7-5.9

innb)

Steps

After

Installation

1. Lower he

vehicle.

2. Connect

he negative

attery able.

3. Start he

engine nd

checkas

follows:

.

lgnition

iming

Refer

o

page

B-8.)

@

B-16



ON-VEHICLE

AINTENANCE

CYLINDER

EADGASKET

Replacement

Caulion

.

Position he hose clamp n the orlginal ocationon the

hose,

and

squeeze he clamp ighlly

with large

pliers

o ensure a

good

fit.

1. Disconnecthe

negative

attery able.

2. Drain he englne oolantntoa container.

3. Removen the ordershown n the igure, eferringo

RemovalNote.

4. Installn the reverse rderof removal,eferringo

InstallationNole.

(30-110

orl(gi 3r-95

h.tb)

firs-11o

cn-&, 6s-95

in.lb)

FEPLACE

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

1.Air

cleaner ssembly

2.

Acceleratorable

Installat ionote........-................

3. Throttle able

4. Hoses

Flemoval

Installat ion

ote.--......

5. Harnesses

Flemovallnstallat ionote.........

6. Waierbypass

ipe

nutsand bolts

7. Alternatorrivebelt

8. Water

umppulley

9. Timing eltcover,upper

10.Timing ell

Removal

Insta||ation..................

age

B 12

11.Front xhaust

ipe

12. ntakemaniiold tay

13.Cylinder eadcover

14.Cylinder eadbolt

Removalote. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

19

lnstallat ion

ote..........................

age

B 20

15.Cylinderead

Disassembly..............................ageB-40

1nspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-48

Assemb1y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-72

16.Cylinder

ead

gasket

page

B-20

page

B-18

page

B-19

B-17



ON.VEHICLE

MAINTENANCE

Removal

Installation

ngte

Hoses

Disconnect

he

hoses

hown

n the

igure.

'1.

Brake

acuum

hose

2. Fuel

hose

B-18

3.

Vacuum

ose

solenoidalve)

4.

Heater

ose



ON-VEHICLE

AINTENANCE

Hatnesses

Disconnect

he harness onnectors hown n the

igure.

01EOBr162

Cylinder

head bolt

1 Loosen

hecylinder ead

bol{s n woor

hree tepsn he

order hown

n the igure.

2. Removehe

cylinder eadbolts.

B-19



ON-VEHICLE

AINTENANCE

lnstallation

note

Cvlinder

head

bolt

1. Applyclean ngine

il o

the bolt

hreads nd seat

aces

2.

Installhe cylinder

eadbolts.

3.

Tightenhecylinder

eadbolts

n wo

or hree teps n he

ordershown

n the

igure.

Tiohtenlnq oroue:

is-gr

-N.n

1z.z-a.l

m-rg, s6-60

ft-lb)

Acceleralorcable

1.

nstallhe accelerator

able.

2. Check he

accelerator

abledeflectior

lf the deflection

s not correct,

djust

by turning

nut

@.

Delleciion:

1-3mm

(0,04-0'12

in)

Stepsalter

installation

1.Fill he radiator

with he specified mount

nd typeof

engine oolant

Refer

o Section

E.)

2.

Connecl

he negative

attery able.

3. Start

he engine

nd checkas

tollows:

(1) Engine il and engine oolanteakage

(2)

lgnitioniming,

dlespeed

Refer

o

page

B-8.)

(3)

Operation f

emission ontrol ystem

4.

Recheckhe engine

oolantevel.

B-20




FRONTOIL SEAL

Replacement

1.

Disconnecthe

negalive

ahery able.

2. Remove

n

the ordershown

n

the

iglre, retefiingo RemovalNole.

3. nstalln the reverse rderof removal.

eferrino

o lnstallation

Nole.

I . . /

-na

I

o

---'r@\!

(a

l-.i 43)

€.,

$

aieurce

1.Timingbelt

Removal Inslal lat ion.... . . . . . . . . . . . . . .

2. Timing belt

pulley

lnstal lat ionote.... . . . . . . . . . . . . . . . . . . . . . .

3. Oil

seal

pageB-12

RemovalNote. . . . . . . . . . . - . . . - . . . . . . . . . . . . . .

lnstallat ion

ote..........

...............

age

B-22

page

B-22

Removalnote

Oil seal

1.Cut he oil seal

ip witha razor

nife.

2. Removeheoilsealwilh

screwdriver

rotecled

ilha rag.

B-21



ON.VEHICLE

AINTENANCE

lnslallationnote

Oil seal

'1.

Applya smallamount

f clean ngine

iltothe

ap l a new

oil seal.

2.

Push he oil sealslightly

n by

hand.

Cautlon

.

The oilseal

must be tapPed

n until

it is flush with

the edge ot the

oil

PumP

body'

3.

Tap heoilsealin venly

itha suitable

ipe

anda hammer'

Oil seal outer

dlametet:50.5mm

1.98

n)

Timing belt

pulley

1.

nstallhe imingbelt

pulley.

2.

nstallthe

ulley

Woodruff

eywith

he apered

idetoward

the oil

pump

body.

\

ALIGNKEY GFIOOVE

B-22



ON.VEHICLE

,|AINTENANCE

@E

gs

; a\&h

ffi

REAFOIL SEAL

Beplacement

1.Disconnecthe negative attery able.

2. Removen the ordershown n the igure, eferringo

RemovalNote.

3.

Install

n the reverse rderot removal,eferringo lnstallationNote.

1.Transaxle 3. Flywheel

MTX)

Serv ice. . . . . . . . . . . . . . .. . . . - . . . . . . . . . . . . . . . .ec t ion

2.Clutch

over,

lutchdisc

(MTX)

MTX

Removalote. . . . . . . . . . . . . . . . . . . . - - . . . . . . . . . . .e low

Serv ice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ec t ion

lns ta l la t ion

ote. . . . . . . . . . . . . . . . . . . . . . . . . .

age

-24

ATX 4.

Drive

plare ATX)

Removal ote............................ageB-24

Installat ionote...-......................

age

B 25

Serv ice. - . . . . . . - . - . . - . . . . . . . . - . . . - - . . . . . . . . . . . - . .Sect ionH

.Oi lseal

Removal ote.............

...............

age

B-24

Installat ionote......-...................

age

B 24

Removalnote

Flywheel

MTx)

Caution

.

Add approx13mm

0,51

n)ol spacers

@)

o space

the

SST

away rom the cylinder

block,

(MTX)

1.Hold he lywheel ith he SST.

2. Remove

he lywheel

olts.

3. Removehe

lywheel.

B-23



ON.VEHICLE

MAINTENANCE

Diive

plate (ATX)

1. Hold he drive

plate

with he SST.

2.

Removehe drive

plate

ockbolts.

3.

Removehe backing

late,

rive

plate,

nd

adapter

Oil seal

'1.

Cut he

oil seal

ip with

a razor nife

2. Remove

he oilseal

witha screwdtiver

rotected

witha rag.

lnstallation

note

Oll aeal

1. Applya smallamount

f clean ngine

iltothe

ip

ot

a new

oil seal-

2.

Push he oil seal

slightly

n by hand

Caution

.

The

oil seal

must be

tapped n

until

it is llush wllh

the

edEeof

the rear

qover.

3. Tap he

oilsealin venly

ithasuitable

ipeand

hammer.

Oil

seal oute,

dlameter:

100mm

3'94

n)

Flvwheel

MTxl

1 Femoveihe

;ahnt

tom he lwheel

boh

holesn hecrank-

shatt

and rom

he lywheel

olts.

Caution

.

ll all the

previous

ealant annot

be removed

rom

a bolt,

replace he

bolt'

.

Do not apPly

sealant

t a new

bolt

is used.

2. Set he

flywheel nto

he crankshaft.

3. Applysealant

o the

lywheel olts

and

nstallhem.

Caulion

.

Add

aporox13mm

0.51

n) ot space6

(O)

to space

the

SSi away

rom the

cylinder

block.

(MTX)

4. Hold he lvwheel nh

he SST

5. Trohten

he bohs

n twoor hreestepsn heordershown

inlhe

igure.

Tiohteninq

orquei

ge-lOg=

1.lm

g.g-ro.s

m-kg,7l-76

filb)

OIL SEAL

LIP

1h}'.

ffi'rl

)

w

@

H

EM

B-24




Drive

plate (ATX)

1. Removehe

sealantrom he drive

plate

boltholes n the

crankshaft

nd rom he drive

plate

bolts.

Caulion

.

It all the

prevlous

ealantcannot

be removed rom

a bolt, replace he bolt..

Do

not

apply

new

sealant

f

a

new bolt is

used.

2. Installheadapier,

rive

plate,

ndbacking

late

nto he

crankshatt.

3. Applysealant

o the drive

plate

boltsand nstallhem.

4.

Hold he

drive

plate

with he SST.

5. Tightenhe

bohs n lvoor three teps

n he

order hown

in the

igure.

Tightenlng

orque:

96-103

Nm

(9.8-10.5

m-kg, 71-76 ftlb)

Steps

After lnstallation

1. Connecthe negative attery

able.

2.

Start

he

engine

nd

perform

ngine

djustmeniss necessary.

osuoBx

72

@s

B-25



REMOVAL

REMOVAL

PROCEDURE

1 Disconnect

he negative

attery

able

2. Dra

n the enorne

oolanl

nd transaxle

il

3 Removen lie

ordetshown

n he

trgure

efernngo Removal

Note

Slep

t

1. Air

cleaner ssembly

2. Battery

lamp

3. Battery

4. Battery arrier

5. Accelerator

able

6.

Badiator

ose

7. Oil

cooler

hose

ATX)

8. Cooling

an connector

B-26

9.

Radiaior

racket

10.

Radiator

nd cooling

an

assembly

11.

Drive elt

12.P/Soil

pump

and bracket

if

equipped)

Removal

ote.......................... ageB-27

13.AJC ompressor

if

equipped)

Rernoval

ote.....

.....

. ..

..

pa1e

B-27



REMOVAL

Steo 2

Disconnecthe

harness onnectorshown

n

the

ioure.

A,/Ccompressor

(it

equippeo

Caution

.

Do noi damage he

hoaes,

1.

Removethe

JC ompressor

ith he

hoses

lillconnected.

2. Positionhecompressorway rom heengine ndaflix t

withwrre.

Removal

note

P/S oil

pump (il

equlpped)

Cautlon

.

Do not damage

he hoaes,

1. RemoveheP/Soilpumpwith hehoses tillconnected-

2.

Positjonhe

pump

away

rom heengine nd aifix

t withwire.

B,-27

i-

A

01E08X.062



REMOVAL

Steo

3

Disionnect

he

hoses hown

n the igure

1-Brake acuum

hose

2.

Fuelhose

Removal

ote. . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . .

e low

3. Vacuum

ose

solenoid

alve)

4. Heater

ose

Removal

note

Fuel hose

Wamlng

.

Keep sparks

and

open

flame

away

rom the tuel

area,

Cautlon.

Cover he

hosewlth a rag becauseuel will spray

oul

when disconnectlng.

.

Plug he disconnected

oses

o

avoid

uel leakage.

B-24

.,**d

Disconnect

he uel

hoses.



REMOVAL

Step

4

GASKET,

B

1.Speedometerable

2.Shift ontrol od(MTX)

3. Extensionar

(MTX)

4. Shitt ontrol able

ATX)

5. Frontexhaust

ipe

6. Clutch able

7. Lowerarm

Removalote. . . . . . . . . . . . . . . . . .. . . . . . . .

age

-29

8.

Driveshatt

Removal ote....-............... .........

age

B-30

L Enginemountmember

Fiemovalote.............................

age

B-30

Removalnote

Lowet arm

1. Removehe bolts nd

nutsat he

eft

and

ight ower rm

ball

oints.

B-29



REMOVAL

2.

Pull he

ower

arm downward

o separate

hem rom

he

knuckles.

Caution

.

Do not

damage

he

ball-ioint

dusl

boots.

Driveehafi

Separate

he driveshafts

rom he

ransaxle

y

prying

witha

bar nserled

etween

he

shaftand

he

case.

Caution

.

Do not

damage

he oil

sgal.

Enoinemount

member

1.

Suspend

heenoine

wrth

a chain

block

2.

Removehe

No.1

and No.2

engine

mount

nuts.

3.

Removethe

ngine

mount

member

olts

nd

nutsand

he

engine

mount

member.

Caution

.

Be

caretul

so that

the engine

does

not fall

when

removlng he

member'

ro, J"o,^.

]F

"o 1"n,",

MOUMI

MOUNT

B-30



REUOVAL B

Step 5

1.No.3 nginemount

01EOBX070

2.

Engjne nd ransaxlessembiy

Removalote......................................elow

Removalnote

Engineand transaxleassembly

Caution

.

Donot damage nycomponenls

n the enginecom-

partment,

Lift he engine nd ransaxlessembiy ut as a unrt.

B-31



REMOVAL

Step

6

Sep'arate

he engine

nd

kansaxle

n

the

order

shown

n the

igure'

MTX

ATX

1.Starter

nd bracket

2.

Throttle able

ATX)

3.No.'1

nginemount

4. Integrated

titf ner

B-32

5.Torque onverternddriveplatenuts ATX)

6.Transaxle

nstallatian

olts

7.Transaxle

ssy.



ENGINE

STAND

iIOUNTING

B

ENGINE

TAND

MOUNTING

PFEPAFATION

ssT

49 01076804

Enginestand

49L0l0 1A0

Hanger

et,

engine

49

1010 01

491010

A0)

engrne

49 1010

102

49 LO101Ao)

engrne

49 L0t0

103

Hooks

lOl

(Pad

ol

=l

49 1010

1AO)

49

1010104

l[$"

g

49 Lolo 1A0)

engine

4 9 1 0 1 0

0 5

Bolts

(Part

ol

491010

1A0)

49 1010

m

Bolls

iParr

oJ

49

L0t0 1A0)

engrne

B-33



ENGINE

TAND

MOUNTING

PROCEDURE

Step

I

Removen

the older

shown

n

ne

gure

1. Exhaust

manifold

nsulator

2. Exhaust

manifold

3. Water

ypass

ipe

4. uC compressor

racket

nd

dler

5.Water

nlet

PiPe

6-

Exhaust

iPe

racket

Siep 2

Caution

.

When

nsralling

he

SST

(engine

hanger)'

use

the

holes

shown

n

lhe

ligure.

GASKET.

EPLACE

C.V'G

\ \ ,

6 \Jl

* n a o

,'-g-\

SKET,

REPLACE

a)5

oi,tuo,

@

REPLACE

L-..:

1-

l-

-)

ao-

-oj

-o)

u l

1ll1

fi ltr

Frl

Fr

B-34



DISASSEMBLY

AUXILIARY

ARTS

'1.

Drain

heengine i l.

2. Disassemblen the

ordershown

n

the

ioure.

o o

z,

\

N,)

o

l

g

@

6P

'1.

Alternatorrivebelt

2. Alternator

3. Intakemanifold tay

4. ntakemanifold

ssembly

5.

ntakemanifold

asket

6.

Distributornd

highlensionead

7. No.3enginemountbracket

8. Oil

pressure

witch

L Engine anger

'10.

Oil dipstick

11.Spark

lug

12.Oil i l ter

B-37



DISASSEMBLY

TIMING

BELT

Disassemble

n the

order

snown

in the

igure,

eferring

o

Disassembly

ote

@

1.

Water

umP

UlleY

2.

Crankshait

ulley

olt

3. Plate

4. Crankshaft

ulley

5.

Pulley

ock bolt

Dlsassembly

ote

......

6.

Pulley

oss

B-38

7.

Timing

elt

cover,

upper

8.

Timing

elt

cover'

ower

9.Timino

elt

oirZ.!"totv ote . . pase -99

rnJp" i t ion. - . . . . . . . . . . .

. . . . . .

. .

pageB-5

1o.Tensioner,

ensioner

pring

-' -inipeition.................

..

..

..

page

B-59

.

page

g-47



DISASSEMBLY

Disassembly

ole

Pulley ock boll

Caution

.

Add approx

3mm

(0,51 n)

ot spacers

@)

o space

lhe SST

away rom the cylinderblock.

(MTX)

1. Hold heflywheel

IVTX)

r

drive

plaie ATX)

lth heSST.

2. tlemove he

pulley

ock

bolt.

Timing belt

1.Turn he crankshaltnd allgn

he marks.

2. Mark he

imingbelt otation

or

proper

einsialiation.

Caution

.

Never

orcetully wist the timing

belt. Do not lurn

it insideout or

bend t.

.

Be carelul not to allow

oil or

grease

on the belt,

==

"G

W*ff.,f

-

p\o'9ecrto

- ' g r

- \ ; - , / \ . t

\\-zz

W:

B-39



DISASSEMBLY

@\

CYLINDER

EAD

Disassemble

n the

order

shown

n the

igure,

eferrinq

o

Disassembly

Noie.

1.

Cylinder

eadcover

and

gasket

13

Cylinder

ead

2.ThermostaloveranogasKel

'lnspection

.

"

page

B-48

3.

Thermostal

'l4

Cylinder

ead

gasket

4.Thermosensor

l5 Valve

eeper

5. Rocker

rm and

shatt

assembly

Disassembly

ote

page

B-41

Disassembly

ote...

.

. .- .

.

page

B-41

16 Valve

pring

eat'

pper

6. Rocker

rm

lT Valve

Prrng

7. Rocker

rm

spring

Inspdction

"

'

page

B-52

8.

Rocker

hafi

lS

Valve

pring

seat'

ower

9.

Camshaft

ulleY

19 Valve

Disassembly

ote

.... ..

. . .. ..

puge

g-11

-

..

lnspeclion

"

page

B-49

Inspeclion.........

page

B-59

20

valve

eal

.

10.Thrust

late

Disassembly

ote

paqe

B

41

'1

1.Camshatt

Inspect

or

weal

and

damage

inspection.........

page

B-52

21 Valve,g-urde

12.Cylinder

eadbolts

-

Inspection

"

"

"

page

B-49

Disassembly

ote

.. ...

...

page

B-41

Replacement

"

page

B

50

-

22.Oil seal

B-40



DISASSEMBLY

Dlsassembly ote

Rocker arm and

rocker

shaft

assembly

1. Removehe rocker rm

and

rocker haftassembly.

2. Code llrocker rmsandsprings

othatthey

anbe

rein"

stalledn

hesame

laces

romwhich heywere emoved.

Camshafi

pulley

1.

Hold he camshaft singa suitable

rench

on the casl

hexaoon.

2.

Remdve

he camshaft

ulley

bolt.

3. Removehe camshaft ullev.

Cyllnderhead bolts

1. Loosen

hecylinder

ead

bolts

n woorthree leps n

he

ordershown n he igure.

2.

Remove

he cylinder

ead

bolts.

Valve keeper

1.

Set heSSTagainstheupper

alve

pring eat sshown

in the igure.

2.

Flemove

he valve

eepers.

Valveseal

Remove

he

valve

eal

with he SST

B-41



DISASSEMBLY

3*:*1T"11?f"-"[TI"tff

.tn",f,

SJ'"'"'""'nn'oo'"'"".'0''*ot"

E

Hr."*".

,

FEPLACE

1.Water

PumP

''i"rv]""..

"

"

" section

2.

Timrng

belt

Pulley

insie"tion..........

Page

B-59

3 Clutch over,

clutch

disc

(MTX)

Serv ice. . . . ._ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ec t ion

4 Flvwheel

MTX)

'Disassembly

Note.

.

..

paqe

B-43

Inspecl

or

wearand

damage

5 Backi;gpbte. dnveplate andadapterATX)

Disaisbmbly

ote.......

.

. .

.

pageB-43

6. End

Plate

7. Oil

pan

diassembly

Note

. ....

..

.. .

page

B-43

lnspect

or damage

8.

Oil

slrainer

9. Main

bearing

upport

late M6sl')

Disassem6ly

dte...

. .

... .

..

page

B-44

Inspect

or damage

10.Oil

pump

-

ierv i ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ec t ion

11. Frontoil seal

bisassembly

ote

...... ... ... pageB-44

12.Rear

over

13.

Rear

oil

seal

Disassembly

ote

.....

.. ....

page

B-44

B-42



DISASSEMBLY

@

Dbaaaembly

Note

Flywheel

Cautlon

.

Add approx

3mm

(0.51

n) ot spacets

(@)

lo space

the

SST

away

rom lhe cylinderblock.

(MTX)

1. Hold he lywheel

ith he SST.

2. Loosen

heclutch overbolts

n two or hreesteps

n the

order

shown

n

the

igure.

3. Remove

he clutch ove..

4. Removehe lywheel

olts.

5. Bemove

he lywheel.

6.

Removehe SST.

Backing

plate,

drive

plate,

and

adapter

ATX)

'1.

Hold he drive

plate

with he SST.

2. Remove

he drive

plate

botts.

3. Removehe backing late, riveplate, ndadapter.

4. Removehe SST.

Oll

pan

'1.

Removehe oil

pan

mounting olts.

2. nsena screwdriver

r a suitable

oolbetweenhe VIBSP

and oil

pan,

and

Pry

hemapart.

Caution

. Do not insert the prying ool between he MBSPand

cylinder

block.

.

Do not

damageor sc6tch

the contactsurfaces.

B-43



DISASSEMBLY

ain beadngsupport

plate (MBSP)

'1.

Removehe

MBSPmounting

olts

rom

hemainbearing

cao.

2.

Inden screwdriver

r a

suitable

ool between

he MBSP

and cylinder

lock,

and

pry

hemapart.

Cautlon

.

Do not damage

or

scratch

the contact

surlaceg

when removlng

old

sealant.

Front oll seal

Remove

heoilseal

witha screwdriver

rotected

itha

rag.

Rsar oil seal

Removehe

oilseal

witha screwdriver

rotected

itha rag.

FOTECT

HEEEAA

COVEFI

PFOTECT

HE

PUMP

B-44



DISASSEMBLY

CYLINDEF LOCK

ONTERNAL

AFTSI

D,sassemblen rheordershown

n

the igure, efefiingo Disassembly ote.

1.

Connecting

od

cap

6.

Piston

Disassembly

ote......................

age

8-46 Inspection..................-................

age

B-56

2. Connectingod

7. [/ain bearing ap

Disassemblyote.......-.............

age

8-46

Disassemblyote .....................

age

B-47

Inspection....-.......-......................

age

B-57 8. Crankshaft

3.Connecting

od

bearing Disassembly

ote.......-..............

age

B-47

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-58

Inspect ion. . . . . . . . . . . . . - . . . . . . - . . . . . . . . . . - . .

age

-58

4. Pislon ing

9.

Mainbearing

Disassemblyote .....................

age

B-46

Inspection......................-....-.......

age

B-58

Inspection......................-............age8-56 10.Thrust earing

5. Piston

in

11.Oil

i l ter

oint

Disassembly

ote

.....................

age

8-46 12.Cylinderlock

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-57

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-54

B-45

tr/:

v r

ry

n



DISASSEI'BLY

Disassembly

Note

Connecting

od

caP

d-torJie.dving

tne'connecting

od

caps'

measure

hecon-

ieciino roo

sid6

clearance

Relero

page

B 66

)

Connectlnq

od

1.Before

e;ovrng

ne

connecing

ods'

measure

he

connect

ino roo

oil clea'rance-

Refer

o

page

B-57

)

2. Remove

he

Plastigage

rom

he

crankpin

ournals'

Caulion

l-do-not

""rar"tt

ttt" clankshaft

ournal

or

the cylin-

der

wall.

3. Use hehandle tahammero

remove

he

pl$on

and

con-

-

i*tlng

t;

uo".uly

through

he opof hecylinder lock

Pision

ring

Caution

.

oJ not

appty

excessive

ension,

which

may

cause

the

rings

to

anap

oul.

Removehe

piston ings

with

a

piston ing

expander

com-

merciallv

vailable)

Plston oin

Caution

.

Ma* lhe

connecting

od

direction

ol

proPer

eas-

sembly.

'1.

Before isassembling

he

piston nd

connecting

od'

check

the

oscillationorque sshown.

iiin"luioe

Lno

aoe"

not

drop

by

itsown

weight,

eplace

the

piston

r

the

Piston

in

B-46



INSPECTION

REPAIR

INSPECTION

REPAIR

PREPARATION

ssr

49 BO12 05

gulde

83)

1. Clean

ll

parts,

eing

ure o

remove

ll

gasketragments,

irt,

oil'

grease'

arbon

moisture

estdue'

nd

olher

oreign

materlals

Z. nsoection"anO

epairs

mustbe

pertormedn he

order

specified'

CautionfuiJt a"t"s" rne

oints

orlrlction surtacesol alumlnum lloycomponentssuchas the cy'-

Inder

head

or

pistons).

orEoBx.oe

CYLINDER

EAD

i. lnspect

he

cyhnder

ead

ordamage,

racks,

nd

eakage

ot

waler

and

oll.

Replace

he

cylinder

ead

f necessary

Z. ,reaiuielni

cvtinaer

eaddistortion

n the

six directions

shown

n

the

igure.

Distortion:0.l5mm (0.006 n) max.

Caution

.

-selole

qrinalns

the cylinder

head,

check h€

tollow'

ing

ani

repair

or

rePlace

he

cylinder

head as

necesaary.

Sinklng

ol

valve

seals

Damagl

ot

manifgld

cgntacl

sudace

cams6aft

oil

clearances

nd

end

play

3.

f thecylinder

ead

dislortion

xceeds

pecification'

rind

the cvlindel

ead

surface

ii

tne

vtinoer

eao

erghl

snot

within

pecilrcation

edace

it.

Heiohl:

107.4-107.6mm

4,228-4'236

In)

Gri;ding:

o.20mm

0.008 n) max.

B-48



INSPECTION

REPAIR

4..

fJ

-sreure

THICKNESS

4.

l\4easurehe manifold ontact urface istortionn he six

directions

hown n the igure.

oistorllon: 0.t5mm

(0.006

n) max.

5.

f

distortion

xceeds pecification,

rind

he surface r

re-

olace he cvlinder ead.

VALVEMECHANISM

Valveand

Valve

Gulde

1. Inspect ach

valve or he ollowing. eplace r resurlace

the valve l

necessary.

(1)

Damaged r bentstem

(2)

Roughor damagedace

(3)

Darnaged r unevenly ornstem ip

2. Measure

he valveheadmarginhickness 1each

valve.

Replacehe valve f necessary.

Margin hicknesa

min.

B3

IN

1.1

0.043)

EX

1.2

O.O47)

3. Measurehe

ength

f each

valve.

Length

mm

{in)

diameter f

eachvalveal the

points

.

Measure

he stem

Dlameter

B3

IN

5.970-5_985 0.2350-0.2356)

EX

5.965-5.980 {0.2348-0.23541

5. Measurehe nnerdiameter feachvalveguideat hepoints

shown.

lnner diameter

B3

IN, EX

6.01-6.03

0.2366-0

2374)

6. Calculatehe

valve

tem

o

guide

clearance-

Subtractheouterdiameter

f he valve tem rom he n-

nerdiameter f the corresponding

alve

guide.

Clearance

lN r 0.025-0.060mm

(0.0010--1t.0024

n)

EX: 0.030-0.065mm(0.0012-0.0026 n)

Maximum:0.20mm

0.008

n)

7. lf the clearance

xceeds p€cification,

eplacehe valve

and/or

alve

guide.

B-49

B3

IN

Standard

108.24

4.261't

1077414.241

EX

Standa.d

109.34

4.304)

Minimum 108.84

4.?85)

|h"::



INSPECTION

BEPAIR

CYLINDEF

HEAD

8. Measure

he

protrusion

eight

of

each

valve

guide Replace

the

valve

guide l necessary.

Height

mm

in)

Replacement

l

valve

guide

lll?

tte

strapes

f the

intake

nd

exhaust

alve

guides realitferent,

nstall

orrectly'

B:fio9Jilh.

"ru"

rioe

rom

he

ide

pposite

he

ombus'

tion

chamber

with

he

SST

B-s0

Installation

1 Fit

he

clip

onto

he

valve

guide'

2.

Usinq

he

SST.

ap

he

valve

uide

n rom

he

combustion

-

"n"ril"i

"io"

to

inat

he

protrusion

erghl

dimension

In the

igure)

s withrn

pecilication

:a;l?h

sft|ke

hard

arter

he

cllP

contacts

he

cvlin-

der

head,

he

cliP

will

be damaged'

EX

IN

ffi

lH

\]H

N



INSPECTION

REPAIR

ValveSeat

1. nspecthe contact

urtace f each

valve

eatand

valve

face or the

ollowing:

(1)

Roughness

(2)

Damage

2. f necessary,

esurfacethe

alve eatwitha45" valve eat

cutterand/or esurfacehevalve ace.

3.

Applya thin

coatol Prussian

lue o the valve ace.

4. Inspectthe

alve eating y

pressing

hevalve gainstthe

seat.

(1) li

blue

does otappear 600

aroundhevalveace, e-

place

he valve.

(2)

lf blue

doesnotappear 600around

he valve eat,

resurlaceheseat.

EAT

CONTACT

WIDTH

if

5. Measure

he seat

contactwidth.

width

DIMENSION

mm

(in)

B3

IN,EX

0.8-1.4

(0.031-0.0s5)

6.

Verifvhat

hevalve eating

osiiion

s at hecenter f he

vave

Tace.

(1)

lf heseating

osition

s oo

high,

orrect

hevalve eat

witha 70o cutter

nd a 45" cutter

(2)

lf the seating

osition

s oo ow correcthevalve eat

witha 40' cutter nd

a 45o cutter

7. Seat he

valve o the

valve eatwith apping ompound.

8.

Inspecthe sinking

l the valve

eat.

Measure

he

protruding

ength

djmension

) of he

valve

stem.

Dimension

: 41.05-41.95mm

1.616-1.652

n)

I N

E"'il

db

\

v . . v l

\€=:.,

B-51



INSPECTION

REPAIR

Out-ol-square

IN

1.42 0.055)

EX

1.42

0

055)

Valve

Spring

1. nspect

ach

valve

pring

or cracks

nd

damage

2. Measure

he

ree ength

and out

oi square

Replace

he

valve

pring

f

necessary.

Frge

length

standard...mm

in),

Mit]imum...N

kg

lb)/mm

in)

CAMSHAFT

1. Set

he

rontand

rear

ournals

n

V-blocks-

2. Measure

he

camshaft

unout

Replace

he camshaft

f

necessarv.

Runout:

0.03mm

0'00'12

n) max.

3.

Inspect

he

camshaft

or

wearand

damage

Replacehe

camshafi

Jnecessary.

4. Measure

hecam

obe

heights

t he

wo

points

sshown

# @

B-52

Height

mm

(n)

41.5-42 { r .634

1.654)

No correcton

n€€ded

42.0-43.0

(1.654-1.693)

Adjusl

withwasher

n sping

seal

areaof

cylinder

head

[4ore han

a3

0

(1.693)

Beplace ylinder

head

B3

IN

Slandard

40 7

(1.602)

Minimum

133.2-r50

(r3

58

1s.37.9 8-33

1!36

(1 17)

EX

Slandard

40.7

0.602)

L4inimum

133.2-150.i

3

58-15.3/

.88-33

l)86

(1

14

B3

IN

Slandard

36.527 .4380)

lVlnimum

36.327

1.4301)

Slandard

36.333

1.4304)

[,'linrm!m

36.133i'1.422s)

mm

{rnl



INSPECTIONREPAIR

5.

Measurethe

ournal

iametersand

Y

directionst he wo

points @

and

@)

shown.

Diameter

Out

of round: 0.05mm

0.002

n) max,

6. Measureheoilclearancesetween

hecamshaftndcyl

inderhead.

{1)

Removell oreignmaterialndoil

rom

he

ournals

nd

the camshaft ore.

(2)

lvleasurehe camshaft

orediameter.

03u081105

Diameler

mm

in)

(3)Subtracthe ournal iameterrom he borediameter.

Oil

clealance

B3

No.1 No.5

43.500-43.525

.7r26-1.7135)

No.2,No3, No4 43.500-43.525

1.7126-1.7135)

No.1 No.5

0.040 0.085

0.0016

0_0033)

N o 2 & N o 4

0.050 0.100

0.0019

0.0039)

No-3 0.065-0.1

5

(0.0a25-0.0045)

0.15

0.006)

(4)

li theclearance xceedshe

maximum,eplacehecam-

shaftor cylinder

ead

7.

Measurehecamshaftnd

play.

f t

exceeds

hemaximum,

reolacehe hrustolate

or

camshaft.

End

play

:

0.060-0.200mm

(0.0023-0.0078

n)

Maxlmumr .2mm

0.007

n)

B3

No.l& No.s 43.440*43.4601.7102-17.10)

No-2& No.4 43.425-43.450

1.7096-1.7106)

No.3

43.41

O

43.435

11.7O9

, 1.71

OO)

B-53



INSPECTION

REPAIR

Rocker

Arm

and

Bocker

Arm

Shaft

1 Check

or

wearor

damage

o the

contact

urface

f he rock-

er arm

shatt

or the

rocker

rm-

Replace

f necessary

2. Checkthe

ilclearance

etween

he

rocker rm

andshalt

Replace

f necessary.

(1)

Measure

he

rocker

rm

nnerdiameter'

Diameter

B3

IN EX

19.000-l

9.033

0.7480-0.7493)

(2)

Measure

he rocker

rm

shatt

diameler'

Diameter

B3

lN,

EX

1&959-18.980

0.7464-0.7472)

(3)

Subt.act

he

shaft

diameter

rom he

rocke'arm di'

ameler.

Oil clearance

mm

(in)

CYLINOER

LOCK

1. Checkthe

ylinder

locklorthe

ollowing

nd

epalror

re-

place

he cylinder

lockas

necessary

(1)

Leakage

amage

(2)

Cracks.

(3)Sconng l wall

Z. Miasurehi

distonion

flhe

op

sLriace

i hecvlinder

lock

in the

slx directions

hown

n

figure

Distort ion:0.15mm

0.006n)

max.

3. lf thedistortion

xceeds

he maximum.

epair

y

grinding

or replace

he

cylinder

iock

Height: 2l.smm

8'720 n)

Grinding:

0.20mm

0'008

n)

max.

G

B3

tN,

EX

0o20-o

074

0

0008-0.0029)

010

(0.004)

B-54



INSPECTIONREPAIR

___n_

o

c2

So

z/-I\"

r " -

$\1-l^

o \ 4 o

-L__-r-

H

o 7

s o

71"1--\v

O s - t o

ry

4. Measure he cylinderbores n

X

and Y directions t ihree

levels

A,

B, and C) in each cylinderas shown.

Cylinder bore

mm rnl

Caution

.

The boring size should

be basedon the

sizeof an

overslze

pislon

and be

the

same

or all

cylinders.

(1)

lf

thecylinder

oreexceedshe maximum,eborehe

cylindero oversize-

(2) If he differenceetweenmeasu.ementsand C ex-

ceeds the maximum aper,

rebore

he cylinder o

overslze.

Taper:0,01gmm

0.0007

n) max.

(3)

lf the difierence etweenmeasurementsand Y ex'

ceeds

he maximum utof-round,eborehe cy{inder

to oversrze.

Out-ol-round:0.01gmm

0.0007

n) max.

5. lftheupper

part

of a cylinder allshows neven ear,

rnove he ridge

with

a

ridge eamer.

B3

Slandard 71.006-71.013 (2.7955-2.7958)

0-25

0.010)

versize 7 1.256-7 .263

2.8053,2.4056)

0.s0

0.020)

vercize

71.506-71.513

2.8152

2.81

5)

0.75

(0

030) oversize

7 .756-71.763

2.8250

2.8253)

1.00

(0.04)

oversEe 72.046 72.01

12.8349-2.4352)

B-55



INSPECTION

REPAIR

o -

R|NG

GnoovE

lo.7m

n)

OIAMETER

PISTON.PISTON

RING,

AND

PTSTON

IN

Plston

Caution

.

lf the

piston

s

reptaced,

he

piston ings

mustalso

be

replaced.

1.

Inspecthe outer

circumferences

f all

pistons

orseizure

or scoring.

Replace

he

piston

necessary

2.

Measureihe uter

diameter

f each

piston

t a rightangle

(90o)

o the

piston

n,

16.5mm

0'650 n) below he

oil

ring and

oweredge.

Piston diameter

mm

in)

3. Measurehe

piston{o-cylinder

learance

Clearance:

.039-0,052mm

(0.0015-0.0020

n)

Maximum:

.15mm

0.006 n)

4. lf theclearance

xceeds

he maximum,

eplacehe

piston

or reborehe cylinderso fit oversize istons

FING

Pision and

Piston

Rings

1 Iveasure

he

piston

ing o

ring and

clearance

roundhe

enlire ircumference

srng

new

plslon

nng.

Clearance

Top

and Second)

B3

0.030-0.070

0.0012-0

0028)

015

{0.006)

lf heclearance

xceeds

he

maximum,

eplacehe

piston.

Inspect

he

piston

ings

or damage,

bnormal

ear, nd

breakage.

eplace

he

piston

ings

i necessary

4. Insert lie

piston

ing nto he

cylinderby

hand

and use he

Diston o oush

it to

the bottom

of the

ring travel

2.

3 .

70.961

7

0.967

2.7937

2.7939)

0.25

(0.010)

ove6ze

71.21

71.217

2.AO36-2.aO2A)

0.50

0.020)

versze

71.461

71.467

12

A134-2.8137)

0.75 0.030) versrze

7 t .711-71 .717Q.A2$-2.A235)

] 00

(0

04)

oversize

71.961-7r .967

2.8331 .8333)

B-56



INSPECTION REPAIR

f-6t'1

L'----\-v

5. Measureach

pislon

ingend

gap

witha

eeler

auge.

Re-

place

he

piston

ing f necessary.

Erd

gap

Top : 0.15-0.30mm

0.006-0.012

n)

Second: 0.30-0.45mm

0,011-0,017

n)

Oil rail : 0.20-0.70mm(0.008-0.028 n)

Maximum: 1.omm

0.039

n)

Pistonand Piston

Pin

1.

Measure ach

piston in

holediametern X

andY direc-

tionsat lour

points.

Diameier:19.988-20.000mm

0-7869-0.7874

n)

2. Measure achoiston indiameler

n X

andY directionsi

four

points.

Diameter:

19.974-19.980mm

0.7864-0.7866

n)

3. Caiculate

he

oistonDin{eoiston learance.

Clearance:

,008-0.026mm 0.0003-0.0010n)

4. Il

the clearance

xceeds pecification,eplace

he

piston

and/ofoiston in.

CONNECTING

OD

1.Measure achconnecting

od

bushing

nner

diameter.

Diameter:

19.943-19.96lmm

(0.7852-0.7859

n)

2. Calculatethe

/earance

etween

heconnectinood

bush-

ingand

piston in.

Interterence: .013-0.037mm

0.0005-0.0015

n)

3. Measure achconnecting

od or bending. epair

r

re

place

he

connecting

od if necessary.

Bending.'

.075mm

0.0030

n) max./somm

1.97

n)

B-57



INSPECTION

REPAIR

CRANKSHAFT

1. Check he

ournals

nd

pins

or damage, coring, nd

oil

holeclogging.

2.

Set

he crankshaft

n V'blocks.

3. Measure

he crankshaft

unout t the

center

ournal.

Replacehe crankshaft

f

necessary.

Runout:0.04mm

0.0016

n) max'

4. Measureach

ournal

iameter

n X and

Y directionst wo

points.

Main

ournal

Diameter:

49.938-49.956mm

1.9661-1.9668

n)

Out-of-round:

.05mm

0.0020

n) max.

Crankpin

ournal

Diameter:

39.940-39.956mm

1.5724-1.5731

n)

Out-ol-round:

,05mm

0,0020 n) 6ax.

5. lfthediameter

s ess han

heminimum,

rind

he

ournals

to matchan

undersizeearing.

Undersize

ea ng:

0.25mm

0.010

n),0.50mm

0.020

n),

0.75mm

0.030

n)

Main

ournal

diameterundelsize

Crankpin

ournal

diameler

undersize

mm

(in)

BEARING

MalnBeadng

and Connecting

Fod Bea

ng

Check he main

bearings nd

he connecting

od bearings

for

peeling,

coring,

nd other

damage.

t t \

f----T----i

\i_,i

Bearino ize

0.25

0.010)

ndersze

49.688-49.706

.9562

1.9569)

0.50

0.020)

ndersze

49.438-49.456

1.9463-1.9470)

0.75

(0.030)

ndelsEe

49

188-49.206

1.9365-1.9372)

0.25 {0.010)

unde6ize

39.690-39.706 {1.5626-1.5632)

0.5010.020)

rndersize 39.440-39.456

1.5528-1.5534)

0.7510.030)rndersize 39190-39.20615429-1 5435)

$dr

E B E

EBB

B-58



INSPECTION

REPAIR

sry6

f,*f^^y

TIMINGBELT

Caution

.

Never orcelully

wist,

turn

insideout, or bend he

timing beh.

.

Do

nol allow oil

or

grease

on the belt,

1. Replace

he iming

belt f there

s any oil

or

grease

n it

2. Check

he iming elt

or damage,

ear,

peeling,

racks,

and hardening.

eplace

he iming

belt l necessary.

TENSIONER,

DLER

Caution

.

Do

not clean

he lensioner

or idler

with cleanlng

fluids.

ll necessary,

use a

solt lag to wiPe

them

clean,

and avoid scratching

hem.

Checkhe

ensionernd

dlerfor mooth

otation ndabnor-

mal noise.

Fleplacehe ensioner

r

idler l necessary

TENSIONER

PRING

Measurehe ree

ength f

he ensioner

pring.Replacehe

tensioner

pring

f necessary.

Free

ength:54.0mm

2.520

n)

PULLEY

Timing Belt

Pulley,Camshalt

Pulley

Cautlon

.

Do not

clean he

pulleys

with cleaning

luids' ll

necessary,

se a soft

rag to wipe them clean,

and

avoid

scralching

hem.

Inspectthe

ulley

eeth

orwear, eformation,

ndother

am-

age.

Beplace

he

pulley

f necessary.

G

r-'E

T{7\\E

sry

lilll-1LlE

-5*\

reF.-

ZilF\

rsr-

Vg

B-59



ASSEII/IBLY

ASSEMBLY

PREPARATION

ssT

49 D011001

suppon

block

49H011 018

Support

lock

insiallation l

49 D011

03

installer

pislon ins

49 8134

044

Piston

pin

quide

inslalatLon

49

E301 60

Brak€,

ng

gear

49 E301

61

Body

ean

oi

49 E3o1

60)

49 E301

62

Collat

(Parl

oi

49 E301

60)

engine

rotation

49

AO12 Pe

sping

ilier

installalion

49

B0l2

012

Body

(Parl

oi

49 BO12

A2)

inslallation

f

498012

13

(Part

r

49

Bo12 A2)

inslallationf

49 8012

14

49 80120A2)

installation

f

49 0636

1008

lilter

installation f

49 SE01

310

Centellng

ool,

installation f

1. Clean

all

parts

before

einstallation.

2. Aoplv

new engine

oil to all

sliding nd

rotatilg

parts.

3. R;phce plainbearingsf theyarepeelingburned'or otherwse amageo

4 Tidhren ll

boltsand

nuls

1o he specified

orques

cluton

.

Do not

reuse

Easkets

or oil

seals.

B-60



ASSEMBLY

CYLINDER LOCK

INTERNAL

ARTS)

TorqueSpecifications

CYUNOEF

WALLS

PAOTBUSTON

9mm 0.75

n)

JOUFNALS

T

8-61



ASSEMBLY

Connecting

Rod

1

Assemble

he SST

as

shown.

2. Apply

engine

il o

the

piston

ln

INOENTIFICATION

ABK

3. Set he oiston

n he

SST

with

he F

mark

acing pward

4 Assemtjlehe oiston

nd

he

connecting

od n

the dlrec'

tion rom

which

hey

were

disassembled

Pressure

torce:

4905-14715

N

(500-1s00 kg'

I100-3300

lb)

5. Whire

nserting

ie

plston

in.

check

he

pressure

orce f

it rs ess hanaoecified,

eplace

he

piston

in

or

thecon-

neclno

oq.

6- Pressihe

iston

in

nto

he

piston

ndconnecting

odun-

til the SST

contacts

he stopper

olt

7. Check

he

oscillation

orque

of

the

connectlng

oo

(Refer

o

Page

8-46.)

Piston

Ring

1.

nstallhe hree-piece

il

rings

on he

pistons

(1)

Applv

clean

ngine

irlo

heotl

ing

spacer

nd

rails

i2) lnslall

he

oil

rinO pacer

with he

ends

upwaro

Note

.

ihe upper

and

owertails

a.e

he

sameand

may

be

lnstalied with elther lace upward.

(3)

Installhe

upper

ailand

owe'

ail

8,-62



ASSEMBLY

THFUSI

METAL

(2)

lnstall

he upper

main

beanngs

nd

hrust

bearings

i3t

Set

he

crankshatt

n the

cyl'nder

lock

Caution

lio

not

totate

rtte

crankshaft

when

measuting

he

oil

clealances.

(4)

Position

Plastigage

top

the

journals

n the axal

directton.

(5)

Install

he

ower

main

beanngs

nd

the

main

bearing

'-'

iaos

according

o tne

cap

number

nd

€

mark

(6)

Tnh€n

he

main

earing

ap

bolls

n lvo

or

hre€

teps

-

in'theorder

shown

n the

igure.

t'?l':!'Jt*.ii'irT-".0

m-ks,0-43 'rb)

17)Remove

he

main

earing

aps.

Fd

measure

he

PlaslF

' '

oaoeat

each

purnal

t

he

wldest

oini or hesmallest

ileirance

and

al

lhe

narrowest

oint or lhe

largest

clearance.

fgr

lt he

oil

clearance

xceeds

pecilicalion

rind he

'

'

crankshaft

nd

useundersze

main

bearings

(Refero PageB-58.)

Oil clearance:

.018-O,O36mm

0'0007--'{''0014

n)

Maximum:

O.lomm

0.004 n)

2.

Apply

|beral

mount

l

clean

ngine

il

o he

main

bea'

inqs,'thrusr

earings

no

main

ournals

s. inidr

thi

crarkst'Jtl

nd

he

marn

ean'rg

aps

accord-

ing

to

the cap

number

nd

e

mark.

4. Tiohten

he

main

bearing

ap

bolts

n two

or

three

steps

in the

order

shown

n the

igure

Tiqhteninq

orque:

!r-sg

-Hm

15.s-o'o

m-rg,

40-43

ft'lb)

B-64



ASSEII'BLY

5. \4easurehe

crankshaftnd

play.

End

play

0.080-0.282mm

0.0031-0.0111

n)

Maximum:

.30mm

0.012

n)

6.

f

heend

play

xceedsthe aximum,

rind

hecrankshaft

and nstallan veasizehrust earing

r replacehecrank-

shaft nd hrustbearing.

Thrust

beadng

width

Standard:

2.500-2.550mm 0.0984-0.1004

0.25mm

0.0t0

ln) overaize:

2.625-2.675mm

0.1033-0.1053

0.50mm

0.020

n)

ove6ize:

2.750-2.800mm

0.1083-0.1

102

0.75mm

0.030

n)

oversize:

2.875-2.925mm

0,1

132-0.1152

Pision

and ConneciingRod Assembly

in)

in)

tn)

in)

MATCHINGMAFKS

Cautlon

.

Prolect

he connecting od bolts with rubber

sleeves

to prevenldamage o the crankpin ournals.

Connectlng

Rod

Cap

'1.

[/easufeheconnectingod bearing

ilclearancessang

thesame

rocedure

s or hemainbearing

ilclearance.

Caution

.

Align he matchingmarks

gn

lhe

cap and he

con-

necting odwhen nstallinghe connecting odcap.

Tighlening orque:

29-34

N.m

3.0-3.5

m-kg, 22-25 ft-lbl

Oil clearance: .028-0.068mm

0.001

-0.0027 in)

Maximum:

.lomm

(0.004

n)

2. fthe

oilclearancexceedsthe

aximum,

rind

hecrank-

shaft nd use

undersize

earings.

Refer

o

page

B-58.)

(_.

:/:\

,.-

|Qro.

oe,l

rl

t'r

\'rinl|*

B-65



ASSEMBLY

MEASURTNG

OCATION

3.

lvleasure

he

connecting

od side

clearances'

Sideclearance:

.110-0.262mm(0.0043-0.0103

n)

Maximum:

0.30m8

(0.012 n)

4. lf lhe

clearance

xceeds

he

maximum'

eplacehe con-

nectingod andcap.

5.

Appry

liberal mount

f clean

engine

ilto he crankpin

iournals

nd

connectlng

oo

Deanngs

6. nstall

he connecting

od

caps

with

he matching

marks

alioned.

7. Tig-hten

he

connecting

odcap

nuts

n wo

or hree teps

Tiohteninoorque:

is-31-Nm {ir.o-e.s

m-t<g,

2-25

lr'tb)

' ' l l l l I L ) )= r

-

8-66



ASSEMBLY

CYLINDER

LOCK

EXTERNAL

ARTS)

TorqueSpecilications

re-25

{1.r-2.6,

14-1r)

GAS(ET,

NEW

g r l

v7h

".*

$

E

GASKET,

EW

7i-r! Nn

(30-1r0

cm-kq,59-95 in-lb)

GASKET, EW

--..-t*

EEi

30-1

ro cD-ks, 6s-95

inrb)

GASKET.

13-25

O.3-2.7,

r3-20)

03uoB1.133

Fear Cover

1.Apply sma,larnount

fclean ngine

iltotheipofa new

o seat,

2. Push he oil seal

slightlyn by

hand.

Cauiion

.

The oil

sealmustbe

pressed

n until t is

flush wilh

the edgeot the rear cover.

3. Presshe

oll seal n evenly

witha suitabie

ipe.

Oil seal outer diameter:

100mm

3.94

n)

4. Applysilicone ealant

o the shaded rea

shown n the

ngure.

8-67



ASSEIIIIBLY

. . ' i

! \o

\,

ILL-

-l- /l

5. lnstall

he

rearcover.

Tiohleninq

oroue:

?.s-t

t-N.m

a8o-l1O

cm'kg,69-95

in-lb)

Oll PumD

1.

Apply

a small mounl

l clean

rgine

orl o the

ipofa

new

oil seal.

2. Push

he oil

sealslightly

n by

hand

Caution

. Theoilseal muslbe pressed n until t is llushwith

the

edge of

the oil

PumP

body.

3.

Press

he oil seal

n

evenry

will' a su

able

pipe

Oil

seal outer

diametef:

44mm

1.73

n)

4. l\y'ount

new

gasket nd

nstallhe

oil

pump

Tiohteninq

orque:

js-zs

-N.m

{i.s-z.o

m-tg,

14-19

tt-lb)

Caulion

.

Do

not sqratch

he oil

Pump.

5. Cut

away he

portion f the

gaskethat

projects

rom

he

body

oward he

oil

Pan

side

Oil Strainer

Mourt a

new

gaskel

nd

nslall f'e

oil strainer'

Tiohteninq

oroue:

?.a-tt-l'lm igo-lto

cm-kg,

69-95

in-lb)

B-68



ASSEi'BLY

Oil Pan

1. Remove ll oreignmaterialrom he

contact urfaces.

2. Applysilicone ealanto the

shaded reas hown n the

figure.

l

-/-=

{. I

Qr)

3. Install ew

gaskets

nto he oil

pump

bodyand he rear

coverwith he

proiections

n he notches

s shown

n

he

figure.

4. Apply

a continuouseadof silicone ealanto he

oil

pan

along he

nside

f he boltholes ndoverlaphe ends.

5. Installhe oil

pan.

Tightening orque:

7.8-ti N.m

80-110

cm-kg, 69-95

in-lb)

End Plale

Installhe end

plate.

Tightening orque:

7.8-ll N.m

80-ll0

sm-kg,69-95

nlb)

Flywheel

MTX)

1- Remove

hesealant

rom

he

lwheel

bolt

holes

n he crank-

shaftand

rom

he

lywheel

olts.

Cautlon

.

lf all the

previous

ealant annotbe removed rom

a bolt,

replace

he bolt,

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

2. Set he lywheel nlo he

crankshaft.

3. Apply

sealanto the

lywheel

oltsand

nstall

hem.

@

BM

B-69



ASSEMBLY

4. Hold

the

flywheel

with

he SST

Caution

.

Addapprox

3mm

0.51

n)ol

spacers

O)

to

space

the S5i

away

rom

he cylinder

lock'

MTX)

5.Trghtenhe oolls nn/vo r h'ee stepsn neoldershow4

Tiohtenino

orque:

go-roJ

H.m

s.s-r0.s

m-ks,

1-76

tt'lb)

Clutch

Disc and

Clutch

Cover

MTX)

Caution

.

Add aporox

13mm

0.51

n)

of spacers

@)

o

space

the

SSi ayyay

rom

the

cyllnder

block.

(MTX)

lnstall heclutchdiscand clutch

over

using

he SST.

(Refer

o Section

.)

Tiohtenino

orque:

i a-zo

-t't

m

ti.e-z.t

m-xl,13-20

ft'lb)

Drive Plate

(ATX)

1.Removeh-e

ealant

rom he orive

plate

boll

holes

n he

crankshaft

nd

rom he

drive

plate

bolts.

Caution

.

ll all the

previous

ealant

annot

be

removed

rom

a bolt. replace

he

bolt'

. Do nor aiply sealant t a new bolt is used,

2. Insrall

heaoapter.

've

plale,

nd

back|.g

plate

nto

he

crankshaft.

3

Aoolvsealant

o lhe

drive

plale

bolrc

and

nstall

hem

+. ttbio tne

drive

plate

with heSST.

5-Tiohtenhe

bo{s

n wo or

hreesteps

n

he

order hown

Tlohtenlnq

olque:

!s-rod tt.mg.s-t0.5 m-ks,7l-76 ft- lb)

i@el

B-70



ASSEMBLY

Timlng Belt Pulley

1. Installhe iming

belt

pulley.

2. Installthe

ulleyWoodrutf

eywith he apered ide oward

the oil

pump

body.

WaterPump

1. Remove ll oreignmaterial

rom

he water

pump

mount-

ino surface.

2. PEcea new

water

umpgasket

n

position.

3.

Install

he

watef

pumo.

Tightenlng olque:

19-25 Nm

(1.9-2.6

m-kg, 14-19 ft-lb)

B-71



ASSEMBLY

CYLINDEB

EAD

Torque

Specitlcalions

{50-90

cn-kg,

43-73

In'lb}

12,2-2.9, 16-211

e-__u

Pe

(65-e5 cd-&, 56-t2

rFlb)

valve Seal

1.

nstallhe

new

valveseal

onto he

valve

guide

by

hand

2. After

nstallation,

djust

he

protrusion

@

to

specitication

Proltusion:

8.1-18.7mm

0.713-0.736n)

93GOBr S0

B-72



ASSEMBLY

@GBEATEF

THAN

@

HEAOSIDE

Valveand

ValveSpring

1 Installhe

ower

pring eat.

2. nstallhevalve.

Caution

.

Install he spring wlth lhe closer

pitch

toward he

cylinderhead.

3.

,nslall

he

valve pnngand the upoerspring eat.

4. Compressne

valve

pring

w[h the SST.and nslallhe

varve

Keepers_

5. Removehe SST.

6.Tapthe ndof

hevalve ternightlylwo r hreeimeswith

a

plastic

ammerto

erifythalthe eepers

re

ully

eated.

Cylinder

HeadGasket

1.Remove ll

oreign

material

rom the op

of

the cylinder

block.

2. Place he newcylinder

ead

gasket

n

position.

CylinderHead

1. nstallhecylinderead.

2.

Apply

lean nglne

il o the bolt hreads nd seat aces.

3. Tightenhecylinder eadbolts

n woor hree

teps

n he

oroer

nown.

Tighteninq orque:

76-81

N.m

7.7-8.3

m-kg, 56-60 tt-lb)

CamshattOil Seal

1.Apply

a thincoat

of engine il o hecamshaftilsealand

cylinder ead.

2.

Tapthe amshaftilsealintothe

ylinder eadwith

suita-

ble

pjpe.

Cautlon

.

The oil seal

must be tapped

n

unlil

it is llush with

the cylinderhead,

Oil seal outer

diameter:

40mm

(1.57

n)

Camshall

1.

Apply ngine , l

o he

Journals

ndbearing

2. Insen ndmounthecamshalt

nto

position

ith he hrust

plate.

B-73



ASSEUBLY

OOWEL

PIN ANO

PIN GFOOVE

.t'i

Camshaft

Pulley

Note

.

Be certain

hat

the

dowel

pin

ot the

camshaft

also

laces straighl

upward.

1. nsiallhecamshaftulley nto he dowelpinwith hepin

groove acingstraight

pward

2. Trohlen

he camshatt

ulley

olt

Hold

hecamshafl

sing

a ;uitablewrench

n Ihe

cast

hexagon

s showr.

Tiohteninq

oroue:

ls-ot'itm

(6.0-o.z

m-tg, 36-45

ft'lb)

Rocker

Arm and

Rocker

Shalt

Assembly

Cautlon

.

Face

he rocker

shalt

ldentilication

mark upward'

.

The nstallation

bolt holes

are

dlfterent

or the ex-

hausi and

intake

sides.

ldentilication

mark

lN

........,.,....

ellow

reen

EX. . . . . . . . . . . . . . .

ink

'1

.

Assemblehe

rocker

rm and

rocker

haft

assembly s

shown

n the

igure-

2. nstallhe

rocker

armand

rocker

haft

assembly-

Caution

.

Thebolts

musl

be ightened

radually nd n he

or'

der shown.

Tidhteninq orque:

zz-za

il.m

(tz.z-z.s

m-xg,

6-21

tlb)

ValveClearance

Adiustment

Refer

o

page

B-7.

B-74



ASSEMBLY

OlEOBXJS3

Temperature

auge

unit

Installtheemperature

auge

unit nto hecylinder eadwith

seal ape on the hreads.

Tlghtenlng olque:

6.4-9.3

Nm

(65-95

cm-kg,56-82

in-lb)

Thermostat and

Thermostal Cover

1. Remove ll foreignmaterial

rom the thermostatover

mounting urface.

2. Installhe hermostatith he

iggle

pin

acing

upward.

3.

Install new

gasket

nd he hermostatover.

Tighlening orque:

l9-25 N{n

(1.9-2.6

m-kg, 14-19

ft-lb)

Caution

.

Thg

pdnted

side ol the

gasket

must ace he

thermg-

stat.

C:lrlinder

Head Cover

lnstallhe cylinder

eadcover.

Tightenlng orque:

4.9-8.8 N.m

50-90

cm-kg,

43-78 in-lb)

Caution.

lf

the

head

cover

gasket

s

reused,apply

sealant

n

the

groove

as shown.

;nY\v

w"ffi

PBINT€O

SIOE

a

_-/-$ 1

? \ +

B-75



ASSEIIBLY

TIIIIING

BELT

Torque

Specificallons

t9-25

O.9-2.5,

r/Frg)

7.t-ll

r*o

(30-110

cr*1, 6!l-95

i.'lb)

12-17

fl

.25-r.75,

r09-r52)

r!i6-106

{16-17,

1r5-122)

Timing

Belt Tensionel

1.lnstell

he ensioner

nd he

ensioner

pring

2.

Temporarilyecure

he ensioner

ith he

spring

ullyex-

tended.

Timino Belt

1.

Verii that hetming

belt

ulley

mark

saligned

ilh he im-

Ing

marK.

o3uoB11s4

B-76



ASSEMBLY

9 a N

(10

kg. 22 lb)

3- nstallhe iming elt o hal here

s no ooseness

t

he

lensionide.

caution

'/-\

.

Do not turn

he

crankshaft

ounierclockwiscd

2. Verifyhat

hecamshaft

ulley

marks realignedwith he

cylinder

eadcovermarks.

4. Turn hecrankshaftwo urns

lockwise,ndalign he im-

ing belt

pulley

markwith he

imingmark.

5.

Verify

hat

hecamshaft

ulley

marks realigned

with he

cylinder eadcovermark.

lf

notaligned,

emovehe iming €liand

epeatrom en-

sioner

nstallation.

6. Loosenhetensionerolt

oapplytensiono hetiming elt.

Caulion

.

Be sure not o apply

ensionother han thal ot the

tensionerspring,

7. Tlghtenhe ensionerolt.

Tightening

orque:

'19-25

N.m

1.9-2.6

m-kg, 14-19 ft-lb)

8. Turn he

crankshaft

ro urns lockwise

ndverityhat

he

timingmarks

recorrectly ligned.

9.

Measurehe iming eltdeflectiony

applyingmoderate

pressure

98

N, 0 kg, 22 b) midway etween

hecrank-

shaft

pulley

nd

he camshaft

ulley.

lf the iming eltdeflection

s notcorrect,emporarilye'

cure

he ensioneroltso hespring

s ullyextended nd

repeat leps4-8 aboveor replacehe ensionerpring.

Deflectlon:

'|

1.0-13.0mm

0.43---0.51

n) at 98 N

('10

g, 22 b)

B-77



ASSEMBLY

TIMING

BELT

covEa

Timlng

Belt Covet

lnsta[ he ower

andupper

iming

beltcovers

and

new

gaskets

Tlqhteninq

olque:

?.4-t

t-Hm

igo-tro

cm-kg,69-95

in-lb)

Crankshaft

Pulley

1. Install

he

pulley

oss.

Caution

.

Add approx

13mm

0,51

n) ol spacers

rt)

to space

the SSi away

ron the

cylinder

block.

(MTX)

2.

Mount he SST

and

ighten

he

pulley

ock

bolt

Tiohteninq oroue:

iso-ro1

*m

oe-t7

m-kg,115-122

inb)

3.

Removehe SST.

4. Installhe

crankshatt

UlleY.

5. Install

he

plate.

waler Pump

Pulley

Install

he water

pump

Pulley.

Tiohteninq

otoue:

?.9-rr-N..

a8o-1lO

cm-kg,

69-95

Inlb)

0rEoBx'3c

B-78



ASSEMBLY

AUXILIARY

ABTS

TorqueSpecilicalions

15-27

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

@w

r

e3-1 13

e.5-tt.s,

3s-€3)

GASKET, EW

19-25

0,9-2.5,

r.-11)

1e-30

(1,e-3,r,

13r2)

Engine

Hangel

Instailhe

ront

and

rearengine

hangers.

Tlghtenlng orque

Front 37-63

N.m

3.8-5.4

m-kg, 27-46

ft-lb)

Real: 19-25

N{n

(1.9-2.6

m-kg, 14-19 ft-lb)

B-79



ASSEMBLY

Spa*

Plug

1. Apply nitserze

ompound

r

molybdenum-based

ubdcant

to the spark

Plug

hreads.

2. lnstallhe

spark

Plugs.

Tiohteninq

oroue:

is-zs'i l .m

1t.s-z.s m-rg, 11-17 ft lb)

Oil

Dlpstick

Installhe

oil dipstick.

Oil

PressureSwilch

lnstallhe oil Dressure

witch.

Tiohteninq

orque:

lz-re-tt.m ti.z-r.8

m-kg,104-156

n-lb)

Oil

Filter

1. Remove

ll toreign

material

rom

the oil

iiltermounting

surlace.

2.

Applya small

mount

i clean

ngine

ilto

he ubber eal

of

the oil

ilter.

3. Install

he oil

ilterand

ighten

t by

handuntil he

rubber

sealcontactshe base.

4. Tighten

he

ilter

1

and

1/6 urn

witha

filterwrench

No.3

Engine

Mount

Brackel

Install

he No.3engine

mountbracket

Tiohteninq

otoue:

ss-t

t3-

Hln

g.s-i1.5

m-kg.

69-83

ttlb)

Allernator

1. Installhe

alternator

trap.

Tiahtenino orque:

iz-sz

-t't.m

1s.e-s.o

m-t<g, ?-38

ft'lb)

2. nstallthe

lternator

ndalternator

rive

beft Looselytight'

en the

alternator

nstallationolt.

3. Adjust

he drive

beltdeflection.

Refero

page

B-5.)

Tightening

orque

Alternator

nslallation

bolt

(D

:

37-52

N.m

3.8-5.3 m-kg,

27_38

ftnb)

Belt-adiustlng

oll

@

:

'19-25

N.m

1.9-2.6

m-kg,

14-19

tt-lb)

B-80



ENGINE

STAND

DISMOUNTING

ENGINE

TAND

DISMOUNTING

PROCEDURE

1.

Remove

he engine

rom he SST

(enginestand)

2.

Remove

he SST

(englnehanger) lom

he englne.

3.

nstallhe

parts

shown

n the igure

Torque

Specitications

waler lnlet

Pioe

'1

. Removelfdreign

material

rom he

water

nlet

ipe

moun!

ino

surface.

2.

Inatall new

gaskel

nd

he waier

nlet

pipe

Tiohteninq

oroue:

is-zs

-Nm

(i.s-z.e

m-kg'

14-19

ft-lb)

37-52

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

\

(fr-----

---

ts=;\

37-52

{3.H.3,

27--33)

1e-25

0,9-2.3,

14-r9)

{8O-iio

m-rq, 69-t5

in'lb)

O.FIING,

NEW

APPLY

ENGINECOOLANT 16-2311.5-2,3,

12-1n

|5fi

B-82



ENGINE TANDDISMOUNTING

3. Applya small mount f engine oolanttohe new

O-ring.

4. nstallhe waterbypass

ipe.

ExhaustPioe

Bracket

lnstallhe exhaust ioebracket.

Tightening orque:

37-52

N{n

(3.8-5.3

m-kg, 27-38 fi-lb)

A/C ComDressor rackel

Installhe uC comoressor

racket-

Tighlening

orque

@:

19-25 N.m

1.9-2.6

m-kg, t4-19 ftJb)

@:

37-52 Nm

(3.8-5.3

m-kg, 27-38 ft-lb)

ExhaustManitold

1. Remove

ll

oreignmaterialrom heexhaust anifoldon-

tact surface.

2. Insiail new

gasket

nd the exhaustmanifold.

Tightening orque:

16-23 Nm (1.6-2.3 m-kg, t2-17 ft-lb)

ExhaustManitold nsulalor

Install

he exhaust

manitoldnsulator.

Tightening

orque:

7.8-11 N.m

80-110

cm-kg, 69-95 In-lb)

B-83



INSTALLATION

INSTALLATION

PROCEDURE

Tighten

ll bolts

and

nuts o the

specified

orques.

Step

I

Join he engine nd ransmission.

Torque

Specilications

TX

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

37-52

(3.3-s.3,

27-33)

37-52

(3.3-5.3, 2?-33)

3?-s2

(3.3-5.3, 27--33)

ATX

37-52

(3,3-5.3, 27Ja)

37-52

e.a-5.3,

27--33)

B-84



INSTALLATION

Step

2

Warning

.

Be

sure he vehicle s

securely

suppgrtedon safety stands.

Torque Speqifications

Engine

and transaxleassembly

1. Suspendhe engine nd transaxle ssembly.

Caution

.

Do nol damaEe nycomponentsn he

engine om-

partment.

2.Align heNo.3enginemountboltswith heenginemounl

mounting oles.

B-85



INSTALLATION

IffiI

No.1 ENGINE

MOUNT

No.2 ENGINE

I,IOUNT

Engine

mouni

1.

nslallhe

\o.1engine

ounl

utand rghten

Tiohteninq

orque:

gz-sr

1m

1il.a-s.s

m-rg,

27-38lr-tbl

2. Installhe No.2enginemounlnut and ighten.

Tiohteninq

orque:

iz-st

-tr.m

(g.g-s.g

m-tg, 27-38

ft-lb)

Engine

mount

member

Install

he engine

mountmember.

Tiohteninq

orque:

ea-es

-Nm

16.s-S.l

m-t<g, 7-66

ft-lb)

Step

3

Torque

Specificalions

15-22

0.6-23,

1r-16)

31,-46

3.2-4.7,

23-33)

40-s4

{4.r-s,5,

2s--r0)

*-"",u.u-",,

r-.",J

37-51

(3.3-5.3. 27-33)

&..-..-..-------'n*.,".*,

',

o,*"

B-86



INSTALLATION

Drlveshaft

1. Apply

grease

o the

end ot the driveshaft.

Caulion

.

When nstalling

he drlveshaft,be caretul

not to

damage he oil seal.

. After nstallation, ull he ront huboulward o con-

lirm that the driveshalt s

sequrely eld bythe

clip.

2 Fil

a newclip and

nstall

he driveshaft.

3. Installhe owerarmball-jointo

he knuckle,

nd ighten

the

clinchbolt.

Tightening

orque:

43-53 N.m

4.4-5.5

m-kg,

32-39

fl-lb)

Clutch cable

lnstall

he clutch ableand

check

diffrection.

(Refer

o Section .)

Shlft control cable

(ATx)

Installhe shitt ontrol

able o the ransaxle.

Tightening

orque:

6.9-11 Nm

(70-110

qm.kg,

l-95

inlb)

Shift control rod

(MTX)

Installhe shift ontrol od

o the

ransaxle.

Tightening

orque:

'16-22

Nm

(1.6-2.3

m-kg,12-16 in-lb)

Extension

bar

(MTX)

Installhe extension ar o the ransaxle.

Tightening orque:

3l-46

N.m

3.2-4.7

m-kg, 23-34 in-lb)

B-87



INSTALLATION

Speedometer

able

lnstallhe

sDeedometer

able

Tldhtenlnq oroue:

?.s-rfN.m iao-rzo

cm-ks,

9-96

In'lb)

Exhausi

pipe

'1

lnstallhe exhaust ipe

and

a

gasketi

hen

oosely

ighten

the ocknuts.

2.

Loosely

ighten

he bracket

ohs

3.

Tightenhe

ocknuts.

Tiohteninq oroue:lo-sl -t'l.m

tl.t-s.6

m-kq,

29-40

ft'lb)

Li,

B-88



INSTALLATION

Srep4

Connecthe hoses hown

n the igure.

Cautlon

.

Posltion he hose clamp n the original

ocationon lhe hose,and squeeze

he clamp lghtly

with largepliers o ensure a good fit.

Siep 5

Connect

he harness onnectors hown n the fioure.

B-89



INSTALLATION

Siep

6

Torque

Specificationa

(30-110

n-ts,

6e-ss

lFlb)

B-90



INSTALLATION

&6

A/C

compressor

(it

equipped)

Installhe uC compressor.

Tightening

orque:

37-s2

N.m

3.8-s.3

m-kg, 27-38

ft-lb)

P/S oil

pump

and bracket

lnstallhe P/Soil oump

and bracket.

Tightenlng orque:

37-52

N.m

3.8-5.3

m-kg, 27-38 ftlb)

Drive

bell

1.

nstallhe P/Sand/or

A/C drivebelt.

2. Adjust he

drivebelldeflections.

Refer

o

page

B-5.)

Radiatorand cooling

an assembly

1. nstallhe radiator nd

coolingan assembly.

Tighlening

orque:

7.8-11 N.m

80-il0

cm-kg, 69-95

in-lb)

2.

Tightenhe

AJC

pipe

bracketo the

radiator.

Tightening

orqle:

6.4-9.3

Nm

(65-95

cm-kg, 56-82 in-lb)

3. Connect

he uooerand

ower adiator

oses.

Caution

.

Poaltion

he hoseclamp

n the orlginal ocationon

ihe hose,and

aqueezehe

claBp lightlywlth large

pllers

g

ensure

a

good

fit.

4. Connecthe coolanteservoirose.

5. Connect

he cooling

an connector.

6. Connecthe

oil cooler ose.

Al'X)

E

01EoBXI5a

I

J .DLEF

IJLLEY COMPFI

B-91



INSTALLATION

Accelerator

cable

1. nstall

he accelerator

able

z. AOiust

ne

caUte

etlection

y turning

nut

@

Deflection:

-3mm

(0.04--'0.12

n)

Battery

duct,

battery

car er,

and

battery

1. nstall

he battery

uct.

2.

Install

he battery

arrier.

Tlohtenlnq

orque:

ig-zs

l.m

(i.9-2.5

m-kg,

4-19

fl-|b)

3.

Install

he battery

and

the

battery

bracket.

Tiohtgnino

orque:

i.s-s.5

N.m'(so-60

cm-kg,

26-52

inlb)

Air

cleaner

assembly

lnstall

he

air cleaner

assembly

Undercover

and slde

cover

lnstallhe

undercover

nd

sidecover.

-YA

steDs After

Installatlon

i.

ii'tn" 6"si"J

o-'l

i"

drarned,

ill with

he specified

mount

nd

ype

of engine

il

(Refer

o Section

D.)

2. Fill he

radiator

with he

specified

mount

nd

ypeof

engine

oolant'

{Retero

Section

.)

s..ii il" to^""*|. oil;.s drained,illwith hespecifiedmount nd ype

of transaxle

il

(Reter

o Sections

,

K

)

4. aonnect

he

negative

attery

able

5.

Start

he engine

and

check

he ollowing

{1) Enaine

il,

ransaxle

il and

engine

oolant

eakage

izi

tgnitioniming.

dlespeed

Refer

o

page

B-8)

(3)

Operation

t

emission

ontrol

yslem

6. Perform

road est.

7. Recheck

he

engine

il and

engine

oolant

evels.

B-92



LUBRICATIONYSTEM

1NDEX.......,.,...,..,.......................,,.,..........

L 2

ouTLtNE.,............,

...,.,

L

3

sPECtFtCAT|ONS....................................

- 3

TnoUBLESHOOT|NG

U|DE.,......,...,.,..,....

L 3

otL PRESSURE.........,.,........................,.,..

- 4

PREPARAT|ON,,...,...............................,.

- 4

TNSPECTTON...................,..................,..- 4

ENGTNEtL,.,.....................,..,.................

- 5

tNSPECT|ON...........,..,..................,.,.,....

- s

REPLACEMENT,,.,....................,.............

- 5

otl F|LTER...,....,..,.,.,.,........................,...

- 6

REP1ACEMENT.......,..............................

L

6

otl PAN..................,,..............................

- 7

REMOVAL|NSTALLAT|ON......,.,..,.,........

-

7

otl

PUMP..,.,...,..,.........................,......,...

L I

REMOVALTNSTALLATION

...................,.- I

D|SASSEt\4BLYASSEMBLY....................

-l l

TNSPECTTON.....................,.,.,,..............

-12



INDEX

INDEX

ENGINE IL

SPECIFICATION

API

SEBVTCED,

SEOB

SF

3.4

ir6.s

3-6us

qr,

3.0

hp

q0

l.

Oil

pressure

4

Oil-Pan

Inspectron...........-....................

page

D-

4

-

Removal/

nstallat ion

"

page

D-

7

2. Engine il 5 OilPumP

l"nspection.......--...-......................

age

D- 5

Removal/

nstallat ion " page - I

Rep1acement................

..

. .

pi6e

O-

s

Disassembly

Assembly

page

D-1'1

3.

Oil ilter

Rep1acement . . . . . . . . . . . . . . . . . . . . . . . .

.

page

D-

6

D-2



OUTLINE, ROUBLESHOOTINGUIDE

OUTLINE

SPECIFICATIONS

Anticipated

mbient

emperatureange

before ucceedingil change,

C

("D

TROUBLESHOOTINGUIDE

D-3

IemHmodel

B:]

Oil

pump

Tvpe

Regulaled

ressure

kPa

kg/cmz,psi)

343 441

(3.5-4.5,

50-64)

Oil

llter

Type

Full.i w,

pap€r

element

Felief

pres€ure

itferenlial

kPa

(kg/cmz,

sl)

98

1.0,

14)

Oilwarn g

p€sslre

kPa

kg/cm' si)

4.9-44

(0.05-0.45,

0.7-6.4)

Oil capacily

Tolal

dry

ensine) lilerc

USqt,

mp

qt)

3.4

3.6,

3.0)

Oll

pan

llers

USqt,

mp

qt)

3.0

3.2,

2.6J

Oiltlter liters

USqt,

mp

qi)

0 .1 7

0 .1 8 ,0 . r 5 )

Englneoil

(APl

serv

ce) SD.

SE,

r SF

Recommended AEViscosity

fc)

('D

-30 -20 -10

0 10 20

30 40

50

,--20

0 20 40 60 80 100 720

Engine il

5w'30

v

30

\

5EA----\

20w.20

:

'l0w-30

@

ffi

Possible

Cause

Remedy Page

Enginehardstarting

Insuflicieni

ngineoi l

D - 5

D - 5

Exceasive

oil

Oilworkng

up o. down

Oil eakage

Reier

to Section

B

Oll

pressurc

drop

Oil eakage

Wom

and/of amag€d il

pump

gear

Worn

plungerinside

il

pump)

r weak

prins

Clossed il strain€r

Excessive

a,nbeanng ,

.orneq

ng rod oea

rc

Clean

Reler to Seclion

B

o_o

Warnlng amp

lllumlnrtes

whlle

engineb running

Oil

prcssure

rop

Maltunction

Joil

pressure

wnch

Mallunction f electical srstenr

Fefer o Section

T



OIL

PRESSURE

49 0187

2AO

Gauge,

OIL

PRESSURE

PNEPARATION

ssT

INSPECTION

1. Remove

he

oil

Pressure

wltch

2. Screw

he SST

nto

he oil

pressure witch

ole.

3.

Warm

up the

engine

o

normal peratng

emperalure

4.

Run he engine

i

10Oo

pmand

3000

pm,

and

note he

gauge

eaorng.

Oll

pressure:

99-196 kPa

(1.0-2.0

kg/cm'

15-28

psi)'1000 pm

294-392

kPa

(3.0-4.0

kg/cmi,

43-57

psi)'3000 pm

5.

t rhe

Dressure

s

nolas

specitied

heck

or hecause

nd

reoaii.

Refer

o Troubleshooting

uide.)

D-4



ENGINE

IL

ENGINE IL

INSPECTION

1.

Be sure

he vehicles on level

ground.

2. Warm ptheengine

o normaloperatingemperature

nd

stop it.

3. Wait or iveminutes.

3. ET?,1",f;r","'i"t'3il"1i*ffitn"

',"u"' ndonditi

E

Note

.

The distancebetween he L and

F

marl6 on the dip

stick represents

.8

llter

{0.85

US

ql,

0.70

mp

ql}.

REPLACEi'ENT

warning

.

Be carelul when drainlng; he oil

is

hot.

1. Warm

p heengine

o normal peratingemperature

nd

stop rt.

2. Removehe oil

iller

ap and

he

oil

pan

drain

plug.

3. Drain he oil ntoa suitable ontainer.

4. Install new

gasket

nd he drain

plug.

Tightening

orque:

29-41 N.m

3.0-4.2

m-kg, 22-30 flnb)

o5u00x.011

5. Relillheengine

with he

specified

ypeandamount

f en-

gine

oil.

Reler

o

page

D-3.)

6. Retit he oil

iller

ap.

7. Flun he engine ndcheck or leaks.

L Check

he oil eveland add oil f necessarv.

Oil

pan

capaclty:

3.0

liters

(3.2

US

qt,

2.6 lmp

ql)

D-5



OIL

FILTER

,',,\

Y

r ) +

e

OIL

FILTER

REPLACEI'ENT

1.Remove

he oil

ilter

witha suitable

rench.

2.

Usea clean

ag

o wipe

otf he

mounting

urface n

the

enoine.

3.Ap-ply smallamountoflean ngine iltothe ubber eal

of

the new ilter.

4.Installthe

il ilter

and

ighten

t by hand

until he rubber

sealcontacts

he

base.

5. Hand iohtenrnq

vpe

Numbers

rinted

n

lilter)

Tiohtenihe

iltei

3i4 of a

turnbv

handafter

t contactshe

cvliinder

lock.

lf tightening

y

hand

s difficult,

se

a

suitable rench

Example:

. Wh;n the oil filter contacls he cylinderblockat

"

l

"

'

turn

il 3/4 of

a turn

fulther to

"4."

Filterwrench

ightening

ype

No

numbers

rinted

n ilter)

Tiohtenhe

ifter and

1/6 urns

witha suitable

rench t-

tei it

contacts

he cylinder

lock.

6. Start

he engine

nd

check

or eaks

7. Check ie oil

eveland

add

oil

f

necessary

Oll fllter

capacity:

0.17 iter

(0.18

US

qt,

0.15

mP

qt)

D-6



OIL PAN

OIL PAN

RE!'OVAL INSTALLATION

1.Disconnecthe negative

attery able.

2. Drain he

engine il.

3. Remove

he undercover nd sidecover.

4. Removen the ordershown n the igure, eferringo RemovalNote.

5.

Install

n the reverse rderof removal,eferring

o

InstallationNote.

GASKET,

BEPLAC€

REPLACE

REPIACE

'@

3r-52

(4.3-5.3,

27-36)

REPlACE

{3!-110

cfrkg, 69-95 tn.tb)

1.

Frontexhaust

ipe

and bracket

, lhr6^r.rorl di1l6n6r

3. Oilpanbolts

4.

Oil

pan

Bemovalo te . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

D- 8

Installat ion

ote..........................

age

D- 8

5.Gaskets

6.

Oil

strainer

D-7



OIL PAN

Rgmoval Noie

1. Removehe

oil

pan

mounting

olts.

2. lnserta screwdriver

r a suitable

ool between

he MBSP

and oil

pan

o

pry

them apart.

Cautlon

. Do nol Insed the prylngtool between hs iIBSP ard

cylindel

block.

.

Do not damage

or scratch

the conlact surlacea.

3. Removehe oil

pan.

lnatallation Note

Oil

pan

Cauilon

.

lf the bolts al€

to be reused,

remove he old aaal-

ant

from the bolt

thr€ada.

Tlghtenlng a boll with old sealant on lt may cause

cracklng

nalde he bolt

hole.

\ ^ Akit*

ffi"::+

1. Remove ll oreign

material

rom

he

contact urfaces.

2. Applysilicone ealant

o the endsof

a newoil

pan gaskets.

3.

Install gw

gaskets

nto he oil

pump

bodyand he rear

cover

with he

proiections

n the noiches

as shown n the

figure.

4. Applya continuous

eadof silicone

ealanto he oil

pan

along he nside

l the boltholesand

overlaphe ends.

5. lnstallhe oil

pan.

Tightenlng orque:

7.8-ll N.m

80-ll0

cm-kg, 69-95

in-lb)

Steps Atter Inslallallon

1. nstallhe undercover

nd sidecover.

2. Fill

with he specilied

mount nd

ypeof engine il.

(Refer

o

page

D-5.)

3. Connect he

negativebattery

cable.

4. Starthe engine

nd check

or eaks.

5-check he oil eveland add

oil f nec€ssary.

o1aoDxo11

D-8



OIL PUMP

OIL PUMP

REMOVAL INSTALLATION

1. Disconnecthe negative

attery able.

2. Drain he

engine il.

3. Removehe imingbelt.

Refer

o Section .)

4. Removehe oil panand ntegratedtittener.Retero pageD-7.)

5. Removen the ordershown n the igure,

elerringo RemovalNote.

6. Installn the reverse rdef

of removal,eferringo InstallationNote.

1.Timingbeltassembly

Serv ice. . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . .ec t ion

2. Oil

pan

Removalo te . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

D 8Installat ionote..........................age

D- B

3. Aiternator

4.

uC

compressor

with

A/C)

Removalo te . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

1

0

5.

Timing

elt

pulley

Serv ice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ecUon

6.Oil

pump

DisassemblyAssembly..........

age

D-1

1

7. Frontoil seal

Serv ice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ec t ion

o

I

i

REPLACE

19-2s

_

2ir-35

(1.9-2,6,14-rs)

e,r-_3.6i1

D-9



OIL PUMP

DISASSEMALYASSEMBLY

1.Disassemblen the ordqrshown n the igure, eierringo Disassembly oie.

2.Assemblen the reverse rderof disassembly,eferringo AssemblyNote.

1.Oilseal 6. Spring eat

Disassemblyote...............................elow 7.Pressure

pring

Assembly ote...

page

D-12 Inspeciion..............................-....

age

D

12

2. Pump over

Inspector distortion

nd damage

3. Outer otor

4. nner otor

5.

Boll

pin

B.Control lunger

lnspecl or wearand damage

L Pumpbody

/nspector

distortion

nd damage

DisassemblyNote

Oil seal

Removeheoilseal

with

a screwdriver

rotected

ith

a

rag.

5.9-3.3

Nm

(60-00.m.kg,

52-73

i.-lb)

o

e-@E.

l t ^

s_@

D-11



OIL

PUMP

INSPECTION

Pressure

Spring

1-

nspecthe

spring

or weakness

r

breaKage.

2. [/'leasure

he

reelength.

eplace

he spring

f necessary'

Free engih:

45,5mm

1.791 n)

RotorClearance

Measure

he ollowing

learances.

eplacehe

rotor

f necessary'

Tooth

lp

clearance:

0.20mm

0.0079

n) max.

Outer

otor

o

PumP

ody:

0.22mm

0.0087

n)

max.

93G0DX{30

Side

clearance:

0.l4mm

(0.0055 n) max.

;LS

r\>:>'\

A€sembly

Nole

Oll seal

1.

Applya smallamount

f

clean ngine

iltothe

ipol a new

oil seal.

2.

Push he oil

sealslightly

n by

hand.

Caution.

Theoil

sealmustbe

Pteesed

n until t is flushwlth

the edge

ol the

oll

PumP

body.

3.

Presshe oil

seal

n evenly

witha

suitable

ipe.

Oil seal

outel

dlameler:50.5mm

1.98 n)

D-12



E

COOLING

SYSTEM

fNDEX. . . . . . . . . . . . . . . . . . .

. . , ' . 'E-

2

ouTLlNE,..............

......

E- 3

spEctFtcATloNS....,......-.......................

-

3

TROUBLESHOOTING

U|DE....................,.

- 3

ENGINE

COOLANT.

...... E-

4

pREPARAT|ON.......................................

-

4

rNspEcTtoN............-.........-..................- 4

REP1ACEMENT..........,...........................

- 5

RADTATOR

AP.....

......

E- 6

PREPARAT|ON.......................................

- 6

rNSPECTrON...................,...........,..........

- 6

RADfATOR...........

......E-

7

REMOVAL

TNSTALLATION

............,........

- 7

rNSPECT|ON............,.............................

-

7

THERMOSTAT.......

.. '...

E- 8

REMOVAL

INSTALLATION

......,............ '.

- 8

tNSPECTrON..........,...............................

-

9

WATERPUMP.......

......E-10

REMOVALrNSTAI1AT|ON.....................- i0

ELECTRIC

OOLING

AN

SYSTEM

...'.......

E-l

t

SYSTEM

|Rcu1r.................."""""""""

E-1I

sysrEM

NSPECT|ON.......................,......

- l

I

FANMOTOR.......,..

. . . ' . '

E-12

tNSpECT|ON

.........................................

-12

REPLACEI,|ENT......................................

-l2

warER THEBMOSWITCH

.........................

-l3

REMOVAL

TNSTALLATION

..........-,.........

-i3

lNSPEcrloN

""""""

E-13

FAN

RELAY...........

......E-i4

REMOVAL

lNSTALLAT|ON

....-................

-l4

lNSPEcrloN..""""""""""""""""""" ' E-l4



E

INDEX

INDEX

1. Engine oolant

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-

4

Rep|acement . . . . . . . . . . . . . . . . . . . .

. . . . . . . . .

age

- 5

2. Radiator

ap

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

- 6

3. Radiator

RemovalInsla|ation..................ageE- 7

4.

Thermostat

Removal

Instal|ation..................

age

E- 8

5.

Water

ump

Removal

Instaj|ation..................

age

E-10

E-2

6.

Electric

ooling

an system

System

ircu i t . . . . . . . . . . . . . . . . .

.

page

-11

Systeminspecr ion. . . . . . . . . . . . . . . . .

ageE-11

7. Fan

motor

lnspec i ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

aSe

E-1?

8ep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . .

page

-12

B.Waterhermoswitch

Removal

Insta||atron..................

ageE 13

9. Fan

elay

Removal

Installation...............

page

E-14

CONNECTOF

ENGINECOOLANT OTALCAPACITY:

5.0

5.3,

..r)

6.0

6,3,

,3)



OUTLINE. BOUBLESHOOTINGUIDE E

OUTLINE

SPECIFICATIONS

Enginemodel

|rem

B3

Coolingsyslem

Waier<,ooled,orced rculation

Coolanl

apacily lite6

(US qt,

lmp

qt)

[4IX 5.0

s.3

4.4) ATX.6O(6.3.s.3)

Centnrugalell-driven

Unllied

mechanical

eal

Tvpe

Openingemperature

'C

fD

86.5

89.5

(187-193)

Full-open

emperature

'C

fR

1OO

212)

Fifopen ltt

mm

(in)

8.5

0.335)

r more

Radiator

corugated

in

Cap

valve

opening

pressJre

hPa

kg/cm?. s, 74-103 0.75-r .05. - r5)

Cooling

an

l4olor

urrenl A

6 . 6 + 1

Outer ameter l

blade mm

(in)

300

r

.9)

TROUBLESHOOTINGUIDE

Problem Possible

Cau3e

Remedy Page

Overhealin9 Coolant

evel nsuiticient

Coolant eakage

Radlatorins

clogged

Badialor

ap malf nction

Cooiing

an

malf nclion

Thermogal

alfunction

Waler

passage

logg€d

Water

ump

malfunction

Clean

Clean

E - 4

E - 6

E-11

E - 8

E - 5

E-10

Coro€lon

E - 5

E-3



ENGINE

COOLANT

ENGINE

COOLANT

PREPABATION

ssT

INSPECTION

Waming

.

Neveiremove

he

radiator

cap

while he

engine

6

hot,

. W;D a thick clolh around he capwhen removing t'

.

wh;n

removing

he

radiator

cap,

loosen

tslowly

to the

tirst

stotuntllthe

Pressure

n the

radlalor

s

released,

and

then

remove

il.

muoEx.oo6

Coolant

Level

(Enginecold)

1. Venly hat

he'coolant

evel s

near he

radiator

rller

eck

2. Veritv

hat

he coolant

evel n he

coolant

eserviors be

weeh the FULL

and

LoW

marks

3.

Add coolant

t

necessary

CoolantOuality

1 Verffvhat hie

is

no buildup

f

rust

or scale

around

he

radiator

ap

or radiator

illerneck

2. Veritv hat

coolant

s lree

of oil

Replace

he coolant

f

necessary.

Coglant

Leakage

1.connect

radlalor

ester

commercially

vailade)

nd he

SST

o the

radiator

iller

neck,

z.

AppV tO3

kPa

(1.05 kg/cm'

15

psi)

pressure

o the

svstem.

3. V'erifv

hat

he

pressure

s

held

4. lt noias specified,heckor

coolant

eakage

E-4

49 DO15 A0 49 D015 02

49 DO15

40)



ENGINE

COOLANT

E

COOL^NTTEMPERATUFE

C

fF)

ol EoEx@7

CoolantProtection

Caution

.

Do not uae alcohol-

or

methanol-based

coolant.

.

Use

only soft

(demineralized)

water In the coolant

mixture.

1. Measurehecoolantemperature

ndspecfiic

ravity

ith

a thermometernda hydrometer.

2. Determinehecoolant

roreclion

y

referring

o he

graph

I

s. iili"

loor"n,

prot""tion

s

nor

proper,

add w"te, o, "oolanl.

E

Antlfreeze solutlon mlxture

percentage

Coobrn

pdeclion

Gravityat

2o.c

(68.0

oolant

Above

-16oC

(

3oR

65 35 1054

Above

-26oC

{-1soR 45 1066

Above 4ooo

i-40on 45

'1o78

REPLACEMENT

Warnlng

.

Neveropen he radialor cap while

the engine s hot.

.

Wrapa thlckclolh

around

hccap

when oosening.

.

When emoving

he radiatorcap, oosen t

slowly

to the tirst stop unlll the

presaure

n

the

radiator

is

released. and

then remove

it.

.

Use cautlonwhendraininghol coolant.

Cautlon

.

Do

nol use alcohol-or methanol-basedoolant.

.

Useonly sotl

(demineralized)

ater n the coolant

mixture.

.

Befors loosening he radlalor draln

plug,

verity thal

lhe radlatgrdrain hose aces slraight

down.

1 Bemove

he

radiator

ap and

oosen

e drain

plug

by hand

(MTE

or by a

wrench

ATX).

2. Drain he coolanlnloa suilable ontaner.

3. Flush

he

cooling

ystem

ith

water ntil ll races f color

aregonei hen et he system raincompletely.

4. Insiall

he drain

plug.

5. Fillwithhe

proper

mount ndmixture f ethylene

lycol

based oolant y referringo the ableabove.

Coolanicapaclty

lilers

USqi,

lmp

ql)

B3

i\,ITX

AIX

5.0

(5.3,

4.4)

6.0

16.3,

.3)

6. Run

heengine

ith

he adiatorap emoved ntilthe p

perradiator ose s hot.

7. With he enginedling,

dd

coolanto the radiator

ntil

t

reaches he bottomot the filler neck.

8. Installhe radiator ap.

E-5



E

RADIATOR

CAP

49 DO15 A0

49 D015

03

Adapler B

49 D015

A0)

RADIATOR

CAP

PREPARATION

ssT

INSPECTION

Radiato.

Cap

Valve

1. Remove

oreign

material

such

s

water

esidue)

rombe

tween

he radiator

ap

valveand

he

valve eat.

2. Attach

he radiator

ap o

a radiator

ap

ester

commer'

ciallv vailable)

ith heSST.

Apply

pressureraduallyo

74-103 kPa(0.?5-1.05 kg/cm" 11-'15

psl)

3.

Waitabout

O aecgnds.

Verityhat

he

pressure

as

not

decreased.

4. Feplace

he

radiator ap

il necessary

N€gative

Pressurc

valve

1.

Pull he negative

ressure

alve

10open

Verify hat

t

closes

omDletelv

hen

eleased

2. Check

or damag;

on

hecontact

urfaces

nd

orcracked

or deformed

eal

Packing.

3. ReDlace

he

radiator p

if necessary'

-,-'-_ \\

kk=fiK"DlN"

'

,--A\,\

\{

,l\\\//rIA\ f- /\\\\}1 \

\lt\v2liK\ -/ \,

' i i : : \ ! @ = -

E-6



RADIATOR

RADIATOR

REMOVAL INSTALLATION

Caution

.

Eetore oosening

the radiator drain

plug,

verlty lhat the radiator d.ain hose ac€s straight

down,

. Poallion he hosedamp in the original ocalionon the hose, and squeeze he clamp ightly

with large

pliers

to ensure

a

good

tit.

1

Disconnecl

he

negatrve

attery

able.

2. Drain he engine oolant.

3. Removen the order

shown n the igure.

4.

nstall

n the reverse

roerol removal

r*n

{3o-1

ro cfrrg,

6F95

hrb)

1.

Coolinganconnector

2.

Coolant eservoir ose

3. Radialor ose

4. Oilcoolerhose

ATX)

5. Radiator racket

6. Radiator

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

7

7-Coolingan

and

radiator

owling ssembly

INSPECTION

Check

or

he

ollowing

nd repair r replace s necessary.

1. Cracks, amage, nd water eakage.

2. Bent ins

repair

itha screwdriver).

3. Distoned r bent

adiator

nlet.

Sleps Atter Installation

1. Fill he radiator ith he specified mount nd ypeof en-

gine

coolant.

Refer

o

page

E-4.)

2.

Connecthe

negative

attery able.

3. Start

he

engine

nd

check

or leaks.

E-7



THERMOSTAT

THERMOSTAT

REi'OVAL

INSTALLATION

Caution

.

Betore oosening

he radlator drain

ptug,

verlty that

the radiator

drain ho€e ace€

slraighl

{oll.

. Position he hose clampIn the originil locatlonon the hose' andsqueeze he clamp ightly

with large

pliers

o ensure a

good

tll.

L

Disconnect

he

negatlve attery able

2. Drain he engine

oolant-

3.

Remove

n

the

ordershown

n the igure.

4.

Installn the

reverse rderof

removal.

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

1.Water hermoswitchonnector

2.

Upper adiator

ose

3. Thermostat

over

4. Thermostat

asket

Installat ion

ote............................

age

E-g

E-8

5.

Thermostat

Inspection.....................................ageE-9

Installat ion

ote........................,...

age

E-g



THERMOSTAT

INSPECTION

'1.

Visually heck hat

he hermostatalve

s airtaght.

2.

Place

he thermostat

nd a thermometer

n water.

3. Heat

he

water

and check he ollowing:

Installation Note

Thermostat

Installthe

hermostatnto

hecylinder eadwith

he

iggle

in

at the op.

Thermoslal

gasket

Install new

gasket

with

he sealinging acing

he

cylinder

neao.

0rEoE( .o16

Steps Atter Installation

1. Fill

he radiator ith

he

specifred mount

nd ype

of engine oolant.

Refer

o

page

E-5.)

z.

Uonnecthe negatrve

attery

able.

3. Start he engine

nd check

or leaks.

01EOEX017

B3

Openingempe.ature "C (.D

86.5-89.5 (187-193)

Fu 'open emperalure

oC

(oD

lOO

1212)

Full-openilt

mm

(in)

8.5

(0.335)

r

more

E-9



WATERPUMP

WATER

PUMP

REMOVAL

INSTALLATION

Cautlon

l-adfore

toosenin' the

radlator drain

ptug,

verity

that the

radlator

drain

hose

taces stralght do{vn.

. oJnoi aisasseiule the water purilp.-tta probtem s found, replace he pumPas a unit'

1.

Disconnect

he

negative attery

able.

2.

Drain he

engine oolant.

3. Flemove

n the order

shown n

the igure.

4. lnstall

n the

reveaserder

of

removal.

f_o

@neeurce

E t

aOREPLAoE

^ _\6

re-2s

0,9-2.6,

4-re)

FEPLACE

1.Timing

belt

4 Water

ump

assembly

Service.........-........

....

.... Section

Inspect

orcracks,

amaged

ounting

2.

Water

ntet

pipe

and

gasket

surface,

earing

ondition,

nd eakage

3.

Waterbypass

ipe

and O'ring

5.

Water

ump

gasket

Steps

Aller

lnstallaiion

i.

Fi|l

n" iio"ioi

ritn the

spec redamount

nd

ypeot engine

oolant

Refero

pageE-5

)

2. Connect

he

negative attery

able.

3. Start

he engine

and check

or leaks.

E-l0



ELECTRIC

COOLING AN SYSTEM

ELECTBIC

COOLINGFAN

SYSTEM

SYSTEM

CIRCUIT

COOLING

TAGNOSTS

CONNECTOF

PBESSUFIE

ADDITIONAL

SWITCH

THEFIMOSWITCH

ABOVE91"C

(196'F):

ON

MAGNETIC

CLUTCH

t-](-%,re

SYSTEMNSPECTION

1.

Jump acrosshe

an

est

OFA)

erminal nd he

ground

(GND)

erminal f the diagnosisonnector.

2.

Turn

he gnitionwitch Nand erifyhat he anoperates-

lithe andoesnotoperate,nspecthecoolingan

system

componentsnd wiringharness.

3. Removehe radiatorao and

place

a thermometern the

radiatorillerneck.

4. Start he

engine.

5. Verityhat he anoperates hen hecoolantemperature

is as specified.

Operation emperalure:

above

91'C

(196'D

lf

the an does

not

operate, heck he water hermoswitch.

(Refer

o

page

E-13.)

0r EoEX.021

E-11



E

FAN

IIOTOR

1.

Cooling

an

connector

2. Fiadiatorowling

E-12

FAN MOTOR

INSPECTION

1.Check hat

he battery

s fullycharged.

2.

Disconnect

he an motor

onnector.

3. Connectthe

attery

ndan ammeter

o

he anmotor

on-

neqor.

4. Verifyhat

current

s

as

specilied.

Current

A)

5. ll current

s notwithin

peciiication

nd/orthetan

oes

not

turnsmoothly,

eplace

he an

motor'

REPLACEMENT

Cautlon

;

Posiiion he

hoseclamp

n the orlginal

ocationon the

hose,and

squeeze

he clamp

lghtly

with large

pliera

o ensu.e a

good

llt.

1. Disconneclhe

negative attery

able.

2. Drain

he engine

oolant.

3. Remove

n the order

shown n the

igure.

4. nstalln

the reverse

rderof removal.

7,3-ll

x{

(30-110

d*q,

30-95

lDlD)

0,01-o.oit

f

(0.ra--a.22

iFtg,

015-o

1l lFlb)

0.oa'0,06 Nfl

(0JHr,56

crF*!,0.3!H.5o

lFlb)

3. Cooling

an

4. Fan

motor

It4TX

ATX

B3

6 . 6 + 1



WATERTHERMOSWITCH

E

WATERTHERMOSWITCH

NE OVAL INSTALLATION


attery able

2.

Remove

n the ordershown n the igure

3. Installn the reverse rderoi removal,eferring

o

InstallatlonNote.

GFING

FEPLACE

1.Water hermoswitchonnector 2. Water hermoswitch

1nspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

- l3

Insialiat ionote..........................

age

E-1

INSPECTION

1.

Place he switch nd a thermometer

n water.

2. Heatthe ater

radually

ndcheck

ontinuityftheswitch

wilhan ohmmeter.

3. t not as specified,

eplacehe water hermoswitch.

lnstallation

Note

Water hermoswitch

1. Applya small mount fengine

oolanto henewGring.

Caution

.

Do not use an

impact wrench or Installatlon.

2. nstallhe water hermoswitch.

Tighiening orque:

5.9-4.8

N.m

60-90

cm-kg,52-78

innb)

E-13

Coolantemperalure

'C

fD

Continuity

[4ore han91

(196)

Less han 84

{183)



FAN RELAY

FAN

RELAY

REMOVAL

INSTALLATION

1. Disconnect

he

negative attery

able

2.

Remove

he

an relay.

3.

Install

n the reverse

rder

of removal.

INSPECTION

1. Check

ontinuity

s shown

withan

ohmmeter.

2.

Apply

12v between

erm,rals

an{

@;

Check

or contrnuiry

etween

ermlnals

, ano

(9)

3. lf not

as specified,

eplace

he an

relay.

:-\_

-=-=l

24

Contlnuity

@ @

NO

o @

E-14



F

tNDEX....,....,,...,...,,.......,..-...,......"....-..

-

ouTLtNE.....,...,,....,...,...,......,.......,..,...

-

SYSTEM |ACR4M.., . .. . . . . . . . . . . . . , . . . . . . . . .-

VACUUI\IHOSEBOUTING

DIAGRAI\ ,1. . . . . . . . , , . . . . . . . . . . . . . . . . . . . . . . , , . . . , .-

wtRtNGD|AGBAM... , . . . - . . . . . . . . . . , . . . . . , . . , .-

spEctFtcATtoNs.... . . . . . . . . . . . . . . . . . . . . . , . . . . .-

coMPoNENT ESCRIPT|ONS..... . . . . . . . .-

TROUBLESHOOTTNGU|DE.... . . . . . . . , . . , . .

-

FELATTONSHTPHART..... . . . . . . . . . . . . . . . . .

-

ustNG Hls EcTtoN.....,... .,.,...,,,..,,.-

DIAGNOSTICNDEX...., . , . . . . . . . . . , . , . . . , . .-

PRECAUTTON,.... , , . . . . . . . , , . . . , , . . . . . , . . . . . . .

-

SYMPTOMROUBLESHOOTING..... . . . . .

-

ENGTNEUNE-UP..., . . , , . . . , . , , . . . . . . . , , . . , . . , . ,-

PREP4RAT|ON..... , . . . . . . . . . . . . . . . . . . , , . . . . , . . .-

BASTC

NSPECT|ON..... . .- . . . . . . . . . . . . . . . , . . .-

ADJUSTi\4ENT,.., , , . . , . . . , , . . . . , , . , . . . , . . . . . . . . ,-

SELF-D|AGNOS|SUNCT|ON,..,...........,

-

DESCRtPTION...., . . . , . . . . . . . . . , . . . , . , . . . . . . . . , .-

PREPABATtON...., , . , , . . . . . . . . . . . . . . . , . . . . . . . . .-

MALFUNCTIONODENUMBEF..... . . . -

swtTcHMoNtToR UNCT|ON..... . . , . . . .-

TNTAKEtRSYSTEM.,... . . . . . . . . . . . . . . . . . , . . . .-

coMPoNENT

ABTS..... . . . . , . . . . . . . . . . , . . . .-

tNJECTtONODY,.... . , . . . . , , . . . . . . . . . . . . , . . . .

-

BAFFLE/INTAKE

\4ANIFOLD..... . . . . . , . . . . .-

ACCELERATOREDAL.,,, , , . . , . . . . . . . .- . , . .-

ACCELEFATORABLE.,,. . . . . . . , . . . .- . . . . . .

-

FUELSYSTEM,..., , . . , . . , . , . , , , . , . . . . . . . . . .- . . . . . .

-

PRECAUTION,,... . , . . . . . . . , . . . . . . , , . , , , . . . . . . ,-

SYSTET\4PERATION...,. . . . . , .- . . . . . . . . . . . . .

-

FUEL ANK,..., , . . . , , . . , . . , , , . . . . , . . , . , . , . . . . . . ,-

FUELPUMP...,, . . . . . . . . . . .- . . . . . . . . . . . . . . . . , . . .-

FUEL tLTER.,,.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-

crRcutT

OPENINGE AY.... . . . . . . , . . . , . . ,-

PRESSUREEGULATOR..... . . . . .- . . . . . . . . .-

iNJECTOR..... . . . . . . . . . . . . . . . . . . . . . . . . . .- . . . . . . . .

-

EXHAUSTYSTEM..... . . , . . . . . . . . . . . . . . . . . . . . . .

-

coMPONENTARTS..... . . . . . . . , . . , . . . , , , . , .-

OUTLINEOF

EMISSION

CoNTROL

YSTEi,.. . . . . . . . . . . . . . . . . . . . . . . . . . .-

STRUCTUEAL

|EW...., . . . . . , . . . . . . . . . . . . . . . .-

2

9a

FUELAND

EMISSION

CONTROL YSTEMS

(EGr-S)

a

9

1 1

1 1

't4

1 6

1 7

61

61

61

62

66

66

67

67

80

83

83

84

86

86

86

87

88

88

90

9 l

93

94

94

s7

97

POSITIVE RANKCASE

VENTTLATTON

PCV)

SYSTEM..,..........

-

99

DESCBtPTtON..... . . . . . . . . . . .- . . . , . . . . . . . . . . . . . .

-

99

PCV

VALVE..... . . . . . , . . . . . . . . . . . . . . . . . . . . , . , . . . .

-

99

EVAPORATIVE

MISSION

ONTROL

sYsTEM....-. . . . . . . . , . , . . . . . . . . . . . . . . . . . . . . . . . , . . . .

- l00

DESCRtPTION,..., . . . . , . . . . . . . . . . . . . . . . . . . . , . . .-

-r00

SYSTEN,iPERAT|ON.,.., . . . . . . . , , . . . . . , . . , , .- l01

SOLENOIDALVE

(PURGE

ONTHOL)..,, . . . . . . . . . . . . . . . . , . .--.

-101

FUEL APOR

ALVE,.... . , , . . , . . , . . . . , . , , , .- l01

cHECKVALVE i'WO-WAn..............,..

-102

cHAFCOAL ANrSTER..... . . . . . . . . . . . . . . . . . .

-102

CATALYTIC ONVERTER

YSTEM...... F-'IO3

DESCRtPTtON.,,.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .- .

-103

oATALyTtC ONVERTER................-...

-l03

DECELERATIONONTROL YSTEM.....

-104

DESCRtPT1ON..... . . , . , . , . . . , . . . . . . . , . . . . . . , . . , ,

- l04

DASHPOT.,... . . . . . . . . . . . . . , . . , . . , , , . . , . . , . . . , . . . ,

- l tX

A/CCUT-OFFYSTEM..... . . . . , . . . . . . . . . . . . . , ,

- l05

DESCR1PTrON..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-105

SYSTEMPERAT|ON..... . . . . . . . , . . , . , . . . . . . .

- l0s

DECHOKE ONTROL YSTEM.............-

-l06

DESCFtPTtON...., , , , . . . . . . . , . . . . . . .- . . . . . . . . . . .

-106

SYSTE|\4PERAT|ON..... . . . . . . . , . . . . . . . . . , . .

-106

AtR

BYPASS

CONTROL

YSTET .,.,..,.,F-107

DESCRrpION..,,-. . . . . . . . . . . . , . . . . . . . . . . . . . . . . .

-107

sYsTEt\4PEFAT|ON..... . . . . . . .- . . . . . . . . . . . .

-108

AIRBYPASS OLENOID

VALVE

@, @, @..... . . . . . . . . . . . . . . . . . . . . . . . .

-10e

CONTROLYSTEI,| . . . . . . . . . . . . . . . . . . . . . . . . . . , . . .

-110

PREPARA'IrON.... . . . . . . . . . . . . . . . , . . . . . , . . . . . . . ,

-110

STRUCTURAL

tEW,..., . . , . . . , . . . , . . , . . . , . . , ,- l1 1

ENGTNEONTFOL

Ntr

ECU..,.. . . . . . .

-112

CBANK NGLESENSOR

itND|STRtBUTOR),... . . . . . . . . . . . . . . . . . . . . . . . .

-r20

AIRFLOW ENSOR

(BYPASS

OT-W|RE

yPq..........,.,,,. F-l21

wATER HEB[,4OSENSOR...,. . , , . , . , . , . . , . .-121

TfIBoTTLEENSOR,.... , . . , , , . , , . , . . . . , . . , . .

- l22

oxyGENSENSOR..... . . . . . . . , . . . . . . . . , . , . . , . .

-123

t\4AtN ELAY..,, . . . . , . . . . . . . . . . . . . . . . . . . . . . .- . .

-124

cLUTCH WTTCHi,,4Tn,.., . . . , . . . . . . . . . ,- . .

- l24

NEUTRALWTTCH

L4TX).,.. . . , . , , . . . . . , . . . .- l25

POWER TEEFING

FESSUFEWITCH -125

o1a0Fx.001



INDEX F

1. Fuel ank

Removal

lnspection

Insta||ation...............................age

F- 90

2. Fuel

pump

Inspectjon........................-........

age

F-

91

Rep|acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-

92

3. Fuel iher low-pressureide)

Rep|acemenl . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

93

4. Fuel ilter

high-pressure

ide)

Replacement.-...........................age

F- 93

5.

Circuit pening elay

Replacemenl . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age

-

93

Inspect ion. . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . .

age

-

93

6. Pressureegulator

Inspection.................................age

F- 94

Rep|acement.............................

age

F- 94

7.

lnjectol

lnspection

on-vehjcle)..............

age

F-

94

Removal/nstallat ion...............ageF- 95

Inspec l ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age

-

96

8. PCV alve

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age

-

99

9. Solenoid alve

purge

ontrol)

Inspection.................................age

F-10'|

RemovalInstallation................

age

F-101

10.Fuel

aporvalve

Inspect ion. . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . .

age

-101

11.

Check

alve

two-way)

Inspectaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age

-102

12-

Charcoal anister

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age

- -102

13.Air bypass olenoid alve

@

1nspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

page

-109

14.Air bypass

olenoid

alve

@

Inspection....-............................

age

F-109

15.Air bypass

olenoid

alve

@

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

109

16.

Engine

ontrol nit

ECU)

Rep1acement.............................

age

F-112

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age -1 2

17.Airflow ensor

fnspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-121

Rep1acement.............................

age

F- 85

18.Water hermosensor

flil"'.Y,fl;......:.''... . ..833:-:,3

19.Throttle ensor

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

122

Adiustmeni . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .

age

1 2

Removallnstallation................

age

F- 122

20.Oxygen ensor

Inspec l ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age -123

Rep1acement.............................

age

F-124

21.Main elay

Rep1acement.............................

age

F-1

4

lnspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

124

22.

Clutch

wilch

MTX)

1nspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

124

Repiacemeni.............................

age

F 124

23. Neutralswitch

N,,|TX)

Inspection.................................

age

F-125

Rep|acement..........................-..

age

F-1

25

24.

Power teering

fessure

witch

Inspection.................................

age

F-12525.Crank nglesensor

Inspection

.................

*t".,H.r_:

F-3



F

INDEX

1.Aircleaner

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

- 62

2.

Dashpot

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-104

Removal/

nstallat ion

...............

age

F- 85

3. njection ody

Inspection.................

.. . ...

page

F-

84

Disassembly

Assembly...........

age

F- 85

4. Bafile

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

- 86

F-4

5. ntake

manifold

Inspection....................

. ........

age

F 86

6.

Intake

manifold

tay

7. Exhaust

ystem

Removal/

nsDectlon

Ins ta | la t ion. . . . . . . . . . . . . . . . . . . . . . . .

pageF

9/

L

Catalytic onverter

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

page

-97



OUTLINE

F

OUTLINE

SYSTEMDIAGRAM

*

9

E

tr

E

o

s

I

I

s

i

@

0

o

6

@

T-

a *

: t

? F

2 =

3 "

F

, 3

I E

t A

9 *

6

{ @

c <

o

F-5



F

OUTLINE

VACUUM

HOSE

ROUTING

IAGRAM

q

q

e

o

l

e

s

E

@

t i e

l ^ O

M u {

i 6

n - A

c

f

;

a

F-6



F

OUTLINE

1,100153

P

ange)

750

1"3

Neutral)

lsnlrion

imino'

Bfqq

Below

38

(6.5,

92)

rtrui-,-

ortprip,""*,"

kPa

ks/cm'

si)

Nylon lement

in

uel

PumP)

235

275

12.4-2.A,

4-40)

FeSrl"rrS

p'e."r'"

kPa

rCcm),

Ps)

Air bypass solenold

valve

@

Alr byp.ss

solenold

valve

@

Alr

bypass solenoid

wlve

@

Solenold

valve

(purge

conlrol)

' t4.6-17.8

Resistance ko 40oc004oR

o"c

(176'D

Bypass ype

ol hol_wre

Besistance

HWN-HWP)

ko

40

00.6,

8.8)

pr< l rs nrl lmp

ga)

t v ' v t " ' r y

Unieaded

RON

0 or

hgheo

SPECIFICATIONS

'TEN

termnal of diagnosls

onnector

grounded

F-8



OUTLINE

F

COMPONENT

ESCRIPTIONS

Component Rems]k

Air bypasssolenoid

valve

@

il j€e1\ot j

$oe'i

SLrpplies

ypass ir nto ntakemanilold y

openrng

bypassarr

passage

at either

ollowng

a) Ensine rankins

b) El€ctric oad

c) P/S

pressure

witchON

d) A,/C witch

ON

e) Bange

hange

N-D)

f) Deceleralionconlrol

.

Electricaoad

a) cooling an

b) Blowermolor swltch

c) Headlighlwitch

d)

Rearwindow

ehoslerwitch

Air bypass

solenold

valve

@

Supplies ypass iranlonlake

manifod y

opening ypass ir

passage

l eiiherollowing

a) Engine

ranking

b) P/S

pressure

wilch ON

c) Deceeralon conlrol

Air bypass solenoid

valve O

S'rpplies

bypass air inlo nlake manifold

by

opedng bypas arf passage with A/C swltch ON

Filiersair enleing injection

body Oil

p€rmeated

Detects anrounl

of

inlake

air; sends signal to

ECU

UsesVref

5v)

as

power

source

Batlle Drrectsuel/ai.

mixture nto ntakemanilold

Cat.lyticconvener ReduceHC,

CO and NOx by chemcal

Stores uel tank lmes whie

enginestopped

Controls

pressure

n iuel

tank

Circuit opening retay Vollage or {uel

pump

while

enEne runnrnq

clutch $viich

(MTx)

Delectsclutch

condlioni sendssignal o ECU SwilchOFFwhen cl'rlch

pedal

eleased

Crank angle sensor

Ne.signal

Detects

rankangleat iaoo inlervalsi

ends

signal

o ECU

Diagnosls

onneclor Concentraled

eMce connectorTerminals:

1.

EGIself.diagnostc

erminal

2. EC-AT elf-diagnostc

ermifal

3. Inilia set

erminal

4. Fuel

pLrmp

heck erminal

5. Coollng an

ch€ck erminal

6. Engine pm

oulput elm nal

2l

pin (located

near

eti strut oweo

Oashpor

Prevents

lter burn when hrotlle aive

closes

Ehglne onlrol unil

(ECU)

Conkols peral n ol the ollowing.

a) Fuel njection

onlrol system

b) Elecironic pafk advance

ESA)

ontrol

c) AJCcur-otisysrem

d) Deceleralion

onlrol syslem

e) Fuel

p'rmp

controlsystem

D

Evaporative

mission onlrolsyslem

g)

Falsale

conkol ystem

h)

Secondaryir njeclionystem

Fuel lllie. Filterspanicles

rom luel

Fuel

pump

Provrdes

Liel o nleclor

Operates

hale

ngine

unn g

Supply

only evaporative missionnto charcoa

can

sler lo

prevent

charcoai canisler from lue

F-9



F

OUTLINE

Componsnt

Remart

lghlllon

swilch

(STABT

posilion)

Engine ranking

ignal

ent1o

ECU

lnhlbllor swilch

(ATX)

Detects

n-gear onditioni

ends

ignal

o ECU

Sw i c h

N

nN or Pr anges

Inleclion

body

a) lniects

uel nto nlake

manilold

b) Adiusls

nlakealr amounl

by throttle

valve

ct

ldl;-upby air bypass

olenoidave

@

d) Detecls

amount

ol intakes

alr by airl ow

Conssts

ol

throtlle

vaive dashpot,

throtlle

sen'

sor,

ast

dle

cam,

airflow

ensor,

nieclor,

res'

sure

egulator,

nd ar

bypass

solenod valve

@

Ini6ctor

lniecrsue

in relatlono

englne eeds

Conrrolled

y

signals

fomECU

High-ohmic

njector

Installed n

injecton

body

Main

relay

(FUEL

NJ

relay)

Supplies

lectric urrenl

o

injector, CU,

lc

t{eurral

wnch

t

TD

Detects

n-gear ondiLon;

ends

ignalo ECU

Switch

ON in

neulral

Orygen sensoa Deiects xygen oncenlrationiends ignallo

ECU

Zrrconiaetamic ndplatrnumoatng

Contros blowby

gas

Introduced

nloengine

P/S

pressure

3witch

Derecrs

/S

operatoni

ends ignalo

ECU

P/Sr

ON

when sleeing

wheel

um€d

Prelsure

regulrtor

AdjustsJue

pressure

upplied

o

injector

Specd

s€nsor

Detects speed: sends

signal

to ECU

Insialledn

nstrumenl

luster

stopllglrr

swllch

Delects

brakingoperalion

deceleranon)iends

signal

o ECU

Solenoid

valve

(purg. conltoD

Conlrolsevaporative

umes

rom canister

0

n_

Throltle sercof

Deiects hrottlevalveop€nlnganglelsendssg_

nal o ECU

Installedn njecuon

ody

Wat.r thetmos€nsor

Delectscoolant

emperature;

ends

signal o

ECU

lnsraledon

iniake

manlfo

F-l0



TROUBLESHOOTING

UIDE

F

TROUBLESHOOTING

UIDE

RELATIONSHIP

HART

OUTPUT

OEVICE

I PUT DEVICE

o

z

d d

9.=

4 0

z r )

6 -

' J

E ?

.,1

o

z

o

o

(,

fi

o

z

o

o

z

=

F

z

L

z

I

z

t5

9

e

I

|rl

c

@

t

=

UI

o

@

o

z

|r|

o

lo

o

-

=

z

@

-

( r^

t o

o o

Q.=

> =

g 9

6 ?

n :

d=.

E

fi

o a

./J-

o <

9. .

S O

q E

J O

u€

ts

=

=

z

F

z

z

=

z

o

(,

=

EOAT @I{TFOL UI{IT

o

DIAGNOSIS O

IECTOR

CTEN

EN INAL)

o

o o

tcNtTtol{ sw|rcH

(START

OSII|ON)

o o

o o o o

E/LSIGNAL'

o

o

o o

P/S

PRESSURE

WITCH

o

o o

o o

a/c swlTcH

o

o

o

INHIBITORSWITCH

ATX}

o

o

o o o

EUTRALAND CLUTCHSWTTCHES

ITX)

o

o

o o o

sToPltGHT SWITCH

o o

SPEEOSENSON o

THROTTLESENSOA

o

o o

o

o o o

o

AINFLOIY ENSOR

o o o

o o o

OXYGENSENSOR o o

o

WATER HER OSENSON

o

o o o

o o o

CRANK

ANGLE SENSON

O{6'SIGNAL)

o

o o o o o

o o o o

'

E/L 3lgnal

ls headlighls, rear window dalroster,

blow€r

3witch

and cooling lan.

F-11



F

TROUBLESHOOTING

UIDE

USING

HISSECTION

lntroduction

Most

ol the

uel

and

emission ontrol

ystem

s electricallyontrolled,

ften

makjngt ditficult

o diagnose

oroblems

n ho system,

speciallyntermittent

roblems.

eforeundertaking

ctual hecks,

ake

a

few minutes

io talkwith

a customer

ho approaches

itha drivability

omplaint he

customer

s often

good

source

of

nlormation

n such

problems,

specially

ntermittentnes.

hroughalks

with hecustomer,

necan

ind

outwhat hesymptomsreand underwhatcondjtionsheyoccur.

work tlow

CHECK

N

I

I

LISTEN

OCUSTOMEBOIVPLAINTS

I

I

REFEB

O TROUBLESHOOIINGAGE

HAT

COBRESPONDS

O

ACTUAL

YMPIOIV

Diagnostic

ndex

No.:

Each

roubleshooting

tem s

assigned

number-

TROUBLESHOOTING

TEM:

There

are26 troubleshooting

items.Choosehe tem hat

mostclosely

orresponds

o

the actual vmDtom.

_

DIAGNOSTIC

NOEX

(Beler

o

Page

F 14)

CHECK

FORWHAT

CHECK

ORWHATPART

S BAD

_ _

I

i i

RTOAIB/FEPLACEMENT

J

I

DETEBI\4INE

F

TROUBLE ASBEENELIMINATED

I

Yes

CHECK

OUT

IS BAD IN SYSTEM

_ -

INSPECTION

ACTION

DESCRIPTION:

Describesach

roubleshooting

ilem.

F-12



TROUBLESHOOTING

UIDE

F

Troubleshooting

hart

05u0Fx.015

OESCRIPTION:

Further escribeshesymptom. onfirmhat hechartaddressesheactual ymptom efore eginning

troubleshooting.

TROUBLESHOOTING

INTS:

fhis describes

he

possible

oint

f maltunction.

STEP:

This

shows he order

ol troubleshooting.roceed

ith roubleshooting

s

ndicated.

INSPECTION:

This

escribesn nspection

o

quickly

eterminethealfunctionf

parts.

f

a detailed

rocedure

snecessary

to

perform

he INSPECTION,

efer

o ihe

page

shownby the

"F"

mark.

ACTION:

This ecommends

he

appropriatectiono ake

asa

result

YeVNo)

f he NSPECTION.

ow o

perform

the

action s described

n he reference

age

shownby

he

"t?"

mark.

0su0F1.016

.En0 ie .unsnomaya ' rdet r

d r e F oush

re

( N os

, r2) l

FROUALESHOOTIIG

HIf,ISI

(cotr*lo^

'or

coorad rehpe'aruE)

*rnund|onc*No'ck'l.y.d

check

o'

cau*

(Ferer

ospsr'd

ch&ks4uercel

Che.N

cLr em'^a lFvorase

(rernion

d ox)

3Cat .F2_r le

EC! andsenDaqDss ch4ker

F-13



F

TROUBLESHOOTING

UIDE

DIAGNOSTIC

NDEX

TROUBLESHOOTING

TEI

OESCRIPTION

PAGE

Willnol crankor

cranks lowly

Reier

o EngineElectical

System

G--4

2

Engne ranks

l

normal pg€d ul shows

o sign

ot

l r ing

F-17

Engine

rank€ tnormal peed utshows nlypar_

tialcombuslion

nd

willnolconlinueo

run

F- r9

Engine lads

omally

when old,butwill

notslana,

ter running

ndhoisoaked

F-21

Eng,ne ranhs

al

rormal speed bul reqJies

eices

sive

cranking time

belore staring

F-23

Same ondition

s

No.swhenengine old

Reslans

normally fter

wa|m_up

F-25

7

Same ondltion

s No.5afler

unning no

hot

Starts

oimally hen old

F-27

8

Enginestalls

ai dle

Engine tallsor

vibrates

xcessively t

|dle

F-29

9 Engine tallsor vlblatesexcessively l idle dlrng F-31

10

Engineunsnomally

t dleduring

watm'up ul

vibates excessively

r

stallsaft€r warmlp

1 1

E/LON

Engine talls

or v brales

excessively l

idle wrcn

}JC,P/S,or

E/LON

F-35

Rough dle/Engine

talls

ust

atier sta(ng

Engine talls f

v brales xcessively

nly

ust

aner

staning

acceleralion

rom

dle)

F-36

13 High

dle

speed

atter

wam-up

ldle

speed

excessve

afterwam_up

FJE

1 4

ldle movesup

and down/ldlehunting

Engine

peedsup and

down

pe.iodically

t dle

F-39

Engrne lallson deceieralion

E^grneune^pecledlv

loos

un'nng th

le dFcele'ar

ing or atler decelefallo.'

F41

1 6

Eng,ne ralls uddenly

lntemiten0

Engine ntemiltent slops unnhg

F42

1 7

Hesitates/Siumblesn

acceleration

Flat soot occurs ust

alier acceleralor

epressed

r

mlld

erking

ccurs

uing acceleranon

F-43

1 8

Surges

Unexpected

hange

n engne sp€€d

which s lsually

rep€lilive

F--45

1 9

Pedo.mance

oor

under

md when hroltle

alve

lvlaximum peed

€duced

F-17

20

Pedormance

oot whileacceleral,ng

F-50

21 Runs

oughon deceleralion/Backlire

Enq,le

runs roughwhiledeceeraing

3nd abrornal

combustion

occurs

in exhaust sYstem

22

Abnomal combustion ccompanied

y audible

''pinging"nois€

F-55

23

Gaso

ne

odor

in cabin

F-57

24

Exhaust

as

smells

ike

rotteneggs

F-58

25 Highoil

consumpnon

Oilconsumplion

rcessNe

F-58

26

Fueleconomyunsalislactory

F-59

F-l4



TROUBLESHOOTINGUIDE

Doscription

ol Drivablllty

STUMBLE

:

Mib

jerking

duringacceleration.

HESITATION:lat

spotoccurring

ust

after he accelerator

edal

s

depressed

SURGE

:

Continuousoft

erking

uringcruise.

03u0Fx 33

ENGINESPEED

WNo.laSURGE

-12'1no

" """o'on

No.21

RUI{SFOUGH

ON

OECELEBATION

No.17STUMaLE

F

F-l5



F

TROUBLESHOOTING

UIDE

22-30

12.2-3.1

16-22t

r+m

(n-kg,

n$)

PUMP

CONNFCTOB

PRECAUTION

Fuel Preasure

Release

nd Servicing

Fuel System

Fuelinhefuelsystem

emalnsnder

igh

pressure

ven

when

the enoines

not runnrno.

a)

Beto're rsconnecltng

ny

uel

ine, eleasehe

fuel

pres_

sure

om he

ue syslemo

reducehe

possibihtv

l niury

or fire.

1.Stan he engine.

2.

Removehe

rearseatcushlon.

3. Disconnect

he uel

oumo

connector.

4.

After he engine

lalls,urn

otf he

gnition witch.

5. Reconnect

uel

pump

onnector

nd nstallthe

ear eat

cushron.

b)Usea

ragas

protectionrom uelspray

whendisconnecf

ino he

hoses.

Pluo he

hoses tter

emoval.

c)

When nspecting

he

uel

system,

se

a suitable

uel

pres-

sure auge.

Cautlon

.

Install hose

clamps

o secure

he tuel

pressule

gaugeto

he

uelfilterand

he uel

mainhoae o

pre'

vent luel leakage,

PinchinoHose

When

p;ching

an

air hoseor

a fuel

hosewith

pliers,

wrap

the hose

witha rag

o

prevent

amage

F-16



TFOUBLESHOOTING

UIDE

F

SYMPTOM

FOUBLESHOOTING

CAANKSNORMALLY UT WILL {OT STARTiO

COMBUSTION}

DESCRIP.

Ttotl

.Engine

ranks t normal peed

butshows o signol

"fting

.

Bane.yn normal ondrtion

.Throttle

alve oi held ullyopenwhiie ranking

Oechoke

yslem

ot

operale)

ITROUBLESHOOTING

INTSI

Becausel

no

combustDn,

ossibly

O

No

spark

.

lgntion ontrolmalfunction

.lgnition

sysiemcomponent

mafunction

@

No

iuel nlection

.

Fuel

pump inopefalive

.Injector

noperative

no

rue i

s

nFL led o

engrn .

o ro

€1 l ion

a l d r lc / l -dar '

€)

Low

uel ine

pressure

@

Lowens,ne

ompressioi

@

ECU

power

upply

rrcuit pen

@

ECU

ground

rcui open

INSPECTTON

acTtor,l

l

ls

svong

blue park

sibe

at disconnecled

gh.

/

>.

/)

PerformSlep

2

4

ll

OK, check rgnton system

(Refer

o lroubleshooiing

''Misfke")

(r

Page

G-17

a

ff not

OK, reler o speciJied

heck

seqlence

or

displayed

ode

No. F

Page

F-?0

2

ls 00" displayed n SellDiagnosis

Checker

wlth gnilLon wilchON?

ri

page

F-67

Maltunctloncode No. displayed

Check

or cause

Beler

o specited

check sequence

or displayed ode

No.)

17

Page

F-7o

"88"

flashes

Check

ECU erm nal lF

vo

ag€

r?

page

F-114

voltage:

Approx. 12v

(lgnillon

switch

ON)

4

ll OK.

replaceECU

ri

page

F-112

+

ll not

OK.

check

wl.ingbelween

ECU and Self

DbgnosisChecker

and ECU erm nal

18 vollage

3 Rer.oveair c eanercoveri s fuei niecled rom

injeclorwhie crankingengine?

1.5-2.0

Nn

{15-20

crks,13-17 in-rb)

Ch€ck ollowng poinls

.Spark

ptugs r

page

c-19

.

tgnjtion mrng

E?

pag€

F-63

.Engine

compressiof

c?

page

B-lO

.Warer

thermosensor

-r

page

F-118

(ECU

20 tem nal vollase)

.Fuel

pressure c7

page

F-89

(lr

njected

uel s

small

ariounl)

.Inlecror

17

page

F-97

(li

njecled uel

s

smallamounl)

Check

or lnjector perating ound

whllecrankng

engrne

+

li OK,

So

o nexl siep

+ l{ not OK, go ro Slep6

F-17



F

TROUBLESHOOTING

UIDE

tNsPECT|Oll

ACTION

Connect

lagnosis

onnector

erminals

/P.and

GND

with

umper

irei

s uel

pump

operarng

solnd

evided

wilh snilion

witch

ON?

-7

pege

F-92

GND

;)).

Check

f iuel is

iniecledwhib crankng

englne

n this condftion

+

lf injected, heckcircult

opening

4

ll not njecred, heck

nieclor

of

cloggingand if lue is in tank

5

ls there

conllnuily

elween

Llel

pump

connecior

@ and @?

Check ncuit

penrngelay

c7

page

F-93

6

ls herc

approx.

2Vmomenlariy

t

ECU2V er_

mnaL

whib cranking ngine?

(Engrne

ignal

monitor

reen

nd red

amps

ilash)

Try io replace

njector

lniector

stuck)

No Check

njeclor

or continuity

+

lf OK,check

wlfinS

elatedo

ECU errninals

Y,2V,2U,

and

+

ll notOK, epace

njeclor

F-l8



TROUBLESHOOTING

UIDE F

CRANKSNOF ALLY BUT W|LL

r,rOT

START

PART|AL

COtitBUSTtOt{) U,HENEI{G[{E COLD

DESCN|P.

Tto

.Engine

ranks t normal p€ed utshows nly

parlial

ombustionnd willnotconlinueo run

.

Batlery n nomal condilion

rrFouBLEsHooTrilc

tNTsl

O

Air/Fuel ixtureoo rich

. Waterhermosensoralluncllon

O

AidFuelnixtureoo ean

.Fuel

nject

n

controlmallunction

(Corection

or

coolanl

emperature)

.Low

iuel ine

pressure

.An

leakage f nlake irsystem

O

Lowensine ompressron

INSPECTION ACTION

1 ls 0O displayed

n SellDiagnosis

hecker

wlth ignilion

switch

ON?

TEST

SWiSELFTEST

Mallunction

CodeNo. displayed

Check

or

cause

Reier

o soeciiied

check

equence)

17

page

F-m

"88" llashes

CheckECU elmlnal Fvoliage F

page

F-114

Voltage:Appror. 12V

(lgnltlon

switch oN)

a

ll

OK, eplace CIJ c7

page

F-112

4

I nol

OK.checkwiring elween

ECU

and S€lf-Diagnosishecker

?

/ \ ^ \ _

/

Checf d sr ouror cdp ard rolor c:i

page

G-23

d\<<=F

=I) 'b

B\

3 Connect iagnosisonnecroretminals /Pand

GNDwilh

umper

wne;s lherecorrectuel

ine

pressure

ith gnition witchON?

e

page

F-49

Fuel lne prossuae:

235-275 kPa

(2.4-2.a

kg/cm', 34-40

psD

PFFSSURE

GAIIGE

' l

t""

otAGNOStS

CONNECTOF

Check uel line

pressure

while

p

nch

+ ll

tuel

ine pressurc uickly

n-

creases, heck

pressure

egulalor

-:

il luel

line

pressufe

gradually

n.

creases, heck or clogging

be-

lween uel

pump

and

pressure

lf not clogged, heck uei

pump

maxmum

pressure

e

page

F-91

High

pre$ure

ls lel relurn ose logged

r res,

lricled?

+

ll OK, eplace

ressure

egulalor c?

page

F-94

.)

ll notOK, epa.

or

replace

F-19



F

TROUBLESHOOTING

UIDE

INSPECTION

ACTION

AreECU

eminal

voltages

K?

lEsDeciallv

C,

1K,20

and 20)

c7

Page

F-112

Check

or cause

-

Page

F-114

F- l16

5

ls lhere air leakageol intakeai svstemcom-

6 Does ngine

tarts

when

waler hemos€nsor

s

Chbck

water hermosensor

!7

page

F-121

7

A'e spark

plugs

OK?

F

Page

G-19

WEAFANDCAFBON

UILDUP

(0.039-0.o4i,

BUBNS

AND

DETERIOFAIION

No

Clean,or rep

ace

tr-

Page

G-19

a

ls enoine omorcssionorrect?

s

Page

B-10

Enoine omDression:

ore

han 1,030

kPa

(t-o.s

glcr;'.

149

psi)-300 Pm

Tryknown oodEcU andcheckaf

Check

engine

condition

.?

Page

B-10

.wofn

pston,

pislon

ings or cylinder

.Defective

cylinder

head

gasket

.

Distorled cylindff

head

.lmproper

valve

s€atng

.

Valveslickins

n

Suide

F-20



TROUBLESHOOTING

UIDE

F

CNANKS

NORMALLYBUT

WILL

OT START

PARTIAL

CO AUSTIOII) AFTERWARM.UP

DESCBIP.

Tt0ll

.Engine

ranks t nomal

speed ndshows

artial

ombustion

utwillnot

continue

o run

afler

Lrnningnd

.8attery

n normal ondition

.

Eng

ne slarts

normallywhencold

rrRouaLEsHooTtNGt{Tsl

O

Ar/Fu6l nixture too ch

.lnsuftcient

uel njectiononlrol

(Corr€ct

n or coolanl

emperalue)

.lnjeclor

uel eakase

@ Vapof ock

.Fuel

pressu.e

otheld n uel ne afier nsine topped

.Hish

RVP

winler)

uelused n warmweather

INSPECTION

ACTION

1

Connecl

iasnor

GNDwith

ump€

swilch

ON, hen

, '

,/,1{Q

to normal operaling lempera-

;is conneclor erminals /P and

r wire

ior

3

minrres with ignilion

l# I 64\

JUMPEF

wlFE

---t

Jl l^

@t),x.

\ \

Change uel o anolherbrand

ts

2 Connect iagnosisonnector

ermlnals/Pand

GNDwith

umper

wirei

s

tuei

lne

pressure

or

r€ct wilh ignitionswilch

ON?

rr

page

F-89

235-275

kPa

(2.4-2.a

kg/cln', 3/t-40

psi)

.riupin

wrne

PRESSUFE

FUELFILTEFi

Check ueL ine

pressure

while

pinch'

.+

lf luel llne

pressure uickly

n-

creases, check

presslre

reguiator

a I luel line prcssure laduallyn

cr€ases, heck uel ine and filter

for clogging

li not

clogged,

check uel

purnp

maxirnum

pressure

r7

page

F-91

High

piossure

ls uel return ose logged r

res

+

li

OK,

eplace

ressure

egulator s

page

F-94

+

li nol

OK,

epair r replace

3 ln same ondilion

sSlep2, is uel ne

pressure

heldaftergnition witchs urnedOFF?

e

p.ge

F-88

Fuel llne

pressure:

Morc than 147 kPa

('1.5

g/cm',2t

psi)

or 5 min.

Go to Step 5

Plugoutlei f

prcsslre

egulator:

s uel ne

pressure

eldatler

gnilion

wilchs urnedOFF?

17

page

F-88

Fuel lno

prc3surq

More han !47 kPa

(1.5

kg/cm' 21

psO

or

5

min.

Beplace

ressLrre

egulatof r-

page

F-94

Check uel

pump

hold

pressure

c7

page

F-84

4

lf

OK, check

nlector or fuel

leakage F

page

F-96

4

lf nof OK, rcplace

iue

pump

.r

page

F-92

F-21



F

TROUBLESHOOTING

UIDE

TNSPECTtOt{

ACTION

5

O:sconnecl

ater

hermosemor

onnectori

does

Ch€ckwater

hermo€ensot

c7

gage F-121

+

It OK,

check conn€clions

t waler

themosensot

nd

ECU20

4

ll not OK,

feplace

water her

mosensor (j

PaSe

F-121

No

6

ls 00" displayed

n S€lt_Diagnosis

hecker

wnh onition

switch

ON?

t7

Page

F-'67

Mallunction

code

l{o. disPlayed

Check

or cause

Belel

o specined

check sequerce)

f?

Page

F_70

"88"

llasheg

CheckECU eminal1F vollage c7 pageF-114

vollage:

appror, 12v

(lgnltion

switch

oN)

4

l i OK, eplace

CU

!1'PageF-112

+

li

nol OK,check

wirng

between

ECU

and Seli'Diagnosis

hecker

7 Are ECU erminal

oltag€s

K?

(Especrallv

C,20 and

20)

c7

Page

F-i12

Check

or cause

-

Page

F-115

F-l17

F- l t9

8

Tryknown

ood

ECU

and check

i

condilion

Replace

ECU

F

Page

F-l

12

Change

uel o another

rand

F-22



TROUBLESHOOTINGUIDE F

CRANKSNORMALLYBUT HARD

TO

START ALWAYS

DESCRIP.

Ttol{

.Englne

cranks

al nomal speedbut

req'rnesexcessive ranklng lme

berore tarling

.

Batlerv

n norrnaconclition

.Engine

uns

nomally t ldle

ll

idle

condllion otOK,

efer

o

"Bough

idle"

Nos.

l2)l

FnoUBLESHOOTtfl

HTNTSI

O Air/Fuelnixtureoo ean

.Fuel

njectionontrol

malluncion

(Correclion

orcoolanlemperaiurd

.Low

uel in€

pressure

@Air/Fuel nure oo ch

.Fuel

njeclionontrol

malfunclion

(Correclion

or

coolant emperalure)

.Calbon

deposiln

hot-wire

assaSe

@

Poo'

snition pafk

tNSPECTtOl{

ACTIO

ls 00" dsplayed

on Selloiagnos'sChecker

wth iqnition wilch

oN?

F

page

F-57

ma[unciion Code {o, dlspl.yed

Check or cause Refero soeciiied

check

sequence)

?

p.ge

F-70

"88"

tl.shes

CheckECU ermlnalFvoltage c7 pageF-114

Vo[.g€:

Appror. l2V

(lgnition

vritchO

)

+

lf OK, replaceECU

t:"

p.ge

F-172

4

ll nol OK,checkwiring elween

ECUandSsll-Diagnosisheckef

2 ls there a r

leakage

ol intake air syslem com-

3

s ar cleanerelementclsan?

-

page

F-62

No Repace irc eaner lemenl

Doesenginesla( easlly

when hrofle valve Ch€ck hrotle

valve

or carbondepos-

t and hen

go

to Siep 6

5 ls

uel ne

prcs$rre

ofieclal idle?

F

page

F-94

235-275

XPa

12.4-2.A

kg/cm" 34-40

psD

FUEL FILTER

Checkuel inepressurehilepinch-

+

ll fuel lne

pfessureuickly

n-

creases,heck

ressure

egulalor

+

ll fuel lne

pressureradually

n'

creases,heck

orclogging

e-

lween uel

pump

and

pressure

ll not

clogg€d, h€ck

uel

pump

maimum

prcssurc

F

page

F-91

F-23



F

TROUBLESHOOTING

UIDE

INSPECTION

ACTION

6

ls ar bypass

solenord

alve

@OX?

r'

p.g€ F-104

SOLENOID

INJECTIONBODY

VALVE@\\\

r )

k!

No

Replace

olenoid

alve

7 Are

ECU erminal

oltagesOK?

(Esoec,aly

C, h and

20)

c?

Page

F-lOg

Go o

nexl slep

Cn""f

io, "uuse

r'

Page

F-115

F-117

F-l19

8

Connect cliagnoss

conneclor

tetminals F/P

and

GND with

umper

wirei does engrne

stan

Eneckcircultopening elay c7 PageF-93

a

ff rclayOK,

repair

or teplace

wi€

+

li r€lay

noi OK,

repiace elay

9 Connect

System

S€lector

o diagnosis onnector

and

set T€st

Switch o

SELFTEST

i

is lhere

corecl gnrtionmng €t dleaiterwarm_up?

e

Page

F-63

lgnilion

iming:

aTDC16

+

1c

,-JE"

Adjust

gntion

iminq

!?

Page

F-63

1 0 ls engine

compression

orreci?

c7 pageB-lo

Englne

ompres€lon

ilinimum):

1.030

Pa

(10.5

ksr'cn',

r49

Fel)-300

Pm

Check

englne

condition

c?

Page

B-1o

.Worn

pislon, Lston

ngs r

cy noer

.

Delecuve

ylinder

ead

gaskei

.

Dlsroded

ylinder

ead

.

lmpropet

valve seating

.valve

st

ckins

n

guide

1 1 Try

known

ood

ECUI oes

ondilion

mprove?

F-24



TROUBLESHOOTINGUIDE

F

CRANKSNORMALLY UTHARO O START

WHE

E GINE

COLD

DESCRIP.

TION

.Englne

crank al nofmal

speed

but rcquires excossive cranking

lime

before

slarl ng

.

Baltery

n nofmal condition

.

Festarc OK after

wam-uo

.Engrne

runs no.mallyat idle

[f

idle cond]tion

s not

OK,

r€ter o

'Rough

ldle'

(Nos.

8-12)l

rrnouBLEsHoollt{GtNTsl

O

Air/Fuel )dureoo rich

.Fuel

njecliononvolmal,unction

(Correction

or coolantemperature)

.Thermowax

allunclion

@A1r/Fuel

xiure oo ean

.Carbon

deposlt n hol wire

passage

.

Fu€l nj€ctiononlrolmalfunction

(Coffeclion

or coolant emperalure)

@

Poor tom ation

.

Low

RVP

summer)

uelb€rng sed

INSPECTION

ACTION

ls

"o0

displayedn SellDiagnosish€cker

wlth gnition witchON?

17

page

F-67

SYSTEM

SELECT:

Malfunctlon Code No, displayed

Check

or

causeFeler 10soeciti€d

checksequencei

E?

page

F-7O

"88"

llashes

Check

CU erminal Fvoltage

c7

page

F-'l

14

Voltage:Approx.12V

(lgnition

switch

ON)

d

ll OK,

eplace

CU

rr

page

F-112

4

ll notOK,checkwiing betlveen

ECUandSelfDiagnosishecbr

2

Are ECU eminal vollagesOK?

(Especiaiy

1C.

2D, and 20)

-:r

page

F-112

Check or caus€

c7

page

F-115

F-117

F- l t9

3 Does engineslarteasily

when hrotlle alve

Check

lhemowar

c7

page

F-85

4

f

OK,

go

to

Srep

5

4

ll

nol

OK,

replace njeclionbody

ls there air leakageol inlakear systemcom'

5 ls arrcleanerelement lean?

cr

page

F-62

Beplaceair

cleanerelement

6 Are spark

plugs

OK?

e

page

G-19

WEAB

ND

CAqBONUILOUP

(0.039-0.043

n)

BUFNS

E AND

DETEFIORATION

F-25



F

TROUBLESHOOTING

UIDE

ls u6l in€

pressure

orrect

l idle?

t7

Plge

F-94

Fuel

line

pre$uaa:

235-275 kPa

(2.4-2.8 kgL/cm"3{-40

p6i)

Check

uel line

pressure

whil€

pinch_

ing uel r€lum hose

+

lf fuel ine

pressurc

uickly

n_

creases,

heck

pressure egulator

+

ll fuel ine

pres$rre raduallyn_

crcases,

h€ck uel

ine o. clog_

ging

betwe€n

uel

PUmP

nd

pr€€sure egulalor

ll

nol clogged, heck

u61

umP

maximum

ressure

c?

Page

F-91

High

prcs3ure

ls

tuel rettim hose

cloggedor

fes

+

ll OK, replace

pressure egulator

-

Page

F94

4 ll nol oK, reparor replace ose

Replace CL,

c7

Page

F-112

Iry known

ood

ECU;

doescondition

mprove?

Change

uel o

another

brand

F-26




CRAI{KS {ORI{ALLY

zuT HARDTO START

-

AFTERWABi&UP

DESCRIP.

n0

.Engine

cranksat normalspeed

but requires xcessive ranking me beiore stadingaller

runnino

and

hol

.

Baitery n normal

condition

.

Enginestarls

no|mallyvlhen coLd

.Ensine unsnormally l idle ll idle ondltionol OK, efer o Rough dle" Nos. -12)l

ITBOUALESHOOTING

I

TSI

O

Ai/Fud rni(ure oo rich

.

Fuel njecton conlrol

malfunclion

.hieclor

luel leakage

@

Vaporock

.Fuel

pressufe

otheld n luel ineafter

ngine

lopped

.HiSh

RVP

wider)

uelused n warmwealher

r{sPEcTtot{

acTrol{

1 ls

"00"

displayed n

S€llDiagnosis hecker

with igniiion switch ON?

NO allunc{lon

Code No. dlsplayed

Check

or

causeSeler

to soectied

check s€quence)

c7

pag€

F-70

"88"

tlashas

Check

ECU ermlnal Fvoltage s

pag€

F-114

Voll.ge Approx.12V

(lgnition

switch

oN)

=)

lf OK, €place CU

E'

pag€

F-112

+

lf not OK, ch€ck wiring belween

ECU and SellDiagnosisCh€cker

2

Are ECU erminal oltages K?

(Especlally

C,20, and 2T)

c7

Page

F-l12

Go

to next step

Check or cause

F

pag€

F-115

F-|17

F-l19

3 Runengine l idlei s uel in6prossures held

after

gnilion

witch

urnedOFF?

.7

p.ge

F-88

Fu€t lne oreaaure:

More then 147 kPa

(t.5

kg/cmz, 1

psl)

or

5

fiin.

NO

Plug ou.tlel f

pressure

egllalor

and

check l Juel ine

pressure

s held

afier

ignilion witchurnedOFF

.+

lf OK, replace

pressure

egulalor

17

page

F-94

+

lf nol OK,ch€ck uel

pump

hold

pressure .7

pago

F-88

lf luel

pump

s OK, ch€ck ntector

lor iuel leak€ge

r?

page

F-96

F-27



F

TROUALESHOOTING

UIDE

JTEP

|l{SPECT|O}l

ACNON

Warm-up

ngine

o normal

op€ratng

emFera_

lure

and slop

l

Connect

raonosisonneclor

erminals

/Pand

GNDMh iumos

wira

or 3 minule6

ilh gnition

switchON; do€s

f englne

$ans easili/?

Change

uel to

anotherbrand

Go

to next

s|ep

5

Try known

good

ECU;do€s condilion

mprcves?

Heptace

ECU

E?

l,d,ge

F-112

NO Change

uel

o anolher

brand

F-24



TBOUBLESHOOTINGUIDE

F

a

ROUGH DLE/EXGINESTALLSAT IDLE

_

ALWAYS

DESCBP-

|

.Engrne

sads

normalv

bul stallsor v,brares xcessvey al

idle n

everyco']d

ion

FROUALESHOOTTNG

titTSl

O

Air/Fuel ixlureoo ean

.

Fuel njeciion

onlrol

malluncUon

.Low

luel ine

pressure

@

Low

ntake ir amount

rn r^^^-4r iira clEAd

. ldlespeedmisadiust'nent

@

Oneor more park

lugs

ol irlng

O

Lowengine ompression

@

Carbon eposit

n injecton ody

INSPECTION ACTION

1 ls

"0O

drsplayed

n SeJi-Diagnosishecker

wilh

ignition

swltchON?

Mallunclion Code No. dlsplayed

Check or caus€ Rete. o soecilied

checksequence)

.? page

F-70

"8a"

tlaEhes

CheckECI.Jerminal F

voltag€ c?

page

F-114

Voltage Appro!. 12v

(lgnltion

€wltchO

)

+

ll

OK,

eplace CU

o

p.ge

F-112

+

ll nol OK,check

wlring etw€en

ECUandSellDiagnosis

heck€r

2

Are

ECU eminal

oltages

K?

(Esp€cially

K,

2M,20 and20)

-r

page

F-112

Checkorcause

F

page

F-115

F-117

F- l19

3 Disconn€€l ach h ightension ead

al

idlei

does

enginespeed decrease quallyat each cylinde?

Go to Step

5

ls

slrongblue spark

visible

at disconnected igh-

/

Ch€ckhrghlensionead

F

psge

G-23

+

ll OK, checkdistrbuto.

cap and

rotor

c7

p.ge

G-23

+

It nol OK, replacehighlenson

5 Arcspark lugsOK?

c7

page

G-19

WE1AF ND

CARBON

BUTLDUP

(0.039-0.0,*l

AURNS

DETERIOFAIION

Check of corect engine ompressionrt'page 8-10

+

lf OK, replace injeclor

c?

Page

F-96

+

lf not OK, check or cause

F

psge

B-10

Cean or

replace

F

page

G-19

F-29



F

TROUBLESHOOTING

UIDE

STEP

INSPECTION

ACTION

6

Connect

Syslem

Sel

ignition

iming orrer

lgnition

lming:

BI

ector o diagnoss

onn€ctor

to

'SELF'IEST"|

is

coffecl

ri at idle aiter

walm up?

.7

page

F-62

1 6

.-

/fEN

Adtust

gniton timing

17

Page

F_52

t ,

GNo

//

-tfi"

INOICATOF

/

D

l.r9*

7

ls uel ne

oressure

orrcclal idle?

c7

Page

F-94

Fuel

ine

pressure:

235-275 kPa 12.4-2.A rg/ctn', 34-40 psi)

{vacuum

hos€

to

pte*3ure

regulstor dls-

connected)

., .ih,

(\

)

""'*Y"'-94u9:-lwlllK;/

-\-,aJ.6V.]Ly.V

/

FUET IITEF

Check

uel

ine

ptessure

while

prnch_

+

ll

fuel ine

pressure

uickly n_

creases,

heck

Pres$re

regulalor

+

I fuel

ine

prcssll|e

sradually

n_

creases,

heck

or clogging

be

tween

ue

punrp

and

pressure

regulatot

It

not clogged,

heck

uel

PUmP

maximum

pressure

I

Page

F-91

I

ls thero an

bakage ai

intake air syslem

com

9 ls eno

ne cornpression

orrecl?

e

paEe

B-10

Ensinecompression

r

!nimum):

t,o3o tPa

Oo.5

kg/cm'.

149

Psi)-300

Pm

Tryknown

ood

ECU

anddoes

on

Check

or cause

F

Page

B-lO

F-30



F

TROUBLESHOOTING

UIDE

ls water

hermosensor

esslancecorrec?

Beplace

water hemosensor

r-

page

F-121

Connecl

Syslem

Seleclor

o dlagnosis onneclor

and

set Test Swtch

o

'SELF

TEST when en_

gine

s cod

Doesenqinespeeddecr€aseas engrnewarms

Reolace

nieclion

odv

F

Page

F-84

Connect

System

Seector o diagnos

connector

and sel Tesi Swllch o "SELFTEST

ls

rqnlron rm

ng corect al

tdb aner warm

upt

ci

page

F-62

lgnilion

tlming:

BTDG 16

*

1"

GND

TESTSW

NDICATOFI

Adjust

€ntion

limlng

G

Page

F-62

G oaae F-112

Try known

good

ECU;

does conditon

mproves?

Change

ue

to anoiherbland

F-32




1 0 ROUGHDLE/ENGINE

TALLS

AT IDLE AFTERWARII.UP

DESCRIP.

TION

.Engine

unsnormally l idleduringwam-upbut

engine talls

r vibrales

xcessivelyfler

warm-up

ITROUaLESHOOTTNG

INTSI

O)

dle

speed ontror vslemmallunction

@ Air/Fuel ixtureoo ean

.Low

fuel ine

pressure

.

PCVvatve stuck

open)

@

ArlFuelmi(ure oonch

.Fuel njecl n controlmal,unclion

(Corection

or coolanl emperature)

@

Poor gnilion

O

Lowengine ompressn

INSPECT|oiT

ACTION

1 ls 00" displayed n

Self-Diagnosishecker

with ignilion

switchON?

e

page

F-67

llalluncfion Code ilo. displ.yed

Check or causeGeler lo so€cilied

ch€ck

sequence)

(?

page

F-m

"8a"

tlashes

CheckECU ermina F vollage c7

page

F-114

Volreg€: Approx. r2V

(lgnition

switch

ON)

+

li OK, eplace

CU

rz page

F-112

+

ll noi

OK,checkwiringbolween

ECUand SellDiasnosishecker

2 Are ECU erminal

voltagesOK?

(Especially

K,

2M, 20 and 20)

F

page

F-112

Check

or

caus€ c7

page

F-115

F-117

F-r9

3

Disconnect ighlension ead at dle; does en-

glne

speed d€crease

quallyal al cylinders?

Go to Slep 10

ls ihere air leakage

ol intakearrsystem om-

5 ls air cleaner

element l€an?

e

page

F-62

No R€placealr cleanerelement

6 lurn thronleadjusling

screwc,

does dlecondilionmprove?

AIFFLOW SENSOR

-ffiqf l";;I

Adjust idle

speed

.?

page

F-62

No Relurn

hrottle

adiuslingscrew o

its

original

ositlon,

nd

go

to next lep

=.\\\

/

F-33



F

TROUBLESHOOTING

UIDE

INSPECTION

ACTION

7

ls fuel

ine

pressure otrect at idle?

c?

Page

F-94

Frel lih6

pr$sure:

235-275

kPa

(2.4-2.A

kg/cmz, 34-40

p3l)

Check

uel

ine

pressure

hile

pinch_

+

ll fuel ine

pressure

uickly

n.

creas€s,

heck

pressure

egulator

+

ll iuel ine

pressure€dually n-

creas€s,

heck

or clogging

e_

tween

uel

pump

and

pr€ssure

lf notclogged,

heck

uel

pump

maximum

prsssure

E7

Page

F-91

I

Connect ystem

electoro diagnoss

onnector

and

set Test Switch

o

"SELF

TEST

ls ignition

iming orrect

t idlealt€rwarm_up?

(7

gage F-€2

lgnition lmlng:

BIDC

16

+

1'

Goto nexl step

No

Adjusl gnrtion

ystem

r'

Pag€

F-62

9 Disconnect

water

hermosensor onneclor

Does nglne

ondition

mprcve?

Replace

wat€r hermosensor

No

Tryknown

ood

ECUandcheck

l

1 0

ls enoine omoression

orrecP

.7

page

8-10

Engine

ompression

llhlmum):

I,O3O Pa

10.5

kgL/cm', 49

psl)-3lx)

pm

Check

engine

r?

Page

&-10

1 1 ls slrong blue

spa

visibleal each d sconnecled

hgh'tension

ead?

c-----,--

\-\

<72oNl #

/

/

Check

high'tension

lead

.7

page

e-23

4

lJ OK,

check dislrlbulor

ap and

rotor

F

page

G-23

+ ll not OK, replacehigh ensron

12 Arespark

lugs

OK?

s

pago

G-19

WEAF NOCAFiBONUILDUP

(0.039-o.043

BUANS

DETEBIOBATION

Try known

good

ECU and check

NO

F-34



TROUBLESHOOTINGUIDE

F

' t l

ROUGII DLE/E GI

E STALLS

AT IDLE

-

WHEI{ A./C.P/S,

EIL

OI{

DESCRIP.

Ttol{

.Engine

talls r vibrates xcessivelyt dlewhenP/Sor E/LON

.AJC,

P/S,headlights,

lower an and

e{eciric

ooling an opelale normally

.ldle

condilions normal hen ,/C.P/S

and

E/LareOFF

rrRoualEsHooTtitc

HtNTsl

O tdle spe€d control svslem malluncljon

;TEP INSPECTION ACTION

ls

'OO

dlsplayedn

SeliDiagnosishecker

wilh ignitionswilch ON?

F

page

F-€7

SYSTEM

SELECII

I

ll.ltuncllon Code

{o. displayod

Check

or

caus€ Refer

o soecilied

check sequenc€)

rr

p.ge

F-m

"88"

llasha6

Check

ECU

erminal

F voltage c?

page

F-ll4

Vollage:

Apprcx. l2V

0gnlrbn

switch

Ol{)

.'

li OK, eplace CU

e

page

F-112

+

ll not

OK, check

wiring belween

ECUandSelf-Diagnosis

heck€r

2 UsingSellDiagnosis h€cke.Monitor ampi

are

switchesOK

with

gnilionswitchON?

F

pege

F-80

k@tl

NO

Lamp nol

ON or

OFF wllh specl-

fied

swatch

Check or causeFefer lo

sDecif d

check sequence)

tr7

P.ge

F-81

F-82

L.mp alwaF ON

Check

wring

beh{een

CU emina

1D andSellDiagoosisheck€r

3 ls air bypasssolenoid alve

OK?

.

A/C.....Solenoidalve

@

rr

prge

F-109

. E/L.....Solenoidalve@ c7 p.te F109

.

P/S.....Solenold.lve

@

r?

page

F-109

AtR

AYPASSSOL.

V.

rf .4

./

(o

F

//-!hVq"l' ,&

AIF BYPASSSOL.V,

@

l t l '

Adjust dleup enginespeed

s

page

F-64

NO

Replace solenoid valve

F-35



F

TROUBLESHOOTING

UIDE

l 2

NOUGH DLE,/ENGIIIE

TALLS

JUST

AFTEBSTATIING

DESC-RtP-

Trotl

.Enstr€

stans

normallybut vibrates

excessively r

slalls

0st

atler

starting

acceleralion

lom idle)

.ldle

conditons

r€ normaln olher

onditons

TTBoUBLESHOOTING

ll{TSl

O

Air/Fuel l{ure

oo ean

.Fuel

njeclionontrol

malfunction

.

Low

uel ine

pressure

@

Throltlesensor

mailur'ction

}TE'

tNSPECT|OI{

ACTION

ls OO"displayed

n Self-Diagnoss

hecker

with onition wilch

ON?

-

c?

page

F-67

SYSTEM ELECT:

No

lr.ltunctlon

Code No. d|sPlayed

Check

or cause

Refer

o specilied

check

s€ouence)

c7

PzEe

F-7O

"88"

tlash€5

Check

ECU

erminalF vollage

ca

p.go

F-114

Volt.ge:

Approx.

12v

(lgnitlon

3witch

ON)

+

It OK,

edaceECU

c?

Page

F-112

+

ll nol OK,

checkwirlng

etween

ECUand

S€lf-Diagnosis

hecker

2

ls

there

air leakage

f intak€air systemcom_

No

3 ls uel ne

prescure

onectal

idle?

e page F-94

295-275

kPa

12.4-2.a

kg,fcmu, l-40

psl)

Checi

or

uel ne

pressure

hile

pinching

uel

elumhose

+

ll

fuel ine

pressu.euicklyn_

creases,

heck

pressure

egulaior

+

ll fuel

ine

pressurc

raduallyn-

creases,

h€ck or cLogging

e

Meen

luel

pump

and

pressure

r€gulator

lf

not clogged, heck

uel

PumP

max

mum

p€ssure

.?

Page

F-91

Hlgh

pre33t|re

ls

fuel ine clogged?

+

ll OK, replace

pressure

egulalor

rj'

Page

F-S4

+

lf notOK,

cplace

Connect

SyslemSeleclor

o dlagnosi

and set

Test Switch o

'SELF

TEST"

ls

ignltioniming orrecl

l idleaiter

,TEN

f : :

GND

(

\tg-aNOICATOFI

go

F--{

3

In same

ondilion

s StsP

in_

specIon

Check

o'

conecl

dle

speed

.?

pag€

F-63

ldle speed:

750

'l

rPtn

(tilTx)

1, t00

1lpm

(ATX)

4

ll OK,

go

io nexl step

+

ll not OK,

adjust

dle

speed

17

page

F-63

L l

]/

TES

6

F-36




STEP

utsPEcTtoN

ACTION

5

Are ECU erminal

voltagesOK?

(Especially

8,

2M, 20, and2Q)

Nole

When ch€cking voltagss, tap, moye,

and

wlgglo harmss and connector to recreate

Go lo neil step

6 Arc

spark

lugs

OK?

WEAF ND

CAFBONUILDUP

{0_03$-0.043

EUBNS

OETEFIIOFATION

7 ls engine ompressionorrec?

F

page

E-10

Englne

ompression

Minimum):

1,030

kPa

10.5

kg/cm',

1as

psl)-3oo

rpm

Try known

good

ECU and check l

NO

Check

engine c7

page

B-lO

F-37



F

TROUBLESHOOTING

UIDE

HIGH

OLE SPEED

AFTEN

WANM"UP

.ldle

spe€dexcessive

lter

warm_up

ITROUBLESIIOOTING

I TSI

EicssJvenlaks n supph€do engne

O

Throttlevalve

nol

lully

clos€d

@

ldle spe€dcodrol

mallunction

.Thermowax

alfuncton

.Air

bypass olenoid

alve

ON al idle

.

1,./C,

P/S

or

E/L sgnai

senl

o ECU

ls lhfotle

valve

ullyclosed

whenaccelerator

ls

lhrottle

inkage orrcc{y

nstalled

+

lf OK,

go

o Slep

2

+

ll nol

OK,clean,

adjustor

replace

linkage

Adjust

dle

sp€edby

iumins

throtlle

!7

page

F_63

o€s ast

idle cam

release

throttle levs?

ls "oo" displayedon SellDiagnosrsChecker

with onition

switchON?

-7

paq'e

F-67

lltaltunction

code

tlo. dlspl.yed

Check

or cause

Beier

o

sp€cilied

check

sequence)

t-

Pzge

F-7O

"a8"

llashe3

Check

ECU

erminal

Fvoltage

e

page

F-114

voltaoe

AoDrox.

2v

-

0initlon

switch

oN)

+

ff OK, eplace

CU

(?

P.ge

F-112

+

lf

not OK,

check

wiing belween

ECUandSelt-Diagnocishecker

Adjust

dla speed

by lurning

hrot

s

'

r'.

Pagc

F-63

Are ECU

1P, R,

15, 1T, U, 2[,'1,

Q,2R,and

2T lerminal

voltagesOK?

Chech

or cause

_7

pag.

F-115

F-117

F-l19

F-38



TROUBLESHOOTINGUIDE

F

t 4 IDLEMOVES PAI{ODOWN/IDLE

UNN G

DESCRIP.

.Engine

spesdsup and down

periodically

l

idle

TroN

I

5X?u68j*:SoorNG

rNrsr

@Throfle sensormisadjusted

@

Fuel njection

mounlnconstant

@

Poor gnition

STEP INSPECTION

acrtot{

1 ls rherea r leakaoear intakeair svstem?

Repajr

or

replace eak€ge

poinl

2 ls PCV

valve

OK?

cz

page

F-99

NO

3 ls arrcl€aner lemenl lean?

4

Disconnecl

ighlension

ead at idle does en

gine

speed decrease quallyal each cylinder?

No Go1o

step9

5 ls

'00

displayed

n SefDlagnosis hecker

wlh ignirion

wtchoN?

e

page

F-57

TESi SWi SELF TEST

NO Maltunction

odeNo. d|spl.ye.d

Check

or cause

Reler

o speciied

check

sequence)

cr

Page

F-m

"84"

flashes

Check

ECU €rminalF voltage

17

Page

F-114

vohage:Approx.12v

(lgnition

swilch

ON)

+

lt OK, eplace CU

F

page

F-112

+

ll nolOK,checkwins b€tween

ECU

and

Sell-Diagnosis

hecker

6 Connecl

yslem elecloro

diagnosisonnector

and setTeslSwilcho " SELF EST'

Tryknown

ood

ECU

F-39



F

TROUBLESHOOTING

UIDE

Connecl

System

Seteclor

o diagnosis

onn€cior

and

set Test

Switch o

"SELF

TEST

ls roftton rmrno

otted at

Ldle

tter

warm p?

7

P.ge

F-62

BTDC 6 + 1.

tNDtcAToB--l

\,,1S\

\|!/

TEsr sw

Adjust

gnition

ming

e

Page

Fl2

Are

ECU eminal

vollages

K?

lEsoeciallv

[/)

e

Pago

F-lla

CtrecX

or

cause

e

Page

F-119

ls strong

blue spark

visible

at €ach disconnected

high'tension

ead?_

:"''-t'

,-t'.--

_1-(_(d

Check

high-tension

ead

+

ll OK,

check

dislribulor

ap and

e

fi not OK,

replace

high'tension

Check

or correct ngine

onrpression

?

page

B-10

CompressionMinimum): ,030kPa

(t0.5

kg/dn',

1r9

Psi)-300

Pm

4

lf OK,

go

to

nexi step

+

tJ

notOK,check

or cause

c7

pag€

A-10

Ar€spark

plugs

OK?

p

17

page G-19

(0.039--o.043

n)

BUFNS

Try known

good ECU and

check l condition

F-40



TROUBLESHOOTING

UIDE

F

1 5 ENGII{ESTALLS ON OECELERATION

DESCATP-

Tro

.Engine

unexpectedly

tops unning h e deceleralingr aJter ecelerallon

.

ldle

condition or,ral

rrRouBLEsHooTtNG

|NTSI

Enginepeed ropsoomuchwhen

eleasingcceleratorr

poor

onnecloronnectionsconnected

y deceleralion

O

Dashpormisadjusted

@

Fuel ut

control

mallunclion

@

ldle

speed

misadjustment

INSPECTION ACTION

ls rdleconditon normal?

Adjustor

perlorm

roubleshoot

g

Nos.8-11 RoUGH DLE"

,-

pag"

l-?9

ls dashpoi correclly

adjustecl?

13

p.ge

F-104

Dashpol set speed: 2,500

+

1O0 rpm

3

|s

"00"

dlspLayed

n SeliDiagnosis hecker

with

gnltion

switchON?

sYsTEM ELECT:1

r:'

page

F-67

Mallunclion Code No. dlsplayed

Check

or cause

Befer

o sDecified

check

sequence) rj

page

F-7o

"88"

tlashes

Check

ECU eminal1Fvollage u

page

F-111

Voltage:Approx. 2V

(bnirion

switchoN)

+

lr OK, eplace CU F

page

F-112

+ ll nol OK, checkwring between

ECUandSe 'Diagnosishecker

Are air bypass sojenoid valves

OK?

SOLENOI

voLut

-@-ll

5 AreECU erminaloliages

K?

(Especialy

B,2lV,20

nd \4

G

page

F-112

Checklor cause

-

page

F-115

F-117

F- l19

6

ls

here

poor

connectiont eilher l lollowing?

.

lgnilion

oi l

.

lsniter

.

Dislribulor

.

C rcuitopeningelay

.

ECU

Try known

good

ECU

Doescondilion

mproves?

F-41



F

TROUBLESHOOTING

UIDE

E GDTE

TALLS

SUDDE

LY

(INTERT|TTENT}

t6

0EscnlP.

Ttoil

.Engrne

ntermitenUylops

unning

.Belore

stallinq,

nsrne ondition

K

TTROUBLESHOOTI

HINTSI

O it'frtrnitt""tv

"" "p"tl

"t no

luel Iniection ausedby

vehicle

vibration,

ccelefaijon,

r cleceloralion

.Poorconn€ctonn wiing harness

3TE

tlrsPEcTtoN

ACTION

ls

"m"

displayed

n

Self-Diagnoss

h€cker

wilh ionition

switchON?

r?

page

F-.67

TESTSW;SEIF

TEST

NO

Maltunction

Cod€

No. d|3played

Check

or caus€

Refef

o sp€cified

check

sequence)

F

Pagd

F-70

Note

.When

checklng

wiaing

hamcssand

conneclol3,

tao. mov6,

and

wiggle

guaFcl

3enaor

and/or

h.r'

ndsg to

r€cGale

Problem

"88"

ll6ah€3

CheckECU erminalFvoltage x7 p.ge F_114

Voltag€:

App.ox. 12V

0gnition

swilch

ON)

4

lf OK, eplace

CU

c7

P3€e

F-112

+

li not OK,

ch€ck

wiringbetween

tCU and

SellDrag.osE

hecklt

2 ls lhere

poor

connection

t eilhel of

lollowing?

.

lgnition oil

.

Distribdor

.

High-tension

ead

. Ckcuit penins elay

.

ECU

3 Are

ECU emina,

oltages K?

{Especial ly

8,

1G,11,2A,24,2C,2E

nd2\ i )

.7

pege

F-112

Note

.when

checklng

volteg€, lap,

move, and

wlggle

halne3s and

conneclor to

recneate

Go o

Troubleshootjng

o.2

"CBANKS

NOBMALLY

UTWILL

NOTSTART

NO

COIVBUSTION)

?

p.ge

F-17

No Check

lor cause

c7

Pag€

F-115

F-117

F- l19

F-42



TROUBLESHOOTINGUIDE

F

17

HESITATESFTUIIBLES

ON

ACCELERATION

DESCND.

TION

.Flat

spotoccurs

ug

ater acceleratorepressedr

mrld

erling

occurs uring c.deraon

ITROUBLESHOOTT

Ht]{TSl

O

Air/Fuel

xlure

oecom€s

ean

nen dep.e€srngccelerator

.Fuel injeclloncontrolmalfunctionCorection or accelerating ondition)

.Fuel

line

pressure

€creases

.Spark

advance

onlfolmalfunclion

INSPECTION ACTION

1 ls

"00"

display€dn SellDiagnosis

hecker

wilh gnilion iwilch N?

I.ltuncllon Code l{o, dhplay€d

Check or cause

Refer

osoec'lied

check

sequerce) o

page

F-70

"88"

fl.3hes

CheckECU erminal

Fvoliage F

page

F-114

Vollag€: Approx, 12V

(lgnitlon

sw[ch ON]

.>

lf OK, cplace CU

ri

pege

F-112

.+

lf not OK, check wiing between

ECIJand Self-Diagnosishecker

2

ls thereair leakageat iniake

air sygem com-

3 ls arr leaner lsment l€an?

tr-

p.ge

F-62

Go

to nen siep

Replace ircleaner lemenl

4

Arc ECU €rminal K,

2M, 20 and 20

voltages

OK?

.?

p.ge

F-l12

Go lo

nexl

step

No Ch€ck

or

cause

c7

psge

F-1r5

F-117

F- l t9

5 ls lhrot lle inl€ge coreclly inslal led nd does

thrcttle valve open frcel',

Cl€anor replaceas requiredany

binding r damagedinkage ndad-

lust

cabl€ dell€ction l inieclion

body e

pag€

F-86

6

ls uel ine

pressure

orrect

t

dle?

.?

p.ge

F-94

Fuel

ine

preasure

235-275

kPa

(2.4-2.8

tg/cm', 3'F/1()

psD

Does

trel lne

pressure

ecrease

whenacceleruting

ulcklf

.+

li decreases, heck uel

line

and

liltef or clogging

4

lf no decrease,

o

to next slep

Check

uel ine

pressure

hle

pinch-

+

lf luel ine

pressufeuickly

G

creases, heck

pres$ire

regulator

+

11lueline

pressureradually

n'

creases, heck

or

clogging

be

tlve€n

uel

pump

and

pressurc

r€gulatot

ll not clogged,check uel pump

maximurn

ressure

17

page

F-91

F-43



F

TROUBLESHOOTING

UIDE

t sPEcTto

acfloll

7 Connect

SysternSeleclor


and set

T€stSwilch o

'SELF

TEST"

ls ignition

iming conect at

idle alt€r warm_up?

ri'

p.ge

F--62

lgnnlon lmlng:BTOC16 + l"

INDICATOR

Does

gnltionming

advance

hen

accelerating?

+

ll

advances,

o

lo

ne)dstep

+

ll

not advan6,

replace

ECU

s

pag€

F-112

NO

8

Are arrduct

and air

hoses orrectlynstalled? Go to nexl step

NO

R€pair

9

ls

exhaust ystem

est cted?

(t

p.ge F-1t7

NO

10 Try known

good ECUand ch€ck f conditEn

F-44



TROUBLESHOOTINGUIDE

F

t a

SUFGESWHILECRUISING

DESCRIP.

TION

.

Unexpecled hanSe n enginespeedwnich s usually epetitive

TIROUaLESHOOTTNG

TNTSI

O

Air/Fuelmixture oo

ean

@ Misfirc

@

Poor onnection

n

wiringharness

STEP tNSPECT|Ot{ ACTION

ls

'0O

displayed

n SellDiagnosChecker

wth ignition

wltchON?

c?

page

F-€?

Go 10

next

slep

No Malluncllon Code No. displ.yed

Check or cause

Beler

o soecilied

ch€ck s€quenc€) !?

page

F-70

"88"

llashes

Check

ECU elminal 1F voltage e

p.ge

F-114

Vo[age: Approx. l2V

(lgnilion sMtch ON)

+

lf

OK, replaceECU r?

page

F-112

+

lf not OK, check wirins benxeen

ECU and Self-Diagnosishecker

2 ls throttle eosorOK?

s D4ge F -122

Go ro ne( step

NO

3 Disconnect xyg€nsensor onnector;does con'

OXYGEN

ENSOR

ONNEC] Ft

Checkoxygensensor

(?

eage

F-123

Are ECU erminalvoltagesOK?

t- page

F-112

Check

or

cause

.7

pege

F-115

F-117

F-I t9

5

ls

lh.ottle

inkage

cofrecly installed nd does

thronde

valve

open op€raies lrcely?

Corfecl, lean,

r

replace s requircd

anybinding r damaged

inkage,

nd

adiusl

calte

dellectionat

injeclion

body

F

page

F-{6

6

ls

hereair

eakage

i inlak€ rrsystem om-

7

ls arrcleanerelement lean?

o

page

F-62

Beplace

ircl€aner lemenl

F-45



F

TROUBLESHOOTING

UIDE

SIEF

INSPECTION

ACTION

a Conn€ct

Syslem

Selector


and sel

Tesl Swltch o

"SELF

TEST"

ls

Lgnll|onmrng orredat

rdle

tler

wam up?

.j

pagc

F-42

lgnitlon iming: BTDC16 + r'

INDICATOF

Does gnition

timing advance

\,rten

4

lf advances,

go

lo na)d step

+

tf not advance,

replace ECU

rr

p.g.

F-112

9

ls uel inepressureorrect l dle?

E7

page

F44

zgs-zzi

xpa

(z.t-z.a

*g,fcm', 34-iu)

p6i)

Does uel inepressuledecrease

whenaccaleating

quickly?

+

tf decreases,

heck

or tuel

pump

maximum

ressure !?

PagG

F-91

li

OK,

check

uel ine and ilter

for

cbggrng

4

li no

decrease,

o

to

n€xt slep

Check

ueL

ine

prsssurc

y

pinchang

+

ll iuel

ine

prcssure

ulckly

n-

creases,

h€ck

pressufa

egulalor

+ lf luel linepressureSraduallyn

creases, heck

or clogging

be

lween

uel

pump

and

pressure

rcgu|alol

li not

clogged, heck

uel

pump

maximum

ressure

c7

P.go

F-91

High

prcas0ae

Check

t tuel ret'rrn

ine s clogged

4

ll OK,

repiace

pressure

egulalor

e

Pag.

F-94

+

ll not OK,

replace

1 0 Check

or

poor

connection f

lollowing

parts

.

lgnitef

. Distribuor

.

Hish

ensionead

.

Crrcuit pening

elay

.

ECU

t l Try known

good

EcU and

ch€ck l

F-46



TROUBLESHOOTINGUIDE

F

1 9 LACK OF POWER

DESCBIP-

Ttot{

.Perforrnance

oor

under oadwhen hrotlle alvewideopen

.

Beduced

maximum

peed

.ldle

condilion omal

TTROUBLESHOOTINGINTSI

O Faclors ther hanenqrnem;runcrion

.Cturch

tipping

.ATX

stipping

.Brake

dragging

.Low

rre

prcssure

.Incorrect

re

size

@

Low ntake iramount

.Throttle

alve ol open

ully

.Clogged

ntake

k system

@ Air/Fuel lxtureoo ean

.Fuel

ine

pressure

ecreases

.

Fuel njection

altunclion

@

Poor gniton

@

Lowengine

ompresson

@

Alcohobended uel

used

STEP INSPECTION

ACTION

l

Check aclorsother

han engine

.

c urch slipping l? page

H-3

.

ATX slpprng .?

page

K-10.

Blake dragging

c7

page

P-5

.

Low tire

pressure

F

page

O-2

NO

2

ls

throltlevalve ully openedwhen

acceleralor

s acceleralor

cab/e correctly

insl,alled r'

page

F-86

4

ll oK, check

hroltle

valve

4

ll nol

OK,

install

cceleralor able

corecty

r? page

F-86

3 ls 00 dlsplayed

wilh

gnition

switch

SETECT

SW: A

TESI

SW' SELFTEST

Mallunclion Code tlo. displayed

Check

or cause

Refer

o soecified

check sequence) E7

page

F-70

"88"

llashes

Check

ECU

ermnal F voltage

- page

F-114

Voltag€: Appror. 12V

(lgniiion

swiich ON)

4

lf OK, replace ECU r:7

page

F-112

€

li no

OK, check wiring betw€en

ECU and S€fDiagnos Checker

ConnectSyslemSelectoro diagnosrs onnl

and set Tesl Switch lo

SELF

TEST

ls

gnition

ming corecl

at dle afterwarm-!

- page

F_

lgnition laming: BTDC

16

*

1.

t\ \\.- \ \\-*rtriff

k\\o\\\t\\t

\ -

'"

p?

62

Check I lgnilion imingadvances

4

ll

advances,

o

!o next step

a

li nol

advance, heck

ECU

emi

nalvoliages r?

page

F112

\NN

l.

cNo

(

\S)

a

o d

-'fi"

INOICATOF

::

( l

r/

TES

5

A.e ECU eminalvoltages K?

(Especialy

K,2M,2K,

nd25)

l?

page

F-112

Check

or cause r:,

page

F-115

F-117

F-l19

F-47



F

TROUBLESHOOTING

UIDE

;TEP

INSPECTION

acTtor,l

6

ls there air

eakageoi

intakeair systemcom_

ls air cleanerelemenlclean?

s

page

F-62

Beplace

ar cleaner

elemenl

8 ls

luel ine

pressure orect at idle?

c7

pag€

F-94

zgs-zzi

rpa

(z.l-z.a

rg/cm' 34-40

psD

Does ue

Ine

pressure

ecrease

when

accelef nng

quickly

+

li

decrcases,

heck

uel

pump

maxlmum

ressure

17

Page

F-91

ll OK

check uel

ine and filtef

or

cloggrng

+

ll not decr€ase,

So

to

ne)d slep

Checkuel ine

pressure

hile

pinch

+

ll fuel

ine

pfessurc

uickly

n

creases,

heck

pressure egulalor

+

lf luel ine

pressureraduallyn'

creases,

heck

or

clogging

e

iween

uel

pump

and

pressure

lf notcLogged,heck

uel

pump

maximum

ressure F

Page

F-91

Hlgh

prcssure

Check

f uel eturn

ine s clogged

+

ll

oK, replace

ressure

egllalor

t7

page

F-95

4 li notOK, eplace

I

Bemoveair

cleaneri s there any

carbon depost

or drn

In njecton bo4,r/

- i -

r t

' { l - \ -

Clean

No

1 0 Are spa.k

plugs

OK?

17

page

G-19

WEAFAND

CAFBON

UILDUP

(0.039

0.044|

AURNS

DETERIOBATION

in)

F-48



TROUBLESHOOTINGUIOE

F

INSPECTION

acTtofl

? l ls resistancel

igntion

oilOK?

c7

page

c-20

Resi6tance

et

20.C

168oFl):

Primary oil winding........

.58--"0.a49

Secondary oil whding.... 9.6-14.4 ko

SECONDAFIY

OIL

'12

ls engine ompfesson

o(ect?

c?

page

B-10

Engine

clmpresslon:

1,030kPa

10.5

kg/cm' 149

psl}-300

pm

No Checkenginecondition

t?

page

B-'10

.Worn

piston,

pislon

lngsor cylinder

.

Deteclrve yiinderhead

gaskel

.

Distorted cylinder head

.hproper valve seatng

.Valve

stickinS

n

guide

1 3

Change

uel;

does condition mproves?

Change

uel

o anotherbrand

Try known

good

ECU

and

see

l

driv'

F-49



F

TROUBLESHOOTING

UIDE

20

POORACCELEFATION

DESCRIP-

.

Pe''omance

poor

whle acceleratng

Tlolil |

.ldle

condilion

nomd

FROUBLESHOOTING

lllTSl

O

Factors lher

hanengine

malfrJnction

.Clutchslipping

.ATX

stippinS

.

Brake raggrng

.LOW

rc

pressufe

.lncoffed

nresze

@

Low

ntake if amount

.Throltle

alvenot

open ully

.Cloggins

n intake rrsystem

@

An/Fuel

ixture

oo ean

. Fuel inepressureecreas€s

.

Fuel

njection

alf ncl|on

@

Poor

gnilion

@

Low

ensinecompreseon

@Alcohol

lended

uelus€d

INSPECTION

ACTION

'I

check

actoG ther han

enorne

.

Clutch lippins

e

P.ge

H-3

.

Brakedrassins

G

page

P-5

.

Low te

pressurc

s

Page

o-2

.

lncor€ct tirc

sze 3

Page

O-2

.

ATX lipplng

-F

page

K-10

2 Does hrottle

valve ully

open wtren cleprcssng

Go to

n€)dstep

No Check

il accelefator

cable

ls coreclly

ndaled

F

page F-86

r+

lf oK,

check

hrotlle alve

+

li nol

OK, install accelerator

cable

conecily

t7

Page

F-E6

3 is

'00'

displayed

n Self-Diagnosishecker

with

gnition witch

ON?

!7

Page

F-67

SYS'IEMELEcTi1

TESTSwi SELF

TEST

Go

o nexl step

llallunctlon

Code {o. dlsPlayed

Cheokor causeRetero specifed

check

sequence)

e

Page

F-70

"88"

llash€s

Check

ECIJ erminal

1F voltage

t7

page

F-114

voltage

Appror.

12v

(bnirion

swilch

ON)

4

ll OK, replace

ECU

-Page

F-112

4

ll

nol OK, check

winnS

belween

ECU

and Sell-Dlagnosis

hecker

Connect

SystemSelector

o dlagnosis

onn€ctor

and setTest Swilcho SELFTEST

ls ignlton

imlng orrecl

l ldlealterwarm_up?

!?

Page

F-62

lgnltion iming:

ETDC16

+

l'

\\ \\.-\\ \\.igA'f

\<\ to\ \ \ l \ t l l

\ - "-

- '

Does

gnition iming

advance

when

+

It advances,

go

to nexl

st€P

+

ll

not advance,

heckECU

ermi'

nal

voltages

tr7

Page

F-112

\M

"fi"

INOICATOF--/

5

AreECU

ermlnal

oltages K?

{Especially

M) tr7 PagoF 112

'Check

Jor

cause

t7

Page

F-115

F-l17

F - l t 9

F-50



TROUBLESHOOTING

UIDE

F

STEP

ITSPECTION ACTION

6 is lhere alr

leakage

al

inlake

ar systemcom-

7

ls here

any

carbon

eposit r did n injection

\

Clean

8

ls

ue line

pressure

ofiectat dle?

c7

page

F-94

235-275 kPa

12.4-2.a

kg/cmz, 34-40

psi)

Check ' luel ine

pressure

ecreases

whenaccel€ralg

qulckly

+

ll decrease,

heck

uel

pump

rnaxmurn

ressure c?

page

F-91

ll OK,

ch€ck

lel lineand iter or

clogg g

..)

ll noldecrease,

o

o

nexlstep

Check

or luel line

pressure

whle

pinchlng

uel returnhose

4

lf luel ine

prcs$re

quickly

n-

creases, check

pressure

r€gu alor

4

lf luel ine

pressrfe

gradually

n-

creases, heck

or cloggingbe

tween

uel

pump

and

Pressure

ll nol clogged,check

'rei

pump

ma-ximum

.essure

c7

Page

F-91

Hagh

ressure

Check l tuel lnes clogged

+

ll OK rcplace

ressure

egu lor s

page

F-95

4

ll notOK, eplace

I

Ar€sparkplugsOK?

-.

page

c_lg

WEAFAND

CAFIBON UILDUP

{0.039-O.0,*t

EUFNS

OETEFIOFATION

F-51



F

TROUBLESHOOTING

UIDE

t sPEcflot{

ACTION

1 ( Change

uel

and

check f acc€leralion

mproves

Change

luel

!o another brand

Go 10 nexl

step

1 1

Chock or corr€ctenginecomprcssion

e

Page

B-10

Engine

ompr$3lon

(ulnimum):

1.030

kP.

(t0.5

kgL/cm',

49

p3lF30O

pn

Tfy known good ECU and check il

engine

condltion

mproves

NO Check

ngne ondition

17

Page

a-10

.Wornpiston, isloo

ings

r cvlinder

.Defective

cylinder

head

gasket

.

Di$oned

c''linder

head

.lmpropet

alve eatmg

.valve

sticking

n

guide

F-52



TFOUBLESHOOTINGUIDE

F

21

RUIIS BOUGHON DECELERATION/BAC|(FIRE

DESCfitP.

noN

.Engine

lirns rough w+)ile ec€lerating nd abnormal ombustion ccurc n exhauslsystem

.Transaxle

n normai ondit n

rrRoualEsHooTr

HtNTsl

O

Ar/Fue{mxlure

oo ich

.Arr cleaner lementlogged

.Fuel

nieclion

ortro malJunclion

Fuel

utcontrol)

.Iniector

uel eakage

.Throttle

sensormalf

nction

.

Dashpolmalfunciion

t]tsPEcTtol{

ACTION

1 ls OO"display€d n SellDiagnosas hecker

with gnitlon wilchON?

u

p'g'e

F-6'7

IEST SW: SEIF TEST

Go to next step

No llallunctlon Codo No, dasplayed

Check

or

causeGeter o soeciiied

checksequence)

rt

page

F-70

"88"

tla3he€

CheckECU eminal1Fvoltage cz pageF-114

Volt.ge: Approx. 12V

(lgnition

swilch

Ol{)

+

lf

OK,

eplace

CU

cz

psge

F-112

4

ll nol

OK, check

wiring beiween

ECUandSelf-Diagnos,s

hsckar

2

ls

there air eal.age at inlake

air system com

3

ls

air cleaner

element

lean?

F page F-62

Go lo nexI step

No

Aeplaceair cleaner

element

Are ECU terminal oliages

OK?

(Especially

21v1 nd

20)

.:7

page

F-112

Ch€ck of calse .7

page

F-1t5

F-117

F-119

5 ls here0V al ECU

2V eminalabove ,000 pm

(Engine

ignal

monilor

reen

amp lluminates)

Try known

good

ECUand check i

6 ls lhrotle sensorOK?

Ei

pag6

F-122

Adjusl

(r

page

F-1ZI

F-53



F

TROUBLESHOOTING

UIDE

Check

if lhrottle

valve is cornamlnai€d

4

li contaminated,

clean

throllle

4

ll nol contaminaled,

replace throt_

ls dashpoi

correctlyadiusted?

c7

page

F-lo4

Daahpot

3et speed:

Approx.

2,500

+

100

Pm

ls

there

nleclor

luel leakage?

.?

page

F-96

Fuel leakage: Below I drop/s mln.

Try

known

good

ECUand ch€ck

i

condition

F-54



TROUBLESHOOTINGUIDE

F

22 KN(rcKNG

DEsilcBlP.

|

.Aolormar

combust,onccompalredy audrble

prnsins

no|se

TIROUALESHOOTTNG

|NTSI

O

Incor€ct gnilioniming

loo

advanced)

@Carbon eposltsncylinder

@

overhealing

@

Ai/Fue mi(ure oo

ean

.Fuel njecton mount otcorrect

.Fuel

ine

pressure

ecfeases

rhile

acceleraling

litsPEcTtoN

ACTION

1

ConneclSyslemSelector o diagnosis onnector

and

set

Tesl

Swilch to

"SELF

TEST

ls ignilion liming

correct at

idle

after wa.rn'up?

E?

page

F-62

lgnilion liming: BTDC 16

+

1'

INDICATOF

2 ls

'00"

d splayedon Self'Diagnosis h€cker

with gn'tionswitchON?

c:r

page

F-67

No llaltunctlon Code

lo. displayed

Checkor cause

Beler

o specilied

checkseqlence) c7 page F-70

"88"

flashes

Check

ECU ermlnal1F vollage

F

page

F-114

volrage: Approx. 12V

(lgnition

swirch ON)

+

lf OK, replaceECU

(?

page

F-112

+

ll not OK. check

wking between

ECU and S€ -Diagnosis

hecksr

3

ls there

air

leakage

ol

intake

air systemcom

ls engine ompressionorrecp

e

page

A-10

Englne ompression

Mlnhum):

1,030

kPa

10.5

kg/cm'

t4s

psiF30o

pm

tligh compr$sion

Check

ngnecondition

c7

page

B-10

F-55



F

TROUBLESHOOTING

UIDE

Does f fuel

roe

p€ssure decrease

whenacceleraling

ulck\,

+

ll decrcas€s,

heck

or clogging

b€trveen

uel

pump

and

pressure

regulator

4

ll not decrease,

o

to

next step

ls fuel

ine

presswe

correct al idle?

t?

PaEe

F-94

Fuel

line

pres3ure:

235-275

kPa

12.4-2-a Wlcm',

3!t-40

psl)

Check

uel ine

pressurc

hile

inch_

+

It fuel

ine

prcssure

ulckly

n_

creases, heck

pres€ure

egulalot

+

ll fuel ine

pressure

radually

n-

creases,

heck

or cloggrng

s

tween

uel

PumP

and

Pressure

regulator

lf notclogged,heck uelPUmP

maximum

pressure

r?

Page

F_91

ls

cooling

system

OK?

.Themostat

.7

Page

E-8

.

Et€ctic cooling

lan

.7

Page

E-1 1

.Rad,ator .?

page

E-7

Replace

EcU

1:7

Pege

F-112

Tryknown

ood

ECIJ nd check

l conditon

Change

uel

o anotherbrand

or use

F-56



TROUBLESHOOTING

UIDE F

23

FUELODOR

DESCRIP.

IION

.Gasoline

dor n cabin

FROUBLESH(X)T|NG

TNTSI

o

Poor

connecflon . oamaqed

al

lue

sysler- o- evaporanve msson cofrol sygem

@ Charcoara,r lerovedowdue o evaporatvemEson ont'ol l,slemmaunct,on

INSPECTIOT

ACT|Oir

ls tirere uel eakageor damageof fuel

system

and evaooatve emission onirol svstem?

2 |s 00" displayedn

SellDiagnosishecker

with gnillon

wilchON?

c?

page

F-67

Go to nexl step

L.lfunction

Code No, dbplayed

Check

or

caus€

Refer

o soecined

check

seqlence)

t7

pag.

F-7O

CheckECU erminal F voltage 6'

p.ge

F-114

Voltag€: Approx.

l2V

(lgnltion

swnch

ON)

+

ll

OK, eplace CU

F

p.ge

F-112

+

li nol OK, check wring between

ECUand SsltDiagnosisChecker

3 ls vacuum ell at solenoid alve

purge

conlrol)

with

engine

runn,ng

and throltle

valve

open€d?

(Neutral

switch connector

disconnected)

Go to Slep 5

No Ch€ck orsolenoidalve peraling

+'

lf OK,check acuum

osesor

clogsins

4

lf noi OK,

go

lo next step

Apply

12Vand

gro0nd

,

ls vacuumeltat solenol(

solenoidvalve

purge

CheckECU eminai voltages

rt

p.ge

F-112

V

'r<a

No Rep lace oleno id al ve

5 Tryknown

ood

ECUand

check

f

condition

F-57



F

TROUBLESHOOTING

UIDE

.Exhausl

as

smells bnormally

TTROUALESIIOOT|NG

INTSI

Highsulfer

contern

uel used

Change

fuel to another

bland

.

Ol consumphon

xcessve

ITRoUBLESHOOTING

INTSI

O rcV sy$emmallunction

6

Enqr#

malunction

O

working p workrng

own or leakage)

Are there

PCV

hos€, venlilation

hose

or |hen al_

lach ng

nipples

separated.

amaged,clogged,

e

P.ge

F-99

ls there

air

pressufe

or oil at

venulalion

os€?

Check

or correci

ngne

compression

page

B-10

Comor€*ion

(

inimum):

1,030

kPa

Oo.5

rgr'cm',

149

l,6il-300

rpm

+

tf OK,

go

to next

step

4

lf not Ok,

check

or cause

e

page

B-10

Crreit

engineconoltion

F seclion

a

.wom

pElon

nng

groove

.Stuckprston

ngs

.Wornpiston rcylinder

ls

vacuum

elt

al

PCVvalv€ at

'dle?

F-58



TROUBLESHOOTING

U'DE

F

26

POORFUELECONOTIY

DESCalP-

fl0N

.

Fueleconomy

unsatislaclory

ITRoUBLESHOOT|NG

|NTSI

Whileuelconsumptions drasticallyncfeasedy citydriving, horl-runperalion,

lopand

go

driving, xtended inler

warm-upp€riods,etc.,as opposed o 'trip" mibage,an atlernplshouldbe made o det€rmineh€se aclorswh€n con

frontedwith

"poor

mileage condlrions.However, ince he operator

s not

alwaysat

taull, he iollowing s oJfercd.

O

Operatordep€sslng accelerator

more han usualdue o

@

Air/Fuel ninur€ oo rich

lowengine

ower

.Hlgh

uel ine

pl€ssure

.Poor

gnltion

@

Alcohol lendeduelused

.Low

intake i amount

@

Highvehicleoad

.Bake

dragsing

.Electronic

soark

advanceconlrol svslemmalJunclion

.Clutch

slipping/ATxlipping

.

Exhaustomponentestricted

NSPECTTON ACTION

1

Check

actorsother han engine

.

Low

tire

pressufe

E7

page

O-2

.

Unrecommendedire size €

pag

()-2

. Clutchslipping s prge H.-3

.

Brake

dragging

s

pege

P--5

.

Exhausl

ornponenl

estricred

page

F-97

NO

2 Are air hosesconnected orrcctly?

.7

page

F-Eil

NO

3 ls

'0O"

displayedn Self'Diagnosishecker

with gnition wilchON?

''

page

F-67

TESTSW: SELF TEST

Go lo next slep

NO

[alfunclion

Code No, dbplay€d

Ch€ck

or

cause Reter o soeclfied

check sequence)

G

gage

F-7o

"88"

ll.3he3

CheckECU €rminal F voltage

F

page

F-114

Volage: Appror.

t2V

{lgnltlon

swltch

ON)

4

,t

OK, eplaceECU

t7

page

F-112

+

ll not

OK, check wiring

between

ECU

andSelt-Diagnosishecker

ls lhere air leakageal intakeair sl,stem om'

5 ls ai cleanerelement lean?

r?

page

F-62

NO Beplaceair cleanerelemer'1

6

Are ECU eminalvoltages K?

(Especially

M,2N, 2R and 2T)

.7

page

F-112

No Check

or

cause

-

page

F-115

F- l17

F- l19

F-59



F

TROUBLESHOOTING

UIDE

It{SPECTTON

acflo1{

7 Connect System

Selecto!

to diagnosjs

connector

and ser Test Swnch

to SELF

TEST

ls ionition minq

co(ect

at idle ajt€r

wafm_up?

.r

gage

F-t62

INDICATOR

Go o

nexl slep

NO

I

ls lu€] ine oressurc

onect al

idl€?

s

P.ge

F-94

23s-274 kPa 12.4-2.a xg/cm' 3l-40

p€l)

Hlgh

Pressu.€

check

if vacuum

hose

o

pressure

rcgulalor

s damagedot

poorly

con-

+

lf OK, replace

pressure egulalor

F

page

F-94

4

ll

nol OK,

repat or replace

hos€

9

Runengin€

t

idle

and

henstopengme

ts uel

in€

pressure

old?

c7

Pege

F-84

Fuel llnc Drcasure:

More than 147

kPa

(1.s

kgr'cn"

21

p3l)

of

5

min,

No Check

njectofs

or tu€l

eakage

e

page

F-96

10 Change

Juel

o anotherbrand

F-60



ENGINE UNE-UP

F

49 8019 9A0

gnilion

iming

ENGINE

UNE.UP

PNEPARATION

ssT

BASIC NSPECTION

Engine

Oil

1. Be sure

he vehicle

s on ievel

ground.

2.

Warmup heengine

o normaloperating

emperature

nd

stop

t.

3.

Wait or five

minutes.

4. Bemoveheoildipstickndcheckheoillevelandondition.

5. Add

or replace il

f necessary.

Note

.

The distance

between

he L and

F markson lhe diF

sllck

represents ,8

irer

(0,85

US

qt,

0.70 mp

qt).

EngineCoolant

Coolant

evel

(engine

cold)

Warning

.

Never emove

he radiator

cap while he

engine s

hot.

.

Wrapa thick

clothalound

hecap

when emovlng

t.

1.Pull ut

hesub

ank ap.

2. Verifvhat

hecoolant

evel s

near he radiator

illerneck.

3. Verifyhat

hecoolant

evel n thecoolant

eservoir

s

be-

tween he

FULLand LOW

marks.

4. Add coolant

necessary.

Batlery

1.Checkthe

ightness

f heterminals

o ensure

ood

electri

cal connections.

2. Check

or corroded .

frayedbattery

ables.

3. Washhe

op olthe battery

ith

watero

prevent

rcover'

4. Verify hat

he electrolyte

evel s

betweenhe upper

and

lowermarks.

Add distilled

ater

f necessary.

F-61



F

ENGINE

UNE.UP

5. Disconnect

he

negative

battery

cable

6. Ooen

he

cap.

i.

Miasure

he pecilic

gravityof each

cell

witha

hydrometer'

Specilfcatlon:

.27-1.29

(at

20oC

68oR)

Alr Cleanet

Element

1. Check

heair

cleaner

lement

or excessive

irt,damage'

and

oil.

2.

Replace

he

air

cleaner

lement

l necessary'

ADJUSTUENT

PteDaralion

1.

Warm

up the

englne

o normal

perating

emperalure

2.

Verilvthatthe

ax

odhasextended

utward

u

y

ano

nal

the

fast idle

cam

has separated

rom he

roller'

3. Turn

all

electrical

oads

OFF.

. Bloweran

.

Headlisht

.

Rear

window

defroster

4. Make

ure

hat

he engine

peed

does

notchange

wnen

Jiiconnecting

he

airbypass

olenoid

alve

@

connector'

Note

.

liine

engine

speea

decreasea,

he

engine

s slill un'

der the

warm-uP

onditlon.

5.

ll the electric

oollng

an

s

operating

wat until

t stops

6.

Verify

hat he

engina

s

running

t

dle n

goodcondilion

7. con;ecl the SST o the diagnosis

onnector'

8. Connect

timing

ight.

s c."""ii a

tacn6m-eter

o

the diagnosis

onnector

G-

lermlnal.

10.Set

switch

G)to Position

1'!.SeiTEST

SW

OSELF-TEST'

Not€

.

liitre

ssr

is not

us€d,lump

across

he TEN

€rmi-

nai and

ttre GND

ermlnai

ot

the diagnosia

con-

nector.

F-62



ENGINE

UNE.UP

F

INDICATOF

fi -)

lgnition Timlng

Inspection

Adjustment

'1.

Perform

Preparation".

(Reler

o

page

F-62.)

2. Verity

hat he dlespeed s

withinhe specification.

ldle speed: rTX

(Neutral)

750

::E rpm

ATX(P range)1,100 '6 rpm

3. Check he

gnitionimingwitha

timing ight.

lgnition

iming: BTDC16

+

l"

4. lf the gnitioniming

s notwithin pecification,

oosenhe

distributorockboltsand

urn he distributor

o make he

adjustment.

5. Tightenhe distributor

ockbolts o the specified

orque.

Tighlening

orque:

l6-23

Nm

(1.6-2.3

m-kg,

2-16 ft lb)

ldle

Speed

1. Perform

Preparation".

(Refer

o

page

F-62.)

2. Check he

dlespeedwitha

tachometer.

ldle speed;

MTx

(Neuttal) ?50 158 Pm

ATX

(P

range)1,'100

"8 rPm

3. l, notwithin pecification,djust

he

dle

bytuning

he hrottle

adjusting

crew.

F-63



F

ENGINE

UNE-UP

/t

"o"".-ird"

i

ldle-up

Speed

1 Perfbrm

Preparanon

(tleler

o

pageF-62

)

2. Check

he

dlespeed

witha

tachometer'

ldle sDeed:

MTx

(Neutral)

750

1fl

rym

ATX

P

range)1'100

'3 rPm

INS

iAL

oi ' l

fhnlriL€

BoD'i

I

3.

Adjusl

he

air bypass

olenoid

alve

@

by the

ollowing

orocedure.

iiCrouno

rn.

arl

bypass

olenoid

alve

@

terminal

@

shown

n

the igure

2) Adiustthe

dle-up

peed

y

urning

headjusting

crew'

ldle speed:

MTX

Neulral)

1,080

+

30 rpm

'

ATX

(P

range)

1,350

+

30

rPm

3) Disconnect

he

umper

wire

4.

Adjust he

air

bypass

solenoid

alve

@

by

the following

orocedure.

i) Ground

he

checkconnector

black) hown

n hefigure'

2) AdiL.rst

he

dle-up

peed

y

urning

he

adjusting

crew'

ldle

speed:

MTX

Neutral)

1,030

:53 pm

'

ATX

P

range)1,700

'6 rPm

3) Disconnect

he

LlmPer

rre

qHECK

CON

'fL

0

DISTRIBUTOFI

ADJUSTSCREW

F-64



ENGINE UNE.UP

F

5. Adjust he air bypass olenoid

alve

@

by the

ollowing

procedure.

1 Djsconnectheconnector f heair bypass olenoid

alve

2)Apply

battery

oltageo air bypass olenoid alve

@

terminal.

3)Adjustthedle-uppeed y urningheadjustingcrew.

ldle sp6ed:

MTX

Neutral)

1,250

+

25 rpm

ATX

(P

range)1,600

+

25.pm

4) Installhe connector f air bypass olenoid

alve

O.

F-65



F

SELF.DIAGNOSIS

UNCTION

SELF.DIAGNOSIS

UNCTION

DESCRIPTION

Whintroubles

ccur n he

main nput

evices routput

evices'

heck

or hecause

sing

heSST

Failures

oieactt

npuiina

outputdevice

ie ndicated

nd etrieved

rom

heengine

ontrolunit

ECU)

s malfunc-

tioncode

numbers.

Note

.

ihe

EGuconstantly

hecks

or maltunction

f the

nputdevic€s.

But'-the-ECU

hecks

ormaF

dndion

ot output?evbes

only

In a

thtee seconds

perlod

after

he ignltion

switch s turned

ON when

he fEN

lerminal ol

the diagnosis

conneclor

s

grounded.

ENGINE

CONTFOL

UNIT

OUTPUT

oEvtcEs

SYSTEM

SELECTOR

SELF.DIAGNOSIS

CHECKER

F-66



SELF-DIAGNOSIS

UNCTION

PREPAHATION

ssr

6

.

lql.

MALFUNCTION ODE

NUMBEB

InspectlonPrccedurc

1.

Connect

he

SST

o the diagnosisonnector.

2. Set switch

@

to

position

.

3. Set

TESTSW o SELF EST.

7 - )

aZWr

,6^

ir

'"!

@@

4.

Connect

he SST o the System

5.

Set

he select witcho

posilion

Selector nd a

ground.

6. Turn he gnition witchON.

7.Verifyhat

88"

llashesonhedigitaldisplaynd

he

buzz-

er soundsor 3 sec, after urning

he gnition

witchON.

8. l

"88"

doesnotflash, heck

hemain elay

Feter

o

page

F-124),

power

supplycircuit,and

diagnosis onnector

wrflng.

9. f 88 lashes nd he buzzer ounds ontinuously

or

more

than20 sec., check or a short ircuilbetweenhe ECU

terminal

Fand hediagnosisonnector. eplacetheCU

if necessarynd

perform

teps and 7 again.

10.

Note nycode

numbersndcheckforhecauses y refer-

ring to the

check sequences hownon

pages

F-70

throughF-78.

Repair

s

necessary.

Note

.

Cancel

the code numbeB by

performing

the after-

repair

procedure

ollowing repairs.

(Refer

o

page

F-79.)

43 80199AO

SystemSelector

diagnosis

49 HO18 A1

Self-Diagnosis

Checker

diagno6is

F-67



F

SELF-DIAGNOSIS

UNCTION

Prlnciple

of Code

Cycle

Malfunction

odes

aredetermined

s

shown

below

L Codecycle break

ihe

tim6between

malfunction

ode

cycles

s 4.0

seconds

lhe

ime

he buzzer

s otD

MALFUNCTION ODE

CYCLE

BFEAK

2. Second

diqit

of maltunction

code

(ones

position)

-'i;;l;il

;i;;;;;i

positn

ot ne

marrtr.,ncli6n

ode

epresents

he

number i

times

he buzzer

ounds

0.4 second

during

one cycle

r cYcL€

MALFUNCTTONOOE

MALFIJNCTION

C O o E : 0 3

sEc. sEc

3. Firsl diqit

ol maltunction

code

(tens position)

-

in" O,gii

" ine lens

position

t

th;

maffunction

;de

represents

he number

f

times

he buzer

is on

1.2 seconds

uring

one cycle.

Thebuzzers off or 1.6 seconds etweenhe ongandshortpulses

I CYCLE

MALFUNCTION

OOE

coDE

22

CYCLE

1 2 SEC

SEC

4osEc

FIRSTDIGIT

SECOND

DIGIT

F-68



SELF-DIAGNOSIS

UNCTION

F

code Numb€rs

Sensor or

Condition Fail'sate

Maltuncllon dbplay

llaltunctlon

CodeNo.

output slgnal

pan.m

Ne'sisnal No Ne-signal

whil-a

crankrng

Stops iu6l injection

02

ON

Open or short of

aif-

08

ON

Openor shod oi

20oc

(68oF)

09

;,

lffilrfljll

throlile ensor

ircuil 33.degree ommand

12

ON

Oxygen ensor

llnues

nchanged

min.afler

engine x-

ceeds ,000

pm

Cancelsengine

1 5

ON

40 sec. atter

engine

exceeds ,500

pm

Cancels

ngine

1 7

ON

{purge

control)

Openor short of

26

ON

vaive

@

valve

@circujt

34

ON

valve

@

valve

@

ci/cr.tt

35

Noie

.

The buzzersounds

only tor the ones

position

when using he DlgltalCodeChecker.

To

iudge

he corect

maltunctioncode number, eler to lhe digital display.

Caulion

.

lf ihere s morc han one failure

p.esent,

he code numbers

will

be

ndicated n numerical

r-

der. lowesl nrmber ttst.

.

Aller repairinga lailure,

perform

he afler-repalr

procedure. Refer

o

page

F-79.)

F-69



F

SELF.DIAGNOSIS

UNCTION

Troubleshootlng

lf a malfunction

6de

number SShown

n the

SST,check

or

hecause

y Using

he

chart

elatedo the

codg

number

hown.

COOE

o.

O:I

DTRIBUTOR

I{E.SIGNAL)

STEI NSPECNON

ACTION

ls

herea

poor

conn€ction

n distributor

ircui0

Repairor

replacewnng

No

2 ls there

continud

b€tweendistributor

erminal

wirc

(B/LG)

and

grcund?

Go

to next

gep

Check

or opencircuit

n wirng

ifom distributor

o

ground

3

ls there battery

voltageat disltibutor

etminal

NO

Ch€ck

or

open

circut

n wiing

trom

dislibutor

o

main

relay

fUEl

INJ

elay)

ls lhere aoorox.

5V at ECU

emlnal 2E?

Wilh

distributor onnector

disconnected)

Go to next slep

neplace CU

5

ls there approx.

5V dist bLrtor

erminal_wre

(G/R)?

At

harneseside onnector

with discon_

Feplace

dist butor

NO

Check

or snort r

open

circuitn

wring rcm disldbutor

ECU erminal

E

Circult

Diagram

O|sTR|aUTOR

IGNITION

swrTcH

BATTEFIY

TO

IGNITION

swtTcH

TO TACHOMEIEFi

TO DIAGNOSIS

CONNECTOR

IGNITEF

DIS]RIBUTOF

G/B

F-70



SELF-DIAGNOSIS

UNCTION

F

CODE

t{o.

08

(ATRFLOW

E SOR)

STEP

IISPECTTON

acTtot{

ls here

poof

connection

n

airilow ensor ircuiP Repair r teplace i

ng

2 ls ECU erminal20 vollageOK?

e

page

F-118

lgnition

wilchON

ldle

ls sameCode

presenl

atter

performing

alter'repalf

rocedure?

+

lf YES, eplace CU

+

lf NO, €check irliow ensor nd

ECU or

poor

conneclion

e

p.g€

F-79

No

Go to nextstep

3

ls lhere

battery

vollage

at airtlowsensor onnec'

tor teminal C with airilows€nsorconnectordis.

Check

orshort r opencircuil

n wir-

ng trom aiflow sensor onneclor er-

mnalC lo main elay.

+

lJOK,checkmain

ealy

+

ll notOK, epair r rcplace

ls lhe.e conlinuiiy belween airilow

sensor lerrni-

na B and

sround?

R€pan r rcplace

iing

5 ls resislance

between arrflow sensor teminals A

and B

OK?

E7

page

F-121

Resistance:+ 1 m eo"C t68.Fl)

ls here onllnuty etween

CU erminal 0 and aidlow

+

lf OK, eplac€ idlow ensor

+ lf notOK, epair r replace

No Aeplaceairllowsensor

Circult Diagram

FFOM IGNITION

swtTcH

t r r l

r l l

r l r l

1l

G/w

ll

clv

,i

AIFFLOWSENSOR

F-71



F

SELF-DIAGNOSIS

UNCTION

CODE

NO.I

09

(WATERTHERI'OSENSOR}

STEP

tNSPECTTOI{

ACTION

1

ls there a

poor

conneciion

n waler

hermosen_

nepair r

leplace

rnng

2 ls there

continuity

between

waler hermosensor

and

ECU?

ECU

A

(R/L)

20

(R/L)

B

C/i

G)

2D

CYi

)

Go o

nexl step

3

ls resistance

f

water hermosensor

orrecf

Coolant

lemp.

Fesislance

kO)

,200c

(

-40D

14.6

17.A

20.c

(

68'D

2.21-2.69

80.c

076'R

0.29-0.35

No Beplace

waler

hermosensor

ls same

Code

No.

prcsent

ollowing fler_repair

F

Pag€

F-67

Waterhemosensor

ndcrcuit

OK

5

Arc ECU

ermlnals

D and

20 voltages orrcct?

c7

page

F-l16

n"pru".

tCu

17

Psge

F_112

Check

or shotl

ircuil

n wiring

rom

waterhemosensor

lo ECU

Circult

DiaEram

ECU

THROTTIE

ENSOR

MOSENOR

WATEBHEFTMOSENSOF

re

@

re

@

\lB

)i

IER

THER

l l

F-72



SELF-DIAGNOSIS

UNCTION

F

CODE

No.

r2

fTHRoTTLE

EI{SOR)

SIEP INSPECTION ACTION

1

ls lhele a

poor

conneclion n throltle ensor

Bepair r replace iing

2 ls

there conllnuity ehdeenhrotllesensorand

ECU?

ECU

A

(LG/R)

2K

(LG/R)

B

(LGMI

2M

(1G,4

)

D

ff/B)

2D

(v/G)

3 ls resislances etween erminalsB

(LG/'14

nd C

(Y/B)

correc"

Below kA

Approx.

5 kO

Adlust

or

replace

throttle sensor

o page

F-12.

ls ECU

terminal 2lV vollage cofrccl?

.7 page

F-116

ReplaceECU 17

page

F-112

Check

or

short icuil

n

wirng

rom

hrcttle ensoro

ECU

Circuil Diagram

IHFOTTLE

ENSOF

RMOSENOR

re

@

re

@

ll

Y/B

jl

TER THE

Y/G

THFOTTLE

SENSON

F-73



F

SELF-DIAGNOSIS

UNCTION

ffiYGEN

sENsoB

tNAcrtvATtot{)

STEP

t]{sPECTlOt{

ACTION

ls there

a

poor

connection

n orygen

sensor

Repair

or replace

wing

2 ls oxygen

sensorodpul

vollage

cotrecr?

F

Page

F-123

Replace

xygon

sensor

3 ls there

continuity

betlveenoxygen

sensor

and

EclJ ermlnal

N?

ls

ECU terminal

2N

voltage correcl?

F

Page

F-1lE

Check

or shod

ircuit

n wiring

romoxvgen

ensor

o

ECU

5

ls

sensitivity f

oxygensensor

correcp

t7

Page

F-123

aadro Fa | | s oaoe

F- t12

Tryknown

ood

otygen ensor

nd

ch;ck

It co;dition

mproves

.?

ptge

F-124

Circuit

Diagram

F-7

4



SELF-DIAGNOSIS

UNCTION

F

mDE No.

.I7

(FEEOBACK

YSTEi|)

STEP I SPECTTON

ACTtOl{

ls

s3meCode No,

present

after

pedorming

aller-

E

7

eagc

F--67

NO

Check xygen ensor ircuitor

poor

+

li OK,

p€rfom

toLrbleshooling

CodeNo.15

s

Page

F-74

.)

lf not OK, repairor replacecon-

Checkmonhor

amp ol Sef-Diaqnosis hecker

l

luminate

at

jdle

alter warming.up ngineand

runningt at 2,500-3,000 pm or

I

minutes?

Go 1o nod step

ilole

.

A/F mixtui€ lB rich

Go o Slep5

Nole

.

A./Fmlrtur! b le.n

or mi8fire occuiing

3 ls tuel ine

pressurc

t dlecorrec0

e

prge

F-94

Fuel llne

Dr€65ure:

235-275

wa

(2.1-2.A

r.glcnf,

3,F40

p5l)

(Vacuum

ho3. lo

preasurc

rcgulrlot

dbconncctcr0

Go to

nextslep

Hlgh

prossuro

ls fuel relurnho€eclogged

or restricted?

+t

ll OK. replace

pres$re

regulalor

-

pag€

ru4

+

lf nol OK, rcpairor replace

hose

ls

here eak€ge t

fuel

njectot

c?

page

F-97

NO

ls waler lhemossnsor OK?

c?

pege

F-121

+ ll OK, Go lo Step7

+

ll not OK, replace water

lhermc

(z

page

F-121

5 Disconn€ct each high-iension lesd at idle; does

enganespeed

decrease

equally at each cyinde|?

NO Go to St€p

ClrcultDlagram

F-75



F

SELF.DIAGNOSIS

UNCTION

STEP

INSPECTION

acTtolr

6

ls tuel

ine

pressure

t idle conecf

r7

P.ge

F-94

Fuel ine Dressure:

235-274

kPa

12.4-2,a

kg/cm', 34-40

psD

(vacuum hose lo pr€*suneregulalor

No

Check

uel

ine

pressr.rre

hil€

pinch

a

I luel ine

pressurc

uckly

n-

creases,

heck

pressure

egulator

t7

Page

F-95

.t

lf iuel

ine

pressureraduallyn

creases.

heck

or clogging

be_

tweenuel

pump

and

pressure

lf notclogged,

heck

uel

PUmP

maximum

pressure

F

Peg€

F-91

7 ls

ihe.e air leal€ge

in intake a

I system com_

Goro Step10

8

Was misfire

ound in Slep

5 oJ

nspection?

Repair r

replace

gnitlonystem

9

b

;me Code

No.

presert

ollowing

edorming

atter-rcpair

rocedurc?

c7

Pege

F--67

Go

o noxl slep

NO

1 0

Tryknown

ood

ECUI

does condition

mprcve?

o

page

F-112

F-76



SELF-DIAGNOSISUNCTION F

CODE

No.

26

(SOLENOID

ALVE PURGE

ONTROL)

STEP INSPECTION

ACTtOl{

Disconnect onn€ctor rom ECIJ

ls lherc balteryvoltageat ECU erminal

2X wire

hamess

R/B)

wnh gnilion

swltchON?

CheckECU erminal onnecloro.

poor

connecrion

+

lI

OK,

eplace CU -

page

F-112

+ ,l notOK, epair r replace iring

2 Keep condilionStep 1

ls

there bafleryvdrage

al soleloid

valve

connec-

tor terminal-wire

(A/8)?

(R/B)

3

ls

solenoidvalve OK?

F

pago

F-101

Check or shod or open circuit n wiing lrom main relay

(FUEL

NJ relay) o

solenoid

alve

Beplace solenoid valve

CODElo.

34

(AIR

BYPASS OLENOID ALVE

O)

STEP INSPECTION

ACTION

1 Disconnec l onneclor rorn ECU

ls there baneryvotage al ECU

eminal 2T wire

harness

BM)

with gnition

swtch ON?

Ch€ckECU

erminal onnector

or

poor

conneclion

.)

ll

OK, rcplaceECU

o

page

F-112

.>

lf notOK, epair r replace iins

2 Keep condilionas Step 1

ls there baltery voltage

at solenojd valve connec-

lor lerminalW.e

R/!9?

Repair iring

(R/Vr)

3

ls solenoid valve

OK?

F

page

F-109

Ch€ckor short r opencircuil n wiringrommain elay

(FUEL

NJ relay)o sol€noidalve

NO Replace o leno valve

Clrcuit Diagram

FFIOMBATTERY

FROMGNITION

WITCH

SOLENOID

VAIVE

SoLENOID

ALVE

),

soLENolo AtvE i

(PUFGEOMIFOL)ii

SOLENOIO

ALVE

(PUNGE

ONTROL)

F-77



F

SELF-DIAGNOSIS

UNCTION

35 {An

AYPASS

SOLEI{OID

VALVE

@)

Check

ECU

etminal

conneclor

or

poor

connecron

+

ll OK,

eplace

CU

-

Page

F-112

.t lf noi OK, eparr r replace rrrng

Dsconnecl

connector

rom ECU

ls

lhere batlery

voLtage

l ECU

e|minal2R

wrre

(F/B)wilh ignilionswilchON?

Repair

i ng

(R/B)

Ke€o ondilion

s SteP

ls th;re

battery

voltageat

solenoid

valveconnec'

tor

termina

wie

(B/Bf

Ctect

tot "lon ot

op.n

"ircul

in wiing

fiom

maln elav

c?

page

F-109

Replace

soLeno

valve

Cllcuit

Dlagram

FFOM

BATTERY

FFOM GNITION

WITCH

AIFIBYPASS OLENOID

valvE €)

z---F-----rr

ufjl-lJ

i

AIF BYPASS

i

SOLENOID

ALVE

G)i

SOLENOIO

ALVE

{PURGE

ONTFOL)

F-74



SELF-DIAGNOSIS

UNCTION

Ff

"

lEJ.

After-repair

Procedure

'1.

Cancel

hememory f mallunctions

rom he ECu by dis-

connecting

henegative attery able

nddepressinghe

brakeoedal

or al least hree seconds.

Reconnecthe

negative attery able.

2. Connectthe

ST

System

Seleclor)

othediagnosiscon-

nector.

3. Setswitch

@

to

position

.

4. SetTESTSW o SELF-TEST.

5. Connect

heSST

(Selt-Dlagnosis

hecker) o the Sys-

tem

Selector nd a

ground.

6. Setthe elect

witch f heSelf-Diagnosishecker

o

posi-

tionA.

7. Turn he

gnition witchON.

8. Start ndwarm p

he

engine,

hen un

t

at

2,000 pm tor

three minules.

9. Verityhat

no codenumbers redisplayed.

F-79



F

SELF-DIAGNOSIS

UNCTION

SWITCH

IONITOR

FUNCTION

Individual

witches

an be

inspected y

the

SST

(Selt-Diagnosis

hecker).

Note

.

itre

TEN erminat

ol the diagnosis

conneclor

must be

grounded

and

the

ignltionswitch

oN

(enginestopped),

. ti e-ntrer f i6e switchesremainaclivated, he monilot lamp wlll be illuminated.

ENGINE ONTFIOLNIT

NEUTRAL

wlTCH

CLUTCH WTTCH

STOPLIGHTWITCH

HEADIIGHT

WIICH

I

I

SYSIEM

SELECTOB

OEFFOS1EF

SWITCH

BLOWEF ONTFOL

SwlTCH

INHIBITOB

Swilch

Self.Diagnosls

Checker

(Monitor lamp)

R€mark

Lighl Ol{

Llght OFF

Clutch

switch

([4TX)

In

gear

Neutral swilch

([/1X) In

gear

Clulch

p€dal

released

Sloplight swilch

Headlighl

wnch

ON

Headlighls/small

ights ON

ON

OFF

Rear

wndow defroster w ch

ON

ON

Inhibltor witch

(ATX)

L, S,

D

or

F range

Inspeclion

Procedure

1.

onnecl

heSST

System

Selector)

o heoiagnosrscon-

nector.

2 Setsw{ch

@

to

posttion

.

3 SeITESTSWITCH

o SELF.TEST,

F-80



SELF.DIAGNOSIS

UNCTION

F

Procedure

Neuiral

and

Clulch

Switches

MTX)

4. Connecthe SST

Sell-Diagnosis

hecker) o the Sys-

tem Selector nd

a

ground.

5. Set heselect witch fthe

Self-Diagnosisheckero

posi-

tion A.

6. Turn he gnition witchON.

7. Check

f monitoramp lluminateswhenach witch

smade

to tunction sdescribed elow.

Caution

.

ll eitherot the switches

emain

aclivated.

he mon-

itor lamp will be illuminated.

.

Do

not start

the

engine,

Checkeach swirchand relaledwting

harness

.Clurch

and Neurral witch .Feler o

pages

F 124. 125

.Stoplightswitch :Reler o SeclionT

.Headlight

swlch Reler o SectionT

.Water

thefmoswilch

Feier o SectionE

.Rear

delrosler switch

:Befer to Section T

.

Blower swilch

Befer o Section T

.lnh

brtorswltch

:Beler o secfon K

Set conditionso deactivate ach

switch

.Ail

accessors OFF

.Transmissionn neutral

Veity hal monltorarnp

oesnot lluminate

Check each switch as describ€d

Shifl

ransmissionnto

gear

ls monilor mp illurninatedilhclulchpedal eleased?

PC

.Neutral

r clLrtchwitch

mallunction

{Relero pages -124,125)

.Open

ckcuil n related irinS arness

.

ECU ermlna

1\/)

maitunciion

(Reler

o

page

F-116)

Depress clutch

pedal

Doesmonitor amp

go

out?

B€tu.n

transmission to neutral

PC

.

Clulch

switchmalunclion

(Reler

o

page

F-124)

Stopllghtswllch

PC

.Sloplight

switchmalunction

(Beter

to Section T)

.Open

circut

in w rlng harnessrom sloplighl

switch

to ECU

.ECU

terminal

1O)

maliuncllon

(F€fer

o

pase

F 114)

Depress rake

pedal

ls monitoramp llumlnaled?

Sloplight wilchOK

F-81



SELF-DIAGNOSIS

UNCTION

Blower

switch

PC:

Blower

witch

malfunclion

GeJer

o Seclion

T)

.dpen

ctrcurl

n ||e wrr'ng

aness

om blower

sw ch o

ECU erm,na

1S)

.ECU

eminal

1S)

maltunciion

(Reiero PageF 114)

'Iun

blower

switch

o ON

position

ls monitor

amp

lluminated?

Headlight

witch

PC:

Headlisht

witch

malfunclion

(Reier

o Sedion

)

.Open

crrcuil

n

w n19

harnessrom

headlighr

swich

o Ecu

ieminal

1u)

.ECU

ermrnal

1U)

mallunction

(Feler

o

Page

F-l16)

Tum ON

headllght

witch

ls monrlor

amp

llominated?

Headllghl

w(ch

oK

Tum OFF

headlighl

wdch

Water

hermoswiich

circult

(not

included

n switch

nsPeclion)

Warninq

I'iie

c'ootins

"n operates

when

he

diagnosls

onnector

ermlnals

TFA

nd GNDare

connect-

ed with

a

iumper

ttrire'

Use caution.

PC.

.

Felay malfuncton

{Beler

lo Section

E)

.Open

circlit

ln wire

harness

rom

watef hermo_

swrlch

o engine

control

Linrl

.Enqrnscontrolunt lelminal1R malluncliof

Connect

diagnosis

onnector

elminals

TFA

and GND

V€rity

hat monilor

amp

ill'rmlnates

Water

hemoswitch

ckcuit

s OK

Dlsconnecl

jumper

wrrc

Rea.

defroster

swilch

rc:

.Fear

delroster

wich

malfunclion

(Befer

o Seclion

)

.bpen

circuit

n wldns

harnessrom

ear

defroster

switcho

ECU eminal

1T)

.ECU

erminal

1T)maliuncton

(Reiero pageF-114)

Tum

ON rear

deffosler

switch

ls

monitor

amp lluminated?

Bear

deirosierswitchOK

TurnOFF

rear delioster

swlch

Inhlbitor

switch

(ATx)

PC:

hhlbiior

switch

malllnct|on

iReter

o Section

K)

.Open

ot shol

crrcuil

relaled nng

harness

.ECU

erminal

1V)

maLfuncton

(Beter

o

page

F

116)

Shiti

ransmission

nlo

gear

ls monitor

amp

luminated?

lnhilitor

swilch

OK

Shlfl

nto

"P

or

"N range

F-42



INTAKE

AIR

SYSTEM

F

INTAKE

AIR SYSTEM

COMPONENT

ARTS

Removal Inspectlon Installatlon

1.Removen the ordershown n the igure, eferring

o

RemovalNote.

2. Visuallynspecthe intake

ir system omponentsnd repair

r replace s necessary.

3. Installn the reverse rderol removal

19-25

(1.9-2.5.1.-r9)

19-25

0,9-2,6,

r/r-r9)

7.6-11 nn

(40-t10

cn.tg,

6H5In-lb)

REPLACE

11 25

,9-2.6,

1a-191-

/a :;;s

(3,3-s.3. 27-33)

1.Aircleaner

Inspector excessive

irt

or damage

2.

Injection

ody

Inspection.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

F-86

4. Intakemanifold tay

Removal

Note

Coolant

1. Drainhecoolant

nto

a suitable

ontainerefore

emovino

the njection ody.

2. Retillwilhcoolanl fter

nstallation.

Cautlon.

Belore ooseninghe radialor

drain

plug

verify hai

the radiatordraln hose

aces stralghl down.

Inspection...................................

age

F-84 5.

ntake anifold

DisassemblyAssemb1y.............

age

F-85 Inspection...................................

age

F

86

F-83



F

INTAKE

AIF

SYSTEI'

Fuel Pressure

Releaae

Belore

isconnecting

ny

uelhne,

elease

he

uel

pressure

trom he

uel

svstem

o reduce

he

possibility

f

Injury

r

fire.

|.

Slad

he en-gine.

2. Remove

he rear

seatcushton.

3.

Disconnecthe

uel

pump

connector'

4. After he enoine talls,urnofi the gnition witch

5. Reconnect

he uel

pump

onnector

nd nstallthe

ear eat

cush|on.

INJECTION

ODY

Inspeclion

1.Check

he

niection ody

ol

wearand deposils

2. Verify

hat he hrottle

alve

moves

moothly

ith he hrot'

tle

valve ever

rom ully

closed

o fullyopen.

Fastldle

(On-vehicle

nspection)

1.Turnall electric

oads

OFF.

.

Blower

an

.

Headlight

.

Rear

window elroster

2. Verifyhat

he wax

od s contracted

nd

hat he

ast dle

cam asn contactwith he roller.

3. Connect

tachometer.

4.

Start

heengine

nd

verifyhatthe

ngine

peed

s below

2,500

nm.

5. Warm p

heengine

onormal

perating

emperature

nd

verfy that

he engine

peeo

gradually ecreases.

6. After

heengine

warms

lp, erifyhat

he

wax odextends

fullvand hat he

camsepartes

rom

he

roller.

7. Vdity that

he dlespeed

s

within pecification.

ldle speed:

MTX

(Neutral) 750

:53 pm

ATX

P

range)1,100

1 rpm

Note

. Air bypass solenoid valve @ opens lrom hsll

ryanhed

up condilion

o

wamed

up condition.

.

Waler empelature

when cam

ust

separates

s

6l

:3"C

(142

1!l.R

@TX),

55

+

8oC

l3l

+

46oF)

(ATD.

4-?-2:

F-A4

FUELPUMPCOVER

PUMP

CONNECTOF



INTAKE

AIR

SYSTEM

F

8. Fieplacehe njection

ody f necessary.

Caution

.

Do

not disasasmble

he iniection ody.

.

Do not turn

he acrewg hown n lhc ligure.

01E0Faog1

Disassembly

Aaaembly

1. Disassemble

n the ordershown n the igure.

2. Assemble

n the reverse

rder

of disassemblv.

1.Air bypass

otenoidalve

@

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-109

2. Dashpot

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-104

3. Throttle ensor

1nspection.................................

age

F-122

Adjus tment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-122

Removalfnstallation................

age

F-I22

4. Airflow ensor

1nspect ,on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Pressure

egulator

lnspect ion. . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . .

Rep|acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Injector

Inspection

on-vehicle)..............

Bemovallnstallation................

page

F-121

page

F-

pageF-

page

F-

page

F

94

94

95

96

GASKET,

EPLACE

3,4-a.S

(35-50,

3O---4:r)

3.4-5.e

(35-s0i

30-4t)

;?iil:"ts

7.4-12

t@-12O,

69-1U)

r.2-r.3(12-13,

0-r6)

O8ING,FEPLACE

2.0-2.s (20-30,

r7_2G)

rl-22 lln

(r.a-2.2

n.l(g,

F-85



F

INTAKE

AIR

SYSTEM

INTAKE

MANIFOLD

F-86

BAFFLE/INTAKE

ANIFOLD

Inspection

1 Visuallv heck

for cracks

or

damage

and

reolace

f

z. 8i"ff#

ai"tonion

f he

ntake

manffold

nd

eplace

f

necessary-

ACCELERATOR

EDAL

Removal

Inspection

/ Installation

'1.

Remove

n the order

shown n the

agure

2.

Visually

heck

he accelerator

edal

and

retainer

or cracks r

damage'

3.

Install

n the

reverse rder

of removal.

1.

Accelerator

able

3 cliP

lnspection

Adjustment....

.. ..

page

F-86

4

Fletum

pring

..

2.

Retainer

5 Accelerator

edal

9!-r5

{100-150,

t7-r3o)

ACCELER,ATOR

ABLE

InsD€ction

Adiustment

1 deoress

he accelerator

edal

ully

Verifyhat

he hrottle

valve

s ullyopened

y

irrning

he hrottle

everby

hand

2.

nspect

he

play

ol the accelerator

able.

Play: 1-3mm (0.04-0.12 In)

3. Loosen

uts

@

to adjust

he

play

f necessary.



FUELSYSTEII/I

FUELSYSTEM

DESCRIPTION

This

system upplieshe necessary

uelat a constant

ressure

o the njector.

Fuels metered nd njected

nto he ntakemanifold ccordingo he njectiononkol ignal om heECU.

Thissystem onsists

f the uel

pump,

uel ilters,

ressure

egulator,

nd

njector.

F

PRESSUFEIEGUFATOB

v-

FUELFILIER

HIGH.PBESSURE

IDE)

FUELFILTER

IOW.PRESSUFE

IOE}

@

\

s

F-87



FUELSYSTEM

F

Fuel Line Pressure nsoestion

Warning

.

Belorc

performlng

the tollowing

operatlon, release

the fuel

p]gs$re

lrcm the

tuel syslem o leduce

the

possiblllty

ot

iniury or tire.

(Reter

o

page

F-88,)

1. Disconnect

he

negatNe attery

able.

2. Connect

fuel

pressure auge.

3. Connecthe

negative attery

able.

4. Connect iagnosisonnector

erminals

/P

andGND

with

a umoerwtre.

5.

Trjrn he gnition witchON.

6.

Measurehe uel ine

pressure.

Fuel

ine

pressure:

235-275 kPa (2,4-2.4 kglcm" 34-40 p8l)

F-89



F

FUEL

SYSTEM

FUEL

TANK

Removal

Inspection

Installalion

Warning

i'-diiJie pertormlns

he following

operalion,

elease

he

fuel-Pressure

rom

he

fuel system

o

reduce

he

pGstblllty

ot

iniury or fire.

(Reler o

page

F-88J

. Wrren itoilns tlte fuel ia;rk,'k;t spalrrs'cigaiett-cs, nd open lamesaway tom it'

.

i'iiiij

iepiirin-g

the

fuet tanti,

ctein

ir ttrr6ug6ty

with

steam

to lemove

all

exploslve

gas.

1. Remove

n the orde.

shown

n the igure.

2.

Visuallynspect

he

uel ankcomponents

nd

repair

or replace-as-

ecessary

3.

nstalln th;

reverse rder

of removal,

elerring

o

Installation

Note

-

,."-, ,

,*-r

,0, rr,

Q

SEAL

RUBBEF,

EPLACE

@

. \

43--6r

r+m

({.4-4.2

n.kg,

3a--{6 tt lb)

r.r-r.7

{r1-17,

9.5-15)

Note

.

Drain

he tuet

lrom the

tuel tank

before

1.

Rear eat

cushlon

2.Fuelpumpcover

3.

Fuel

pump

connector

4. Fuel

hoses

5.

Evaporative

oses

6. Fuel ank

straps

F-90

removing

he

tank.

7. Fuel

ank

Inspeclor cracks nd

corrosion

8. Check

alve

twoway)

L

Fuel ank

unit

10.Fuel

vapor

alve

11.Non-return

alve



FUELSYSTEiI

F

lnstallationNote

1. Pushheendsof hemain

uelhose, uel eturn ose, nd

evaporative

oses nto he

uel

ank

ittings i least25mm

(r.0

n).

2.

Pushhefuelfillerose nto he ueltank

ipeand

iller

ipe

al least 35mm

1.4

In).

FUELPUMP

Inspection

ltlaximum

pressure

Warnlng

.

Setore

performing

he

lollowlng operalion,

release

the tuel prcssu|e rom the fuel system o r€duce he

po$lbllily

ol Inlury or

lire.

(Reter

o

page

F-{8.}

.

When inspecting luel system

palts,

keep sparks,

cigarettes,

and open tlames away

rom the fuel,

'1.

Disconnecthe negative aftery

able.

2. Connect fuel

pressure auge

o the uelmain

pipe

and

plug

heoutlet f he uel

pressureauge

sshown.

lnstall

clamos s shown.)

3. Connect

he negativebatterycable.

4.

Connect

iagnosisonnectorerminals

/PandGNDwith

a lumperwre.

5.

Turn

he

gnition witchON or l0 sec.

o operatehe uel

pump

and

measurehe uel

pressure.

Fuel

pressure:

491-658 kPa

(5.0-6.5

kg/cm',

7l.l-92.4

p6i)

6.

Turn

e

ignitionwitch FF nddisconnect

tte

umper

ire.

7.

f not

as

specified,eplacehe

uel

pump.

Conlinully

1. Removehe rearsealcushion.

2. Disconnecthe ueloumD onnector.

3. Checkor continuityetween

he erminals

@

and

@

of

the connector t the

uel

pump

shown

n

the

igure.

4. lf there s no continuity,eplace

he uel

pump.

(Refer

o

page

F-92.)

FUELPUMPCOVER

REAN

SEATCIJSHION

22--.30

12.2-3,

1, 1G-2'

Nfl

(Gks,

n.D)

|

CONNECTOB

F-91



F

FUEL

SYSTEM

-.:-n

@Y...

&

s:'5

4 ; /

GNO

Fuel

pump

oPeration

ound

1.Turn

he

gnrtion wtch

ON

2.

connect

dlaonosis

onnector

ermtnal

/P

o

GND

g

Removehe

r.relfilterap

and

verityhat

hefuelpump

per-

ationsound

s heard.

Replacement

Warning

i-

-riltreri

replacins

ttte

tuel sysiem

parts,

keep sParks,

cigarettes'

and

open

flames

away

lrom

the tuel.

. ieioie oerfotmfns he tollowlngoperalion, eleasehe tuel pressure romthe fuel system o

reduce

he

possibility

ol iniury

or

tire.

(Refer

o

page F-Ear'

1.

Remove

n the

ordershown

2. nstall

n

the reverse

rder

of

in the

igure.

removal.

r.r-r.7

(1r-17,

.s-rs)

*k/

UE!

HOSE,

{30-r

o,

69---eq

WASHEF, EPIACE

2.7

4.1

123-42,

2a---36t

1.Rear

seat

cushDn

2. Fuelpumpcover

3. Fuel

pump

gauge

unltconneqor

4.Check

alve

5.

Fuel

hoses

6.

Fuel

pump

gauge

unit

F-92

7.Fuel

pumpconnector

8. Bracket

9.

Rubber

mounl

10.Fuel

ilter

'11.

FLrel

ump



FUELSYSTEM

F

.F\

FUELFILTER

Replacement

Low-pressure side

Refer

o

page

F-92.

7,a-lr

{a0-r1o,

6r-95)

Hlgh-plessure ide

the fuel iltermustbereplaced t he ntervalsutlinedn he

maintenancechedLrle.

Warnlng

.

Belore

pertorming

the tollowing

operation,

release

the tuel pressure rom the luel system o rduce the

posslbility

ot iniury or

fire.

(Refer

o

page

F-88.)

.

When replacing the tuel filter,

keep

sparks,

cigarettes

and open tlamesaway

lom it.

'1.

Disconnecthe uelhoses rom he

uel ilter.

2. Removehe uel ilterand bracket.

3.

Installn the reverse rderof removal.

CIRCUITOPENING

ELAY

Replacement

'|.

Disaonnecthe negative atteryerminal.

2. Removehe ECU.

Refer

o

page

F-112.)

3. Removehe relaybrackel

4.

Remove

he circuit

opening elay rom he relaybracket.

Inapectionot Continuity

1. Check ontinuity etweenerinals

@

and

@

in the ollow

ing condition.

2. Replace he relay f not as specified.

CIRCUIT

OPENNINGFELAY

f--_-1

Gl'.

r*{ry

I

L.ora\€)

(b_oorqA

T , _-ir

Te.minals

Aoolv

12V

Continultv

{aA

-

G))

@ * @

NO

@ " @

No

F-93



F

FUEL

SYSTEM

PRESSURE

EGULATOF

Irsp€ction

Fuel lne

pressure

WarninE

.

BebA oerforminq

he

ollowing

operatlon,

eleaae

the fuel'presaure lom the fuel system o lsduce the

possibllity

ot

Iniury

or tlre.

(Reter

lo

page

F-88.)

.

When

inipecting

the

pressure regulator'

keep

sparks,ciiaretl$,

and

open

lames

away

rom it'

1.Disconneq

he

negatNe attery

able

2. Connect

fuel

Pressure

auge.

3. Connect

he negative

attery

able.

4. Start

he engine

nd

run t at

idle

5.

Measure

he uel

ine

Pressure.

Fuel ine

Pressure:

235-2i5

kPa

(2.4-2.a

kglcm''

34-40

psi)

Noie

.

The tuel

line

pressurc wlll mt

change

when

remov-

Ing the

vacuum

hose

lrom

the

Plessule

regulator

at ldle.

nepbcement

Warning

.

Betoie oedormlng

the

following

operatlon,

lelease

the

fueipressure

from the

luel system

o lsduce

ihe

possibllity

of iniury

or tire.

(Reler

o

page

F-88.)

. iivhen replaclng tuel system componenta' keep

sparks,

cigareties,

nd

open

lames

away

rom he

lusl.

Cautlon

.

Aller removlng

he

air cleaner,

cover

he lntake

ah

pagsag€ with a ctean

rag to

Protect

the alrtlow

3enaor.

1. Remove

he air

cleaner.

2.

Disconnect

he

negative

attery

able

3. Removehe pressureegulatorsshownn the

igure

4. lnstalln

the reverse

rder

ol removal

INJECTOR

Inspection

(On-vehlcle)

1. Remove

he air

cleaner

over.

Caulion

.

Perform

he

tollowing

nsPection

arelully

o

Pro-

tect the alrflowsensor tom

damage.

2. Start he

enoine

nd

run t at

idle.

3.

Using sound

scope,

erifyhat

njector

peraling

ounds

are

nearo.

3.a--{.a

{35-50,

3O--a3)

OAING,FEPIACE

PRESSUFIE

IEGULATOFI

vAcuuM

HosE

^ \

NJECTTONOOY

F-94



FUELSYSTEM

Removal lnstallation

Warning

.

Betore

performing

he following

operalion,

elgase he uel

pressure

rom the tuel

systemot

reduqe he

possibility

of injury or tire,

(Reter

o

page

F-88.)

.

When

emoving he fuel

syslem

parts,

keep sparks,cigarettes,and open lamesaway rom

the tuel.

1.Loosenhe radiator

rain

plug

and drain he coolant.

2. Removen

the ordershown n the igure, eferringo RemovalNote.

(Refer

0

page

F-95-)

3.

nstalln

the

reverse

rder

ot

removal,eferringo InstallationNote.

(Refer

o

page

F-96.)

7,3-11

(30-110,

69-9s)

GASKET,

SEPLAC€

CIFINGS,FIEPLACE

CUSHION UBBEF, rQ-25O,e-2.6, .-t9)

ad

-e

re-25

0.e-2.6,

.-19)

GASKETS.

EPLACE

1.Aircleaner

2. Water ose

3. Fuelhose

4.

Air

bypass

ose

5. Injecuonody

6.

njector

over

7. njector

Removd Note

.

When eplacinghe njector,

ush

he

njector ozzle

ut

wjtha

plastic

r woodstick.

F-95



F

FUEL

SYSTEM

REPLACE

HION

lnslgllation

Note

.

Use

newGrings,

cushion

ubber,

nd

gaskets

.

Applya

small hount

of silicone

rease

o

he O'rings e

lore

nstallation.

.

Installthe

niector

quarely

nto njection

odyand

do not

twist

t while

nstalling.

. Afternstallation,onnecthediagnosisonnector,/Pand

GND erminals

ith

a

iumper

ire, nd

check

or uel eak'

age

with he

gnition witch

ON.

Refer

o

page

F-96.)

Inspection

Warning

.

whe; inspecting

the iniector,

keep sparks,

cigarettes,

and

open

tlames

away rom

the tuel-

Iniector esistance

1. Disconnect

he niector

onnector.

2.

Measure

esistancel

the niector

ith

an ohmmeter.

Resistance:

-20

(20'C

l68oFl)

Fuel

dakage

est

Caution

.

Perlorm

he

followlng

nspection

arefully

o

pro'

iect the air

bypass

passage

of the

airflow

sensol

lrom the enllance

of dust

or dirt.

1. Remove

he air cleaner

s

shown

n the

agure.

2. Connect

hediagnosis

onnector

erminals

/P andGND

with

a

ilmper

wire.

3. Turn

he gnition

witchON

and

check

or uel eaks

rom

the

njector.

Fuel eakage:

Less

han

I drop/s

minutes

F-96

t



F

OUTLINE

OF EMISSION

CONTROL

YSTEM

OUTLINE

OF

EMISSION

CONTROL

SYSTEM

STRUCTURAL

IEW

The

ollowing

ystems

re employed

o

reduceCO,

HC,and NOx

emissions.

1. Positive

rankcase

entilation

PCV)

yslem

2, Evaporative

mission

ontrol

ystem

3.Catalyticonve(er

W

SOLENOID

ALVE

(PURGE ONTFOI)

CANISTEF

GHECK

VALVE

TWO_WA

AR

-til

F-98



POStrtvE

GRANKCASE

ENTILATION

PCV)

SYSTEM

F

posrilvE

GRANKCASE

ENTILATION

PCU

SYSTEM

DESCNIPTION

The

PCV alve s operated y the

ntakemanifold

acuum.

When he engine

s running t idle, he

PCV alve

s opened lightly nd a

small mount

f blowby

as

is drawn

nto

he

ntakemanifoldo be burned.

Astheenginespeedisesthe CV alvesopenedurther, llowing proportionatelyargeramountotlow-

by

gas

o be drawn nto he ntake

manifold.

PCV VALVE

Inspectlon

1.Warm p he

engineo

normal peratlng

emperaturend

run t at idle.

2. Disconnecthe

PCV alve ndthe

entilation

ose rom he

cylinder

eadcover.

3. Block he

PCV alveopening.

4. Verifyhat

vacuum s telt.

5. Removehe

PCVvalve.

6. Blow

hrough he

valve rom

port

@

and verify hat airflows

lromot

gort

6).

7.

Blow hrbughl-he

alve

lom

port

@

and

verityhatno air-

flows kom of

port

@.

8. Reolacehe

PCVvalve f not

as specified.

F-99



F

EVAPORATIVE

]IIISSION

ONTROL

SYSTEi'

EVAPORATIVE

M]SSION

CONTROL

SYSTEM

DESCRIPTION

INHIBITOH

WITCH

ATX)

THFoTTLE

ENSoF

)\M

\ l h -

s!q.t

OXYGEN

SENSOB

WATEF TH€RMOSE

q_l

rnrrori

sersoa

CANISTEF

@

CHECK

VALVE

FIJEL

VAPOFI

VALVE

Theevaporative

mission

ontrol ystem

onsists

f the

uelvapor

valve' he-ch€ck

alve

two'way)'he

chircoai

canister,

he solenoid

alva

purge

ontrol),

he engine

ontrol

nit

ECU)'

nd

he

nputdevices'

Theevaporative

umes

rawn

nto heengine

ndburned

s

controlledy

purge

ontrol

olenoid

alveThe

ibU a.G"is

fne enqine's

perating

oniitions

y hevarious

nput

evices nd

controlsthe

olenoid

alve

operation

y electrical

ignals

ccording

o these

alues.

Operation

ilie solenoid

alve

purge

ontrol)

scontrolled

y

signalsrom

he ECU

o

periorm

urging

f he

charcoal

canister. urgings donewhen heseconditionsremet:

(1)

After

warm-up

(2)

Driving

n

gear

(3)

Accelerator

pedal

depressed

(4)

Oxygen

ensor

unctioning

ormally

F-l00



EVAPORATIVE

MISSION

CONTROL

YSTEM

SYSTE"

OPEFATION

1 Wam

up he

engineo

normal perating

emperaturend

run I

at idle.

2. Disconnecl

he

vacuum

ose rom

he solenoid

alveas

shown

n hefigure,

nd

verifyhat

novacuum

s eltat he

solenoid

alve.

3. f not as specified,heck hesolenoidalve

SoLENO|D

VALVE

PURGE

ONTBOL)

Inspection

1. Drsconnecthe

vacuum

oses

om he solenoid

alve

2. Verity hat

no air

lows hrough

he

valve

rom

port

@

to

pon

@.

3. Disconnect

he

solenoid

alve

onector nd

apply12V.

4. Verifyhat

air

lows hrough

he

valve rom

pgrt

@

t9

pgt!

CD.

i no air

s

elt,measure

he resistance

l the

solenoid

valve.

Reslstance:

2

+

20

5. f not as

specified,

eplace

he solenold

aNe-

Removal

Inslallation

'1.

Disconnectthe

vaporative

osesirom

hesolenoid

alve

2.

Disconnect

he solenoid

alve

onnector.

3.

RemoveJhe

ut and

he solenoid

alve.

4. lnstall

n the

reverse rder

of

removal.

Tlohtenino orque:

?.4-t

r-Nfl

480-1

O cm-kg,69-95 in-lb)

FUEL

VAPOB

VALVE

Inspectlon

1. Verifu

hatair

lowsthrough

hevalve

rom

port

@

asshown

in he ioure.

'-?j-r1

(30-110,6e-9q

F-10 t



F

EVAPORATIVE

MISSION

CONTROL

YSTEM

2. Verify

hat no

air lows

hrough

he valve

rom

port

@

as

shown

n the

gure.

3.

Replace

he uelvapor

valve

f necessary.

CHECK

VALVE

GWO-WAY)

Inspecilon

1. Remove

he

valve.

2. Check

he operation

f the valve

witha

vacuum

ump.

3. Replace

he check

alve

f not as specified.

CHARCOAL

ANISTER

Inspectlon

1. Visually

heck

or damage nd

cracks

2. Blowair

ntoeach

port

and verify

hat

heyare

notclogged.

3. ReDlace

he charcoal

anister

f not as

specified

Blow ,lrough

valve rcm

Pon @

Applyapprox. 7mmHg 1.46nHg)

vacuumat

port

@

Applyapprox.

4 mmHg

1.73

nHg)

vacuum

at

port

@

F-l02



CATALYTICCONVERTER YSTEM

CATALYTICCONVERTER YSTEM

DESCNIPTION

Thecatalytic

onvertereduces

CO,

HC,and

NOxby chemicaleaction. he

converter

ontains

latinum

and

rhodium

ompounds.

F

01E0F2.1{s

CATALYTIC ONVERTER

Inspection

Ngte

.

The insulatorcannoi be removed.

Removehecatal!4iconverternd

visuallyheck or

deteri-

oration nd cracks.

F-l03



F

DECELERATION

ONTROL

YSTEM

DECELERATION

ONTROLSYSTEM

DESCRIPTION

Thedashpot

s used o

prevent

he hrottle

alve romsuddenly

losing

osuoFxss

DASHPOT

lnsgeclion

1. Open he

hrottle alve

ully.Push

hedashpol

od witha

finger

and

verity hat

t

goes

nto he

dashpot

lowly

2. Releasehe

rod and

verify hat

t

comes

out

quickly.

3. Replacehe dashpot

f

notas specified

4. Warmup the engine

nd

run t at

idle

5. Connect tachometel

o

the diagnosis

onnector

G-

terminal nd ncrease

ngine peed.

DIAGNOSIS

CONNECTOB

6. Slowly ecrease

heengine

peed

ndverify

hat he ever

touches

he dashpot

od at the specified

peed.

Specification:

,500

+

100

rPm

7. f notasspecified,

oosenhe

ocknut nd

urn he adjust-

ing screw o adjust.

F-l04



A./CCUT.OFFSYSTEM

A/C CUT.OFFSYSTEM

DEsihrPrtoN

To mprovedlesmoothnessfter

ust

startingheengine nd o mprove cceleration

erformance,

n

AJC

cut-offsvstem

s used o controlA,/Coperation.

Operation

TheA,/Cs cut off under he conditions elow.

F

THFOTTLE

SENSOR

u'o"""o*'1=:9J-1

fr"

.*,r""

I

IGNITIONSWITCH

MAGNEITC

CLUTCH

DETEFMINATION

E

glne

condlllon Cui-otl

pcriod

Thrcttlevalve ully

open

lmpfoveddravabilily

Accelerationrom stop

:. ;.!9-

rHRorrLE

L'NK

SYSTEiIOPERATION

1. Turn he gnition witch, lowerswitch,

ndA,/C witchON.

2.

Open

he hrottle alveandverity hat he

additionalfantops

for approximately 1 second.

F-l05



DECHOKE

ONTBOL

SYSTEM

tu'rJisO"C

iz"n

or

uelow.

hisallows

he spark

plugs

o dry

and

purges

xcess

uel

rorn hecylinders

DECHOKE

CONTROL

SYSTEM

OESCRIPTION

iJtacifitate tartinq

ne engine

t thespark

plugs

become

ouled, uch

as when he

engine

s looded,

uel

injection

s

cut

t h; thronle

alve

sheldwideopen

whi'e

rankingheengine

f heengine

oolant

empera

SYSTEMOPERATION

1.Ve4fuhat he enqrne

oolant

emperaiure

s below ooc

(32oF)

2. Verii

that he enaine

will not slart

whencranked

t normal peed

with he hrottle

alve

ully

3. f theengine tarta,

nspect

he hrottle

ensor.

Reier

o

page

F-122

and he ECU erminal

U

(Reler

o

page

F-116.)

F-l06

open.

voltage.

CFANK

ANGIE

SENSOE

THFIOTTLEENSOF

WATEFTHEFMOSENSOR

INJECTOF

DEIEFMI.

NATION

cur



AIR BYPASSCONTROL

SYSTEM

AIR BYPASSCONTROL

SYSTEM

DESCFIPTION

Theair bypass ystem perates

o improvedlestability nd vehicle rivability.

Thissystem upplieshrottle

alvebypass ir nto ntakemanilold ccording

o engine

oad

condition nd

driving onditions.

Thissystem onsists t two solenoidalves ontrolled y the ECU.

AA AYPASS

SOLENOIO

ALVE

@

ArF

BYPASS OLENOTO

ALVE

@

AIF BYPASS

SOLENOID

ALVE

@

THAOTTLE

VALVE

Operation t

Ai. BypassSolenoidValve

Englno condltlon

Air

bypa$ aolenold wlve

@ @

Duing cranking

To

improve$anability

o

o

lgnition

wilchOFFrON

To

prcvenl

rorn

slickng

o

'Acc€ssory

ON

To improve

srartability

o

P/S

pressure

w{ch ON

o o

,dJCswilch ON

o

o

Wam up (asoc-8ooc)

o

Selecl

everN-D

(ATX)

To alleviats sudden engine speed

drop

o

Dunng d€celelation

{d€celelation

conlrol)

To improve

divabilty

o o

'Accessory

is headlights, ear windowdefrosler,blowerswilchand coolingJan.

F

F-107



AIR BYPASS

CONTBOL

SYSTEM

FAST DLECAM

SYSTEM

OPERATION

1.

Warmup

the engine

o normal

perating

emperalure

2.

Verityhat

he hermowax

nit

ode)dends utward

ullyand

that

he cam

separates

rom he

roller.

3. lf

lhe electric

ooling

an is operating,

ait

until

t stops.

4. Verify

hat he

engine

s idling moothl,

soLENoto

vALvEO

\

/ry

5.

Verifuhatclick

s

heardrom

heail bypass

olenoid

alve

@

when urning

he

ollowinglectficalload

N

andOFF

Electrical

oad

.

Blower an

.

Headlight

. Rearwindowdetroster

6. Verity

hat click

s from

he air bypass

olenoid

alve

@

when he enoine

tans.

7.Turn

he gnition

witch, lower

witch, nd

AJC witch

ON.

8. Rotate

he hrottle

ink by

hand.

L Verirythatclick

sheard rom

heairbypass

olenoid

alve

@.

F-108



AIR BYPASS

CONTROLSYSTEM

F

AIF SYPASS

SOLENOID

AIF BYPASS

OLENOID

AIR

BYPASS

OLENOID

VALVE

@

DISTFIBUTOR

AIB aYPASS

OLENOTDALVE

@,

@, @

Inspeclion or

contlnuhy

1. Disconnect

achair bypass olenoid alve

onnector.

2. Inspector

continuityetweenhe solenoid

alve

onnec-

tor terminals.

3. Replace

he air bypass olenoid alve

f not

as speciiied.

Inspection

or Airllow

1. nspect

ir bypass olenoid alve

@.

1)Remove

he air cleaner.

2)

Closehe bypass ir

passage

ith ape.

3) Disconnect

he bypass ir hose rom he

air bypass ole

noidvalve

@

as shown n the igure.

4) Verifythat

oairflowsthroughir

bypass olenoidalve

@

whenblowing

ir ighty nto he air

bypass ose.

5)Turn he

gnition witch

ON.

6)

Groundhe ermlnal

@

as shown n the lgure.

4

Verify

hatair lows

hrough irbypass olenoidalve

@

whenblowing

ir

nto

he air bypass ose.

2. Inspect

ir bypass olenoid aive

@, O

1) Bemove

ir bypass olenoiddve

@

or

@.

2) Blow hrough

hevalve fom

port

@

and verify

hatno

air

comesout of

port

@.

3)Apply

12V o the solenoid alve

onnector.

4)

Blow hroughhevalve

rom

port

@

and verify

hatair

comes ut oi port@.

Adiustment

idle-up

speed)

Reler

o

page

F-64.

r-:\*

t r t l W

PATTEFY

__-,/'

d

\

r-i

sotENoto

VALVE

',:,,%rc,!

F-l09



F

CONTROL

SYSTEM

CONTROL

SYSTETI'

PREPARATION

ssT

499200162

Engine

ignal

ECU

49 GO18 03

ECU

49 GO18

04

Sheet

ECU

49 D015 01

49 8019

9AO

Syslem

Seiector

ignitioniming

F- l10



F

CONTROL

SYSTEM

ENGINE

CONTROL

NIT

ECU)

Reolacement

'1.

Remove

n the

ordershown

n the

igure.

2.

Install

n the

reverse rder

of removal

1. Negative

attery

able

2.

ECU

Inspec l ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-112

3.

ECUconnector

Inspection

1. Disconnect

he ECU

connectors.

2. Connectthe

STS

Engine

SignalMonitor

nd AdaPter

Harness)

o the ECU

as shown.

a1EAF2210

F-112

(.3-rr

(60-rr0,69-es)



CONTROLSYSTEM

6 ' d

ffi

o .

3. Place he SST

(Sheet)

on the EngineSlgnalMonitor.

4. Measurehevoftage

t each erminal.

(Refer

o

pages

114

o F-119.)

5. f anyECU ermjnaloltages

ncorfect,heck he elated

inpui

or output evices ndwiring.

f

no

problem

s ound,

replace

he ECU.

Refer

o above.)

Caulion

.

Neverapply voltage o SST erminals

A and

g.

6

-d'

ffi

F-l13



CONTBOLSYSTEM

F

Inco]r€ct Yolt.ge

ROOtvl

0,Alse

burned

Op€n rcuii

n

wi

ng komROO|0A

fuse o ECU eminal14

Main relay mallunclion

Rel6r

o

page

F-124)

Op€n or shortcircuit n wiring rorn main relay o ECU erminal18

Always V

($aner

urns)

.

Open r shori ircuit

n wiringrcm gniton witch

MTX),

r inhlbitorwitch

iAlx)

to ECU erminal C

Main elay

FUEL

NJ etay)mallunclion

Reler

o

page

F-124)

Op€n ircuitn wiing

,rommain elayo diagnosls

onneclorerminal

B

Open r shod ircuit

n wiringromdiagnosrsonn€clor

ermlnal EN o

ECU erminal D

Always battery

voltage

Poor onnectiont

ECIJ onnector

ECUmallunclion

ECUmallunclion

2.5V

No displayon Self-

oiagnosisChecker

Main elay

FUEL

NJ elay)

malfuncllon

Reler

o

pase

F-124)

Open irclit

n wirlngrom

main elayo diagnosis

onnectoreminal+B

' 'SA

displayedand

.

Open or shorl

circuil n wiing

from diagnosis onneclor

erminalFEN o

ECU ermlnal

1F

Always Baliery

voltage Poorconnection l

ECu connector

ECUmallunction

.

Shon

circuit n wirinS iorn

gniter

o ECU eminal

1G

t.4alnelay

FUEL

NJ relay)

malrunclion

Befer

o

pase

F-124)

Poor onnectiont ECU onnector

Open kcuil

n wking romcncuit pening

elay

o ECU erminal l

.

Open ircuit

n wiing romAC

re

ay o

ECLJerminal

J

.

Shon

ncoitn wirng romdiagnosis

onnectorerminalTEN

o ECU erminalK

Alwaysbatlery

vonage

.

Open

ncuitn wiins trom

diagnosisonneclor

erm alTEN o ECU em|

.

Open icuil in wirins

fomdiagnosisonneclor

erminal ND o

ground

AIways V or

Approx. V

.

Open

r shon ircoii n wiring

rcrn

peed

witch

Seclion)to ECU emi

na

1[,1

Always elow

1.ov

sloplights

K)

.

Open ircuit

n

wiring

roms1opllghtwilch

o ECU em

nal10

P/S

ressurc

witchmalluncllon

eier

o

page

F-125)

Short ircuit

n wning rom

P/S

pressure

witch CU

erminal P

ECUmatlunction

Always battery vollage

P/S

ressure

wilch

maltunclion

Refer

o

page

F

125)

Open tcuil

n

wking

romPA

presslfe

wilch

o

ECU e|nrinal

1P

Op€n

ircuil n wiring

romP/S

prcssure

wilch

o

grcund

F-l 15



F

CONTROL

SYSTEM

TenninJ

Input

Oulprd

Test condition

Cor'ecl

Yolage Remark

1 0 o

lgniton switch

ON

PJC W N

and

Below

1 0V

A/C SWOFF

Batlery

ollage

1R

o

Coolingan operaungeng ecoolant

temperaturever

97'C

(207'D

of das

nosls onnectoremina

TFA

gtounded)

Below .0V

Fan nol operatinq

idle)

Batreryolage

o

BlowercontrolswitchOFF

Batery otage

ON

Elower ontrol

witchON

Below

.0v

1 T

o

Rear windowdeilosler

swilchOFF

Below

1

0V

lgnlion switch

ON

Rear w ndow de'rosler

swlch ON

Batlery ollage

o

l-leadliq swnch

HeadlighlsON

Bateryvoltage

HeadlighlsOFF

Below

.ov

o

Neutral/Clutch

swilches

(MTX)

Nedral

posllion

r clutch

Pedal

Below

.0v

Olhers

Batery

oltage

(ATX)

Below

.0V

Others

Banery

oLlage

Ground

lnieclor)

OV

28

Ground

Oulpul)

OV

2C

Ground

cPU)

Constani

OV

2D Ground

lnput)

Constanl

OV

2E

o

(in

disrributoo

(Ne'sisnal)

lgnitionswitch

ON

or

5V

2G

2H

2l

2J

Ground

TITX

Below

1.0V

Open

ATX

Batleryvolage

2K o

Throttle enso/Ec

(ATX)

?t

F-1 16



CONTBOLSYSTEM

F

.

Open ircuitn wiing lromAJC witcho ECu erminal 0

Always baltery vollage

.

A/C sulch maliunclion

Reler

o Section J)

(electc cool ns tan OK) Open r shorl ircuitn wirng

rom

an

retay

o

ECU

effnina

B

ECUmallunction

Alwals

below1.0V

blower

an OK) Shon

ircut n wiring

rom

blower onlrol wilch

o ECLJerminal 5

Poor

onnecliont ECU onneclor

ECU

maltunclion

Alwaysbatlery

voltage blower

an OK)

.

Open rcuit n wirins rcmblower ontrol wilcho ECU erminalS

t .0v

llluminalionamp

ON Op€n r shorl ncuirn wirlngrom earwindow strosl€rwtch o ECU

lenninal T

neverON

Open

ircuit

n

wir

ng rom gnition

witcho

rearwindow elrosterwilch

Fearwndow

defroster

witch

malfunction

Beler

o Section )

Alwaysbelow 1.0V HeadlighlsOK)

. Open r shoncircuitnwiringromheadlighlelayo ECIJ erminalU

Neulfal wilchmalluncton

Refer

o

page

F-125)

Clutch

witch

maliunction

Beler

o

page

F-124)

Shon ircuitn wnino romECU erminalV to neukal r ciltch switch

Neutrai

wilchmallunclion

Feler

o

page

F-125)

Clulch

swlch malfunction

Rerer

o

page

F-124)

Open

crcut

n

widng

rom ECU enninal1V o neutral r clurchswitch

Poor

conneclion t ECU connector

Inh

bilor swltchmallunctionReler o SectionK)

Short ircuitwiringrom nhibitorwitcho ECU erminal

V

nhibitor wilchmallunclion

Refer

o SectlonK)

Openorcult in wiring rorn nhibitor wrtch o ECU rerminal1V

Poor ontacl

l

ground

erminal

Open

ircuit

n

wir

ng romECU o

ground

Always

pprox0V or approx. V

.

Refer o Troubleshooting,

ode No.02

Reler

o

page

F-70)

A ways battery vollage

.

Opencircuilwiring rom o

ground

Shon ircultn wiring romECU enninal K o thrctlle ensor

C

AT convol

unil

ATX),

r ln

aidow

sensor

Poor onnection

t

ECU

onneclor

ECU

mallunclion

Beow 4.5V of above 5.5V

.

ECUmailuncton

F-117



F

CONTROL

YSTEM

- : .

-

Inpui

Oulput

connection

lo

Teal condition

Consct

ontgg

Rcmark

o

Thrcttle

ensor

c_

(ATx)

Accelerator

Pedal

releas€d

Accelelalor

pedal lully depressed

2N o

lgnron

switch

ON

ldle

(cold

engine)

OV

0-0.1v

lncreasng

engrne

speed

altef

warmup)

0.5

1-0v

0-0.4v

20 o

(positive)

lqn,lon sw{ch

ON

ldle

Appfox.

1.2V

2P

o

(negatve)

OV

2A o

Engine

oolant

emperature

0oC

68oD

Below

.5v

2R

o

noid

valve

@

Engine ranking

nd

ew seconds

iter

Appox

2.3V

Other

conditon

Battery

dlage

2S

2T

o

nold valve

@

Accessory

ON

Oth€rs

ondition

Batlery

onage

2U o

hjector

(negative) Constant

2V

o

Inieclor

positive) lgniton

swtch

ON

EngineSignal

I

ash

Below

1.0V

o

noid

valve

@

OFF

ON

Batlery

vdlage

o

Solenoid

alve

(purge

conlroD

lgnition

witch

ON

Baltery

oltage

ldle

Battery

ohge

2\

o

lgniUon

witch

OFF

OV

ON

22

o

EC'AT

onlrol

rnrl

(ATX)

Engine

coolant

empelalurc

elow

70'C

(15860 at rdre

Engine-

oolant

emperaLrre

bove

o'C

Batery

ofiage

F-l18



CONTROLSYSTEM F

Incorrect

voltage

Open ircuil

n wking romECU erm

Open

rcuit n wiringromECU erm

Open lrcuitn w1ringrcmECU erm

nal 2[,1 o throtte sensor

nal 2K

to thrct

e sensot

nal 2D to lhrclile sensor

.

Throtfle ensormrs3dtushent

.

Beler

o

Troubleshooting

ode

No.15

Reier

o

page

F 74)

Always pprox V afler

wamr-up

.

Refer o Troubleshooting,ode No.17

(Refef

o

page

F 75)

Always pprox.

V or approx. V

.

Refer o Troubleshooting,ode No.O8

8efer

o

page

F-71)

.

Open ircuil

n

wirinS

rom

ECU erminal P o airllow ensor

Always approx. 0V or approx.

5V

.

Reier o

Troubleshootns,

ode No.09

Reier

o

page

F

72)

.

Ferer o ftoJblesnoor,ng. ode No.35 Feler o

page

F-78)

.

Feler o T

ouble.hoorng,

Code No 34 (Beler o

pagF F-781

.

Openor short ircuit

n wing irom njector

o ECU

enrinal v

.

Open ircuiln wiins

lrom njeclor

o ECU €minal2V

.

Open or

shortcrcu't in wking frcm ECU terminal W 10air bypass olenold

valve

O

Always pprox. V or approx.

2V

.

Reter o TroubeshoolinS, ode No.26

Reler

o

page

F 77)

.

Oper

crcLrr

1

wrflng rom man

relay

o ECU r€lmrnal Y

Alwaysapprox.

oV or appfox. 12V

.

Openor shoncircuiln wr ng romECU erminal 2 to EC'AT onlrol nit

termlnal

N

F-119



F

CONTROLSYSTEM

USE

CONNECTOFI

CRANKANGLESENSOR

lN

OISTRIBUTOR)

Inspection

1.Bemovehe drslnbutor.

Befer

o SeclionG.)

2. Connect

he distributor

onneclor

s shown

n the igure.

3. Connect

he high-tension

ead.

4. Turn he

onition witchON.

5. Connect

he SSTS

Englne

Signal

Monitor

and Adapt-

el) to the

ECUas shown.

6. Set heSSTS

Engine

Signal

Monitor

and Adapler)

er-

minal E.

7. Botatehe distributorrive

by

handand

measurehe ou!

put

voltage.

Speclflcation

8. After he

nspection,nstall

he distributor.

(Refer

o Section

G.)

9. Stari he engine

nd adjust he

gnition

imlng.

(Reier

o

page

F-63.)

lgnit ion imlngr

BTDC16

+

10

0. Tightenhe distributor

ockbolts o the specifiedorque

Tighlening orque:

t6-23 N.m

1.6-2.3

m-kg,

12-16 tt'lb)

^-

t:,?\

l ; - \ '

l , ! , - , :

ferminal Tesl

condition

Voltago

2E Rorate istributorne ull urn Apprcx.

5V

4

pulses)

F-120



CONTROL

SYSTEM

F

INJECIION

BODY

ATRFLOW

ENSOR

BYPASS

HOT-WIRE

YPE)

lnapoction

1.

Removehe air cleaner.

2. Visually

heck

or

anopen

circuit f

heairflow ensor ot

3. Check he

airflow ensor ody

or cracks.

4. Disconnecthe airflow ensor

onnector.

5. Using n

ohmmeter, easure

esistanceetween

he er-

mrnals.

Speciticaiion

Femoval

Installalion

Reler o

page

F-84.

WATER

THERMOSENSOR

Removal

1. Disconnect

he water hermosensor

onnector.

2. Remove

he water hermosensor

sing

he

SST.

lnboeclion

1. Place

hesensor

n

water

withathermometernd

heat he

water

graduallY.

2. Usingan ohmmeter,

easure

esistancef the

sensor.

3 , 0

n i

(ko)

2

WAIEFTEMPEMIUFIE

{"C I"FD

Terminal

F$islance

(20'C

I68"Fl)

A - B

A - C

B - C

;ffi-fl

INTAXE

FIEPLACE

WATERIHENMO

SENSOR

Coolant

Fesisance

kO)

-206C

| -4aF)

14.6

17.A

o.c ( 32.D

6.5

2o.c

(

68.R

2.21- 2.69

40oc

(10!oR

1 . 0 1 . 3

60oc

(140oR

050,

0.65

80oc

{176oR

0.29- 0.354

F-121



E

a

CONTROL

NIT

THROTTLE ENSOR

Inspection

1. Warm

up

the engine o

normal perating

emperature.

2.

Verify hat he hermowax

nit od extends

utwardullyand

the cam separates

rom he

roller.

3. Stop he engine nd urn

he ignition

wilch o ON.

4. ConnecttheSSTSEngineSignalMonitorandAdaptet

Harness) o

the ECUas shown.

5. Set he SST

(Engine

Signal

Monitor)

o terminal M.

6. Rotate

he hrottle

inkby

handand

veriiy hat he voltage

is within pecif

cations.

Speclflcallon

ECUTerminal

Throtlle

valv€ conditon

2M

0.30

0.80v

7. ll not as

specified,

diusthe hrottle

ensor.

Adiustment

1. Connect

he SST o

the diagnosis

onnector.

2. Setswitch

@to

position

.

3. Set

TESI SW o SELF-TEST.

Note

.

lf the SST s not used, ump

across

he TEN ermi-

nat

and

the

GND erminalsol the diagnosiacon-

neglor.

4. Loosen

he hrottle

ensor crews.

5. Rotatehe

hrottle ensor

radually

nd until hat

he volt'

age

s withjn pecification.

6.

Afleradiustmenl,

ightenhe hrottle

ensor crews

7. Remove

he SST.

Removal Inslallation

'1.

Turn

he gnition witch

OFF.

2. Disconnect

he hrottle

ensor onnector.

3. Remove

he hrottle

ensor.

Cautlon

.

Do not drop

the thloule

aensor.

4.

Adjust he hrottle

ensor fter

nstallation

(Refer

o

page

F-122.)

THFOTTLE

SENSOB

fNJECTfON

BODY

Ztt

n

l.trtg,

tFbl

F-122



CONTROLSYSTEM

OXYGEN ENSON

ONNECTOF

OXYGEN ENSOR

Inapectlon ol Termlnal Voltage

1.Warm p heengineo normal peratingemperaturend

run t at idle.

2. Disconnecthe

oxygen

ensor onnector.

3. Connecta

voltmeter

between

he

oxygen sensorand a

oround.

4. Measurehevoltage hile

ncreasingnd

decreasinghe

engine peed uddenly everalimes.

Specitication

".+try'",,'

-\1

@

o

o

5. Replacehe oxygen ensorf notas specified.

Inspectlonot Sensitivity

1.Warmup he engineo normal peratingemperature.

2. ConnectheSSTS

System

Selector and Self-Diagnosls

Checker) o the diagnosisonnector s shown.

3. Set switch

@

to

position

.

4. SetTEST W o Oz MONITOR.

lnspectionot Heatel

1. Measureesistanceetweenerminals

@

and

@.

Realstance: 0

(20"C

l68oFl)

2. Reolacehe heaterf not as soecified.

MONITOF

5AF-m6|$S6 o€OGR

;O-.

ooo

tl_l

/

1r\

o

r:]

I

5. Increasehe engine peedo between2,000and 3,000

rpm, andverily

hat

hemonitor

amp lashesor

0 sec..

lf not as specified,eplacehe oxygen

ensor.

(Refer

o

page

F-124.)

Monltor amp:Flasheamore

han

S

imes/l0

seconds

6. Replacehe

oxygen ensor

t not as specified.

Engine

ondilron Voltage

M

Below .4

Above0.5

F-123



CONTROLSYSTEM

F

NEUTRAL

WITCH

MTX)

Inspection

1. Disconnecthe

neutral witch onnector hown n

the iqure.

2.

Connect n ohmmetero the switch.

3.

Check ontinuity l the switch.

Replacemenl

1.Disconnect

he neutral

witch onnector.

2.

Remove

he bracket.

3. Remove

he neutral witch.

4. Install

n the reverse

rderof rcmoval.

Tightening orque:

20-29 N.m

2.0-3.0

m-kg, 14-22 ft-lb)

POWER

TEERING RESSUREWITCH

In€pectlon

1.

Disconnecthe P/S

pressure

witch onneclor.

2. Connect n ohmmeter

o the switch.

3. Stariheengine

nd

et

t dle.Check ontinuityf heswitch

while urning

he steering heel.

Contnuilv

Other anqss

4. lf not

as soecified.eolacehe neutral wrtch.

P/S

Continuily

Turnrng

Nol urning

4. lf not

as specjfied,

eplace

he P/S

pressure

witch.

F-125



ENGINE LECTRICAL

tNDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- 2

ouTLrNE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- 3

SPECrF|CAT|ONS.....,...........................-..- 3

TROUBLESHOOTTNG

U|DE......................

- 4

DTAGNOSTTCNDEX.........................,......- 4

SYMPTOIVROUBLESHOOTING......,...,....- 4

GHARG|NGYSTEM.................................

-

6

PREPARAT|ON.......................................- 6

ctRculTD|AGRAM.................................- 6

TROU81ESHOOT|NG..............................- 7

8ATTERY...............................................- 8

A1TERNATOR........................................-r0

DRTVEE1T...........................................- l4

rGNrTtoN

YsTEM,...................................

-r6

PREP4RAT|ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- r6

ctRcutTDIAGRAM.................................-16

T8OU81ESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-17

lGNrTtoNtMtNG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- l8

sPARK

1UGS.......................................

-l9

tGNtTloNo11.......................................-20

DtSTRtBUTOR......-....-.....-......-.....-........-20

tGNlTER. . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . , . . , . . . . . . . . . .-23

HrGH-TENSTONEA0..............................-23

START|NG YSTEM.......................... ........-24

PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-24

CIRCUI'l IAGRANiI................................-24

sTARTER...............................................-25

l



INDEX

INDEX

YTE LEVEL

7Y

\'t

1.Battery

Inspectron......

......

.

paSe

9

Recl'argrng

.............

age

G-

2.

Alternator

Removal

Installataon..........-.......

age

G-l 0

Disassembly

Assemb|y.............

age

G-1

1

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ageG12

3. Drivebelt

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

page

G-1

Adjus tment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

G-14

8ep1acemenl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

G-1

4. High-tensionead

inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

G

23

5. Spark

plugs

Removal

Insta

ation..................

age

G-1

9

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . .

age

G-19

G-2

6.

gnition

oil

(in

he distributor)

-

Inspection..................-...

- . .

page

G

20

7.

Distributor

Spark

est . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

age

G-20

Eiectronrc

dvance

nspeclion

..

page

G-20

Removal/

nslarlation..........

age

G

21

Disassembry

Assemb'y........

aqe

G-22

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . - .

. .

age

G-23

8.

gniter

in

he distrlbutoo

Inspect ion. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .

us"

9-?9

Replacernent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

G

23

L Slarter

Flemoval/

nstallation..........

..pageG 25

Performance

nspection......

....

age

G-27

Disassembly

Assembly

. .....

page

G-28

inspecron.....

...

Page

G-29

8

9



TROUBLESHOOTING

UIDE

o.

-1

Troubl6hooting

lems

Page

will noi crank-starter

motor do€s

not operare

G - 4

2

a

will not crank

slartermolor sp

ns

c F 4

G - 5

Ale 1alorwah

1q laarp

rlu-inares whrc enSLre

unnrng

G - 5

5 Discharged

anery

G - 5

6 Mislire

TFOUBLESHOOTING

UIDE

DIAGNOSTIC

NDEX

SYMPTOM

ROUBLESHOOTING

1

wlll not crank-starter

motor do€s

not

oPerate

]TEP INSPECTION ACTION

1

Does ngine rank

with

ullycharged anerv?

Check

charging

syslem

17

Page

G-7

2

ls banery

vollage

pr€6ern

t

terminal8?

TERMINALB

Check

wiring

harness

3

js

battery

oltage

present

al lerminaj

S with

gn i

lion switch

n START

Posltion?

TERMINAL

S

.

Check

maSnetc

witch

-

Page

G-29

.

Check

leldcol

F

Page

G-30

.

Check

armalure

.?

Page

G-31

.

Check

nhibtor switch

ATX) F Section

K

.

Check

sntof

swtch

r7 Section

T

.

Check

wring

harness

will not

crank-statler

motor spins

JTEP

INSPECTION

ACTION

1

ls

drve

p

n on

pushed

oul

while crankrng

(clck

is heardwhen

pushed

oul)?

Remove

slarter

nd check

lywheel

ng

gear

teelh

and slarier

d

ve

pin|on teeth

Check

magnetic

wilch

e

Page

G-29

G-4



TROUBLESHOOTING

UIDE

3

Cranks

alowly

STEiP

INSPECTION

ACTION

l

Does engine

crank normallywilh

ully charged Check

m'girg syslem

s

Page

G-7

2 Are $aner cable

connectionsooseor

corroded?

CHECK

HECK

Bepairor repace connecton

Ch€ck

stadff lor binding

such

as

bruslrand

armature.)

4

Altemalor

waaningamp llumlnates

whileengine

unnlng

INSPECTION

ACTION

1

ls baneryvoltageconect al

idle?

Specificalion:

4.'l-14.7v

Ch€ckwring

haness benreen

arcrna-

lor L teminal and alternator

warnlng

Check chaelng

system

c?

Page

G-7

Discharged

bsttery

INSPECTION ACTION

1

Check

haelng

system;s t OK?

l?

page

G-7

Tum

gniuon wilchON and

measurc

darkcurrcnl

s shown

Dafkcunenr: elow 0mA

Repair r

replace

arts

as

necessary

G-5



CHARGING

YSTEM

49 9200020

Tension

auge,

CHARGING

YSTEM

PREPARATION

ssT

Thealternator

asa self-diagnostic

unction

o warnof the

ollowing

roblemsn the

charging

ystem-

lf a

problem

rises,

he alternator

arning

ampalluminates

1.Terminal circuit pen

2. No voltage

utput

3. Field oil circuit

open

4. Terminal

circuit pen

5. Voltage utput

oo

high

G-6

CINCUIT

DIAGRAM

I

I

I

CHAFTGE

AMP

T

BATIEFY



CHARGING YSTEM

TROUBLESHOOTING

INSPECTION

acno

1 Check battery

voltaget is il

cofiecP

Spocltlcatlon: Above 12.4V

Chec( batlery rt_

page

e-a

2 SrarlenEnei does allernarorwarn^g

lamp go

Go to ne,( slep

Go io Slep 4

3 ls voltage al alternalor term nals coffect?

SpeclllcElion:

l o n . O N M

14.1-14.7

L 14.1-14.7

S 14.1 14.7

Checkwiringharness etween erminal

.

Checkwiringharness

.

Replacealtefnator F

page

G-10

1.

Connecl

n

ammeler

70A

min)

between

terminai

and haness

2. Starl ngine

3.

Turn

all

electricaoads

ON anddepress

4. ls

output

urrenl65A

r

more

al

2,500-3,000 pm?

Caution

.

Do not

grolnd

terminal a

Chargingyslem orna

5 is drive belt e nsionOh?

N

iks,

b)

Drive belt

451-745

(46-80,

101-176)

392-588

(40-60,

88

132)

491 589

(50

60.

1 1 0 1 3 2 )

422 491

(43,50,

95 110)

Replacealternator

e

pag€

G-10

.

Adjustdrive belt €nsion

G-7



CHABGING

YSTEiI

BATTERY

Inapecllon

Electrolyte

evel

1.Chec{

the

electrol}4e

evel ies

between

he

upper

and

lower

ines.

2. f low' add

distilled

ater; o

not overfill.

Speclfic

gravily

ol electrolyte

Measure

he specific

ravitywltha

hydromeler'

Specilication:

1.27-1.29

(at

20"C

168'Fl)

Voliage

leat

Check battery

voltage

Ouick-charge

ol s

minutesno

ouick-charse

r

1-3

hours

I

l l

Below 12.0V

Above

12 0V

Ouick-charge

or

3-4

hours

"*o*Cu

-----*J',ou

I

Quick

charge

or 30

minutesancl

rccheck

vollage

rf=r

Below 2.4V

Above

12-4V

G-8



CHARGING YSTEM

40

(164)

0O

076)

TEMPEFATURE

CTFD

Te]mlnaland

cable

1 Checkhe ightness

f he erminalso ensure

ood

eli?ctri-

cal connections.

2. Check

or corroded r rayedbattery ables.

3. Check he

rubber

protector

n he

positive

eminal or

proP

er coverage.

4.Cleanhe erminalsf necessary,nd coat hemwithgrease.

Slow{harging

It is not necessaryo removeheventcaps.

Ouick-charging

Remove

he baneryrom he vehicle

nd removeheventcaps.

Warning

.

Beto.e

pertorming

malntenance

r rechatging he

banery, urn

ofl

all

a@essories

and stop the

€ngine.

. The negative ablemusl be removed irsl and in-

stalled

ast.

.

Sel the battery

n water

when

quick{harging

to

pre-

vent overhealing he

battery.

Recharging

Battery Slow harge

4

Ouick

charge

(A)

3itB19L€

Under

lvlax. 20

G-9



CHARGING

YSTEIIiI

ALTERNATOR

Removal

Installation

Cautlon

.

Be sqre

the battery

connections

are not

reversedbecause

his

will damage

he reclifier'

.

Do not

use high-v6hage estefs

such

as a megger

because

hey

will damage

he

rectitier'

. Rememberh;t battet vottage s alwayspresentat the alternator erminalB'

.

Do not

ground

erminal L

$rhile he engine

s

running.

.

D,onot;tart

the engine while

the connlctor

is disqonnected

rom terminals

L and S'

1. Remove

n the order

shown n the

igure, eferring

o Removal

Nole.

2. Installn the

reverse rderof

removal,

eferringo lnstallation

Note

7,r-11

|}n

{3o-r

r0 cGrs, 69-95

h.lh}

19-25

O,e-2,6

.-r9)

37-52

(3.5-5.3,27-33)

1. Negative

attery able

2. Connector

3. Mounting olt,adjlst nut

4. Drivebelt

Inspedron. . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . -

AdJustment . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement . . . . . . . . . .

. . .. . . . . . . . . . . . . . .

G-l0

5.

N4ouniing olt

6.

Alternator

Disassembly

Assembly.... . . . . . . . . .

age

G-1

1

Inspec t i on . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -

ageG-12

page

G-'14

page

G-14

page

G-15



CHARGINGYSTEM

Removal lnstallationNote

Thealternators emoved nd nstalledrom

underthe

ehicle.

0rEoGx94

Disassembly

Assembly

1. Disassemble

n

the ordershown n the

igure.

2. Assemblen the reverse rderof disassembly.

orEoGX015

1. Nutset

L Stator

2. Pulleyet

Inspection..........-........................

age

G

12

3. Front over 9.

Regulator

4. Bearing

10.Rectifier

1nspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

G-12

lnspect ion. . . . - - . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

G

13

5.Retainer 11.Brush older ssembly

6. Spacer

Inspection

7.Rotor

(Brush

nd

brush pring).........

age

G-13

Inspect ion. . . . - . . . . - . . . . . . . . . . . . . . . . . - . . . . . . .

age

G-12

12. ear racket

G-11

bN

#9_,5.$-?.3

(60-30,

53-70)

3.2-3.9

(33-39

2S-33)

3,2J.s

($--ne,

2e-3E

46J3 Nm (4,7-5,4

ckg, 3.r-4G fi-lbl

r.6-2.0 (i6-20. 14-13)



CHARGING

YSTEM

Inspectlon

Rolor

1. Usean ohmmeter

o measure

he

resistance

etweenhe

slip ings.

Specilicatlon:

.4-2.90

(at

20"C

[68cq)

2. l not within

pecilication,

eplace

he

rotor.

3.

(1)

Usean

ohmmeter

o check

continuity

etween

achslip

rinoand

he core.

(2)

Replacehe

rotor

f there

s

continuity

4. Ule

tinesandpaper

o

smooth

ny oughness

n he

slip

nng sunace.

Stator

1. Usean

ohmmeter

o check

ontinuity

etweenhe stator

coil eads.

2. Replace

he stator

f there

s no continuity.

3. Usean ohmmeter

o check

ontinuity

etweenhe

stator

coil eads nd

he core.

4. Replace

he stator

f there

s continuity.

Bearlng6

1. Check or abnormal

oise,ooseness,

nd sticking.

2.

Replacehe bearing(s)

l necessary.

01E0GX.020

G-l2



CHAFGINGSYSTEM

Rectiller

Cautlon

.

Don't uae megger ester to

p€vent

lhe

reclifier

trom

breaklng

down.

1. Useananalog hmmetertoheck ontinuityfhe diodes.

2. Replacehe

rectifier

f

necessary.

Bruah

lf a brush s wornalmosto

the imitor beyond, edaceall

the brushes.

Siandad:

25.0mm

0.984

n)

ilinimum: 6.0mm

0.236

n)

Brush apring

1. Usea spring

pressure auge

o

measurehe orceof he

brush pring.

2. Replacehe

spring f not within.

Standard lorce:

2.9-3.9 N

(300-400 g,

10.6-14.1 oz)

Minimum:

0.8-1.2

N

(80-120

g,

2.8-4.2 o2)

Note

.

Read he spring

pressure

wlth the brush ip

proiect-

Ing 2mm

(0.079

n).

Conlinurty

E

B

NO

E

NO

B

G-13



CHARGING

YSTEM

DRIVEBELT

Inspection

1.Check

hedrive

elts nd

pulleys

orwea., racks, nd

lay-

ing. Replace

s necessary.

2. Nleasure

rive

belt ension

witha tenslon

auge

Tension N{ks,b)

3. reasurethe

eflection

yapplying

moderale

ressure

98

N, lO kg, 22

lb) midway

etween

he

pulleys.

djust

f

necessary.

Detlection rnmrn)

Adiustment

1.

oosen

bolls

A)

and

@.

2. Move

he alternator

n or out

as necessary

y urning

d-

iustino

ur

O.

s. ignt6n ootd@ and@ and

recheck

he beltdeflection

Tidhtenino orquea

Boh

E;19-26

N.m

1.9-2.6 m-kg,

14-18

ft'lb)

Bolt

@:

38-51

Nm

(3.8-5.3 m-kg,

28-38 ft'lb)

Dfive belt

451

745

(46-80,

101-176)

392-588

(40-60,88

132)

A/C and P€

49t-589

(50-60

110

132)

422-491

(43,50,

95-110)

Dflve bell

5.5

7.0

{0.21

0.28)

6.0-7.5

(0.23-O.30)

AJC and

P/S

8-9

(0.31-0.35)

9-t 0

(0.35-0.39)

G-l4



CHARGING

YSTEM

Replacement

1.

Bemove

he uC and

P/Sdrivebelt.

t equipped

Note

.

Retel

to B Section,

2. Loosen lternatorotts@ and@.

3.

Removehe

afternatoreli.

4.

Installtheew

alternatorelt

andadjust

tto specifications

5.

Tighten ll bolts

o the specified

orques.

Tighlening

torques

Mounling

bolt:

38-51

Nm

(3.8-5.3

m-kg,28-38

fi-lb)

Adlusting

bolt:

l9-26

Nm

(1.9-2.6

m-kg, 14-18

ft-lb)

6. Install

he AJC nd

P/Sdrive

beh i equipped, nd

adjust

it to specificataon.

Note

.

Reter

o B Seclion,

G-15



IGNITIONSYSTEi/I

IGNITION

SYSTEM

PREPARATION

ssT

49 80199A0

System

S€l€clor

self-diagno€is

nd

igniton iming

49 HO189A1

Self-Diagnosis

Checker

sell-diagnosis

CIRCUIT

IAGRA''

GFOUND

TACHOMEIEFi

DTAGNOSTS

CONNECTOF

IGNITION

WTCH

G-16



IGNITION YSTEM

TNOUBLESHOOTING

6

fi6tire

JTEF

|lrsPEcTtoN

ACTION

ls

"00

'

displayed

on

Self-Diagnosis

hecker

with gniton swilchON?

.?

p.ge

F-67

llallunctioncode no. displayed

Checkor cause

Beler

o specified

checksequence)

E7

Page

F-67

"8a"

tlash€s

Check

ECU eminal

lF voltage

t7

psge

F-114

Vollag6: Approl

l2v

(lgnilioh

switch

ON)

4

li

OK,

replace ECU

(j

page

F-112

+

lf nol OK, check

wiring

harness

belweenECU and

SelfDiagnosis

2 Bemove park

plugi

s

here

a

slrong

blue park

whie engine

s

cranking?

lgn ion syslem

s

normal

Checkspark

pug r?

gage

G-2O

lf OK, Go o next step

lf notOK,clean r

.eplace park

plug

3 ls resistance t high-tension

eadsOK?

specification:

16 m

per

lm

(3.28

l)

c?

page

G-23

Repac€ high ension

eads

Afe here orroslon,amage r cracks n he

disrribulorap androtof

17

page

c-23

5

ls ignitron oil nomal,

(7

page

G-2O

6

Aredisrributoronnectornd

ECU

connector

Measure

oltage

ot

@

termlnal

(dislibutoropconnector);s l coffec?

Voltage:

Apprcr. l2v

Check

main use,

gnition witch,

wiflng

harness, nd ECU

I

ls ECUnormal?

l?

page

F-r12

Replace

ECU

G-l7



IGNITION

SYSTEM

---.--.-

_e\,t-

tc_

IGNITION

IMING

Adiustment

1.

Warm p

heerg'ne

o

normalperaling

enoeralure

nd

run

at

rdle

P

ranqe

ATX]

r

neLtrdl

L4TX])

2. Turnall

electrical

oads

OFF.

3.

Turn he

uC switch

OFF.

4. Connect test achometero hediagnosisonnectorG-

terminal.

5. Connect

he SST

to the diagnosis

onneclor.

6-

Setswitch

on he

System

elector

o

position

and

TEST

SWITCH

o SELF

EST.

Note

.

To create

he est

condition

without using

he

Sys'

tem

Selector,

connect

erminals

TENand

GNO

of

the diagnosisconnector

wiih a

iumper

wiae.

7. Check he

dlespeed

and set

t to the

specitied

peed

t

necessary.

ldle speed:

600-650

810-860

15."u-t'\

- , €=4

,N.

rpm

rPm

(MTX)

(Arx)

8.

Check he

gnii ion

iming.

Specification:

BTDC

16

+

1'

9.

ll

the

gnrtron

im ng

is nol as

specilied

oose'l he dislribL

tor |oc: bofts nd

urn

le dlsllibt

ol

Io makelhe

adiugment

1O- ighlen he

dlstributor

ock bolts

o

specilied orque.

Tiohteninq

torque:

ie-za

-H.m

{i.s-z.s

m-tg,

12-16ltlb)

G-l8



IGNITION

SYSTEM

)x

SPARKPLUGS

Removal Installation

1. Remove nd nstallhe

high-iensioneads arefully.

Caution

.

When he spark

plug

lead s to be

pulled

ofi,

pull

on the boot itself, not the wire.

2.

Remove nd

nstailhe spark

p

ug

with

a

plug

socket.

Caution

.

Be sure the socket

must be tit squarelyover

he

spark

plug.

3. Apply ntiseizeompoundrmolybdenum-basedubricant

to the spark

plug

hreads.

4. Tightenhe

spark

plug

o the specifiedorque.

Tightening

orque:

15-23 N.m

1.5-2.3

m-kg,11-17 ft lb)

Inspection

1.

Remove

he

spark

plug.

2. Connecthe spark

plug

10

a high-tension

ead.

3. Hold he highiensionead

wth insulated

liers

-1omm

(0,20-0,39

in) froma

ground.

4. Crankheengine ndverifyhat heresa strong lue park.

Note

.

It there

s no spark, eplace he spark

plug

or high"

tension

ead

as necessary.

5. Checkthe

ollowing.f

a

problem

sfound,

eplacehespark

plug.

.

Damaged

nsulation

.

Wornelectrodes

.

Carbon eposits

ll cleanings necessary,se

a

plug

cleaner r a

wtre

brush.Clean he upper

nsulator lso

.

Damaged

asket

.

Burned ondition

Plug

gap:

1,0-1,lmm

(0.039-0.043

n)

CAFBON

BURNED

G-19



IGNITION

SYSTEIIi|

IGNITION

OIL

Inspection

Primary

coil

rvindlng

use an'ohmmeler

o

ineasurees

$anceol

he

pIimary

oll

winding.

f not

within peciflcation,

eplace

he gnition

oil.

Specification: .68---0.840al 20oC 68"F1)

Elecironic

Advance

nspectlon

Verify

hat the

ignition iming

advances

with engine

ac-

celeralon.

Secondary

oil

windlng

Usean ohinmeter

o

measure

esistance

f

he

primary oil

windlng.

f not

within pecification,

eplace

he gnition

oil.

Soeciflcalion:

9.6-14.4

ko

(at

20"C

[680Fl)

Reolacement

1. Replacehe

distributor.

Refer

o

page

G-21.)

2. Adiust

he gnltion

iming

(Refero

page

G-18

)

01aoGXo40

DISTRIBUTOR

Spark

Test

1 Disconnect

he

hiqh-tension

ead

roma sparK

lug.

2. Hold

he ead

5-iomm

(0.20-0.39

in)

rom

a

ground.

3.

Cfank he

engine nd

verify

hat a

strong

bluespark

s

visible.

/

G-20



IGNITION

SYSTEM

Removal Installalion

1.Removen the ordershown n

the

igure.

2. nstalln the reverse rder

of

removal.

o140cx.019

'1.

Negative attery able 4.

Mounting olt

2. High-tensionead

5. Distributor

lnspection...-...............................

age

G-23 DisassemblyAssembly.............

age

G-22

3.Connector 1nspec1ion..................................-

age

G-23

G-21

{r.c-2.3

Gtg, 12-16 ft-tb)

2

a''

,:t,



IGNITION

SYSTEM

Disassembly

Assembly

'1.

Disassemble

n the ordershown

n

the

rigure

2. Assemble

n the

reverse rderof

disassembly,

eferring

o Assembly

Note.

ef

^ )

,

r,o-2,0

o0-20,

0.7-1n

1. Cap

4

Crank

angle

sensor

nd gniter

Inspec1ron...................................

age

G-23

lnspection

.....

page

G-23

2.

Rotor

5.

gnition oil

Inspection...................................ageG 23

-

InspecUon .. pageG-20

3. Cover

G-22



IGNITIONSYSTEM

Inspectlon

Capand

rotor

1.Check

orcorrosion,amage,ndcracks.

2. Replacel

necessary.

01E0GX.055

IGNITER

lmpqction

1.Check he

ECU.

Refer

o

page

F-| 12.)

2. Check hecondition f the connector,

istributorap, o-

tor, gnition oil,and high-tension

eads.

3. l allarenormal utmisfire tilloccurs,

eplacehe gniter.

01a0GX.021

Feplacemert

1.Replacehe distributor.

Refer

o

page

G-21.)

2.

Adjust he gnitioniming.

Refer

o

page

G-18.)

OlAOGX€2

HIGH-TENSIONEAO

Insp€ciion

1.Measureesislancef

high'tensionead.

Spscification:

16 m

per

I n

(3.28

f)

2. f notas specified,eplacehe high-tensioneadset.

G-23



STARTING

SYSTEM

49 E3011'14

---)

.-\J--6-)

\--=---

installalton l

STARTING

SYSTEM

PREPAFATIOI{

ssr

CIRCUIT

DIAGRAI'

PULL]N COIL

FIELDCOI

G-24



STABTING

SYSTEM

STAFTEN

Inspection

on

vehicle)

1.

Measure

he battery oltage.

Specitication:

bove 12.4v

2. Crankthengine, ndverifyhat hestarterurns moothly.

3. lfthe

stader oesnot urn,

heckthe oltage fterminalS.

4.

lf

the

voltages above V,

emove nd

nspecthestaner.

ll the

voltages below V,check

hewiring

arness,gni-

tion

switch, nd nhibitor Mich

ATX).

01E0GX.O60

Rgmoval Installation

'1.

Removen the order

shown n the igure, eterringo

RemovalNote.

2. Installn the revers€ rder

of removal,eferringo Installation

Ngte.

ATX

a7-5r l+n

(3.&-5-3

m.kg, 2H3 n

|b)

(t.3-5.3

rkg, 2a-33

fi.rb)

1. Negative attery able

2. S terminal,

terminal 3.

\.4ounting

olt

connector

G-25



STARTING

SYSTEM

rl-25

l+n

O.9-2.3

rlq,

'a;^

37-51

n

(3,3-s.3

rl(g, 23-$

n.|b)

1. Negative

attery

able

2 Terminal

onnectors

and

B

3 lvounting

olt

G-26



STARTING

SYSTEM

Removal Insiallation Note

ATX

Thestarters removed nd nstalledrombelow he

vehicle.

MTX

Thestarter

s removed

nd

nstalledromabove.

01A0GX{25

Pe.tormance Inspection

i,lagnetic awltch

Disconn€ct

he erminal\,4 ire,and

perlorm

he ollowingests.

Pull-ln est

Theswitchsnormal

f

heoinion iects

utward hen hebat-

tery s connected s shown n the igure.

Caution

.

Do not apply

power

continuously

or mote han 10

aeconqs.

Hold-ln esl

Aftercompletinghe

pullin

test,disconnecthe wire rom er'

minalM

(with

he

pinion

eftejected).

heholdin oil s unc-

tioning

properly

f the

pinion

oes

not return.

Adiuahent of

pinion gap

1. Disconnecthe wiring rom erminal

M

2. Whenhebattery

s

c;nnected

etweenerminal and he

starter ody,he

pinion

illbeejected nd

hen

top.

Meas-

ure heclearance

pinion ap)

betlveen

he

pinion

nd

he

stoooer.

Note

.

Do not apply

power

continuously

or more han 10

aeconds.

Pinlon

gap:

0.5-2.omm

(0.020-0.078

n)

3. lf the

pinion ap

snotwithin pecficaton. ake djustmenl

by ncreasingr decreasing

he number fwashers etween

the magnetic

witch

nd he drive

housing.

ihe

gap

be'

comes maller

s the number i washers

s

increased.)

G-27



STARTING

SYSTEM

o-r2

(so-l30,

79-ii2)

Disassembly

Assembly

i.'-o-iJiJi.6r"

in the

ord;r shown

n the

figure' elerring

o Disessembly.

ote

i.

iiGii,r.ln

*"

,""erie oroer

of disasse-mblv,

eferring

o Assembly

Note

1.

Magnetic

witch

5- Front

over

l;spection...... Page

G 29

9 eYe'

. .

2. Rear over T DrivePinion

3. Brush

older

assembly

B Armature

Inspection...............................

.

page

G-30

Inspection""

"

"

page

G-31

4. Field oil

Inspection.................................

age

G-30

G-28



STARTING YSTEM

DisaasemblyNote

Drlvs

plnlon

Removehe stopper

or

the overrunninglutchwitha

pipe

as snown.

Assembly Note

Drive

pinlon

1. Set hedrive

pinion

nto hearmature nd

nstall

he ring.

2. Installhe stopper

with

he SST

and

press

t,

as shown.

Inspoctlon

agnetic awilch

1. Usean ohmmetero check ontinuity etween

he

S and

M erminals.eplacehemagnetic

witchf here s

nocon-

tinuity.

2.

Useanohmmeter

o check ontinuityetweenheS ermi-

naland he body.Replacehe magneticwitchf there s

no continuity.

3. Usean ohmmeter

o check ontinuity etweenhe M and

B termanals.

eplacehe magnetic witch

l

there

s

con-

tinuity.

G-29



STARTING

SYSTEM

Brush and

brush

holder

1. Usean ohmmeter

o check ontinuity

etween ach

nsu'

lated brush

and

the

9late.

Replacehe

brush

holderl there

s continuity.

2. Usea spring

balance

o measure

he

orceol

the brush

spring.

Standard:

18.9-23.1

N

(1.89-2.31

9,

4.18-5'12

b)

3. Replacehe springf notas specified

Brush

It

a brush

swornalmost

o he

wear imit

or b€yond'

eplace

all he brushes.

Standard:

17mm

0.67 n)

Minimum:

l.smm

(0.453

n)

Field

coll

1.

Use

an ohmmeter

o check

ontinuity

etween

he M

ter-

minalwireand

hebrushes.

eplacehe

yoke

assembly

f

there s

no contnuity.

2. Usean

ohmmeter

o check

ontinuity

etween

he M ter:

minalwire

and he

yoke.

Replacehe

yoke

assembly

f there

is continuity.

3. Check

l

the ieldcoil

s oose.

Replace

he

yoke

assembly

if it is.

BAUSHSPFING

WEAB LIMIT

STANDARD

01EOG) O73

G-30



STARTING

SYSTE

Armatur€

1. Usean ohmmeter

o check

continuity

etween

he com-

mutator

nd hecore.

Beplacethe

rmature

tthere

s

con-

tinurty.

2. Usean

ohmmeter

o check

ontinuity

etween

he com-

mutator nd

heshaft.

eDlacethe

rmature

ltherescon-

tinuity.

3. Place he

armaturen

V-blocks,

nd

measurehe runout

witha dial

ndicator.

lfthe unout

s notwithin pecification,

epair

t witha lathe

or replace

he armature.

Runout:0.05mm

0.002

n)

4.

Replacehearmature

t

theoutel

diamele'

f hecomrru'

tator s almos(

t or less han

he

rnlnlmum

5. t the

commutator

urface

s dirty,

wipe t witha

cloth; f it

is rough, epair

t witha

latheor

tinesandpaper'

Gdnd

lmlt:31.4mm

1.23

n)

6. ll thedepth

of

hemoldbetween

egments

salmost t or

less

han he minimum,

ndercut

he

grooves

o he stan-

darddepth.

Depth

:

0.5-0.8mm

(0.02-0.03 in)

Minimum:0.2mm

0.008

n)

G-31



CLUTCH

rNDEX.............................................,.,......

- 2

ouTL|NE..,,,....,.,...,........,.........................

- 3

spEctFtcATtoNs....................................

- 3

TROUBLESHOOTTNG

U|DE...........,....,.....

- 3

cLuTcH

PEDAL.....................................,.

- 4

ADJUSTMENT...............................,..,.,...- 4

REMOVAL

INSPECTIONINSTALLATION.,

-

5

CLUTCH ABLE,..............................,.......

- 6

REMOVALINSPECTIONINSTALLATION..

- 6

GLUTCH NtT.....,..........-........................

-

7

PREPARAT|ON..,....................................

- 7

REMOVALTNSTALLATTON.....................

- I

CLUTCH OVER,........-............................

-l

1

tNSPECTtON......,...................................

-11

cLuTcH

Dtsc ...................,.....................

-r1

tNSPECTrON.,.....................,.,.,,.............

-r1

RELEASE OLLAR.............. .............,....,.,.

-i2

tNSPECTtON..........................................

-12

PTLOT EAR|NG.......-..............................- '2

1NSPECTtON. . . . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . .

-12

FLYWHEEL........................-.....................

-l2

rNSPECTtON................,.........................

-12



INDEX

INDEX

TFANSAXLE

ERVICE,

SECTION

CLUTCH

WITCH

EFVICE.

SECTION

'|.

Clutch

edal

Inspection

Adjustment

....

. .pageH-

4

Bemoval

Inspection

Ins ta | |a t ion

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

H

5

2. Clutch

able

Removal/

nspection

Installat ion

...

.. ......

....

age

H-

6

3. Release ollar

Removal/

nstallation......

.....

page

H- 8

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

page

H-12

4. Release

ork

Removal/

nstallation...

.-.-

. ..

page

H- 8

H-2

5. Clutch

over

Removal/

nstallatron... . .

.

pageH- 8

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . .

ageH-11

6.

Clutch

isc

Removal/

nstallat ion

. ..........

age

H- I

Inspection.......................

. ..---..

age

H-11

7. Pilotbearing

Removal nstallalion

. .

page

H- 8

lnspectron..

Page

H-12

8.

Flwheel

Removal/

nstallalion

..

page

H- I

Inspection..................

.

.

page

H-12



OUTLINE. ROUBLESHOOTING

UIDE

H

OUTLINE

SPECIFICATIONS

Enghe/Transarle

Itodel

B3

B5Mfi

Diaphragmprng

S€t

load N

(kg,

lb)

2 943

(300,

60)

Clutchdisc

Ouler

dameler mm

n)

180

O

lnnerdiameter rnm

jn) 12514.92)

Pressure

late

mm

(ln)

3.2

0.126)

Rywheelside mm

(in) 3.0

0.118)

Clutch

pedal

Type

5.83

Full

svoke mm

(in) 138

s.433)

Helsht

Wlh

carpet)

196,207

\7.72-8.15)

TBOUBLESHOOTING

UTDE

Problem

Poaslble Cause

Page

Slipping Culchdisc acingwornexcessiveiy

Cbbn disc acing urface ardened r oiled

Pr€ssure

late

damaged

Diaphfaqmprangamaged r weakened

Insuflcientlurch edalplay

cturch

edat

licking

H - 8 , 1 t

H 8

H - 8

H - 8

H - 4

H - 5

H - 8

Faulty db€n-

gagoment

Excessiveunoul

or damaged lulch

disc

Cldchdiscsplnes usled i worn

Diaphragmpringweakened

Excessive lutch

pedalplay

Rernove

ust or repace

H- 8,

11

H - 8

H 8

H - 8

H - 4

Clulch vibraies Clutchdisc oiled

Torsion ubbersweakened

Clutchdisc

tacing hardened

r

damagod

Clutch disc lacing ivels oose

Diaph€gm springweakened

Pressure

lale

damagedor excessive unout

Flwheel surfacehardenedor damaged

loose or

worn engrnemoum

Tighlenor replace

H - 8

H - 8

H 8

H - 8

H - 8

H - 8

H , 8

Feler

o Secuons

,

J

Clutch

pedal

3licking

Pedal

shan

nor

prop€rly

ubricated

CLutchelease oilff damaged

Poor ubricalon f r€leaseollar leeve

Torson ubbercwsakened

Excessive rankshalt nd

play

Pilor

bearing

worn or

damaged

Worn

pivot points

oi

re

ease

ork

H- 8,

11

H - 8

H - 8

neier

to Section

B

H-

A, 12

H 8

H-3



CLUTCHPEDAL

REIIOVAL INSPECTIONINSTALLATION

1. Removen the ordershown n the

igure.

2.

Inspect

all

pads

and

repair

or replaceas necessary.

Note

.

Apply lilhium

bas€d

greaas

to the bushlng and

pins

b€tore

installation.

3. lnsiall n the revers€order of removal.

4. After nstallation, erify he clutch

pedal

ree

play. (Refer

o

page

H-4.)

\q

' €

1.Adjusting ut

2. Clutch able

3. Pedal

pad

4. Nut

5.

Lockwasher

6. Bolt

7. Bushing

L Spring

10.Clutch

edal

H-5



CLUTCH

CABLE

CLUTCH

CABLE

REIIOVAL

/

INSPECTION

INSTALLATION

1.Remove

n the

ordershown

n the

igur€.

2.

lnspect

all

parts

and repair or

replace

as necessary.

Note

;

Apply firhlum

based

gtease

lo lhe

pln

and lhe

release

leve]

bslore

installation'

3. nstall

n the

reverse rder

ol removal

4. Alter

installation,

erity he

clutch

pedal

ree

play.(Refer

o

page H-4.)

\-,-

\\

1.

Adiusting ut

2.

Pin

3. Clip

H-6

4. Clutch

able

Inspect

or damage

Adjustment................................

age

H-4



CLUTCHUNIT

H

CLUTCH

UNIT

PREPAFATION

ssT

49 E301 €0

Brake,ing

gear

engine olation

49 E301 61

Body

49 E301 60)

49 E301062

Collal

(Parl

ol

49

E301 60)

engine otation

49

SE01310A

Cente ng lool,

49 1285071

Pu er,Jle€dle

-G:

b€aring

49 1285073

Chuck

ead

ol

49 1285 71)

beanng

H-7



CLUTCH

UNIT

REI'OVAL

INSTALLATION

Note

.

Dq

not rcmove

the

pilor

bealing

It not necesaary,

1.

Removen the

ordershown

n

the igure, eferring

o Removal

Note

2. Installn the reverse rderof removal,eferringo InstallationNote.

t5-r03

p.a-r0.5,

7r-761

ra-2a

o

V

1.Transaxle

service

"

" section

J

2.

Return pring

3.

Releaseollar

Inspection...................................

age

H-12

4.

Reamer olt

5. Release

ever

6. Releaseork

7. Clutch

over

Removal

ote....

.. ...

. .

page

H- 9

Inspection...................................

age

H-11

Installat ion

ote..........................

age

H-11

H-8

8. Clutch

disc

Removal

ote....................

....

age

H- 9

lnspection...................................

aSe

-1-1

Insiallat ion

ote..........................

age

H-1

0

9.

Pilotbearing

Removal

ote....-.............

. ...

page

H- 9

Inspection......................

.. . ..

page

H-1?

Installat ionote..........................

age

H-10

10.Flywheel

Removal

ote..

............

paqe

H- 9

Inspection...................................

age

H-12

Installai ion

ote..........................

age

H-10



CLUTCH

UNIT

Rgmoval Note

Outch cover and disc

1. nstallhe ssT.

Caution

.

Put 8pacs6 between he

(49

E30l

060)andlhecyl-

inder block, setling dimeaion@ as shown in the

figure o l3mm

(0.51

n).

(Except

83 ATX)

2. Loosen

ach

boltone urn

at a time

n a

crisscross attern

until

spring

ensions released. hen emovehe

clutchcov-

er and disc.

Pilot

bearing

Removehe

pilot

bearingwith he SST

f

necessary.

Flywheel

Note

.

After removlng he lly'rvheel, nspeci or

oil

leakage

pasl

the crankshatt

rear

oil seal,

lf ngcess€ry,

eplace he

oil seal.

(Rete. o SeclionB.)

1. Hold he

lywheel

ith he SST.

2. Removehe bolts n thesequence hown n the igure n

steos.

3. Removehe

lywheel.

H-9



CLUTCH

UNIT

lnstallation

Note

Flvwheel

1 hemove he sealant

rom he

lwheel boh

holesn thecrank'

shattand

rom he

lYwheelolts

Caution

. ll all the previoussealantcannot be removedflom

a

bolt,

replace the

bolt.

.

Do not apply

sealant

lf a

new bolt

is

used.

2. Set

he lywheel

nto he

crankshatt

3. Apply sealant

o the tlywheel

bolts

and

install hem

4. Hold he

lvwheel

ith heSST.

5 Tiohtenhe boltsn

woor hree

teps

n heorder

hown

ti"otrt.nino o*r",

gHos'l*tn

ig.a-to.s

m'kg'

7l-?6

ftJb)

Pllot bearing

Note

.

Insiall

he

pilol

beafng

flush with

the tlywheel.

Instail

he new

bearing

witha

plastic

ammer.

3. Set he clotch

disc

onto he

lywheel

iih he SST.

Clutch disc

'1.

Clean

he clutch

iscsplines

nd

maindrive

gear

splines

2-

Lightly

rease

he splines

ith

molybdenum

rease.

@E@

01EoHX{]7

H-l0



CLUTCHUNIT.CLUTCHCOVER,

CLUTCH

DISC

Clutch cgver

'l.

Installhe SST.

2.

Align he dowel

holeswith he lywheel owels.

3.

Tightenhebolts venly nd

gradually

n he

pattern

hown.

Tlghtening

orque:

18-26 Nm (1.8-2.7 m-kg, 3-20 ft-lb)

CLUTCH

COVER

INSPECTION

Note

.

trlinorscoringor burning

should be removedwlth

emerypaper.

'1.

Inspecthe contact

urface f he clutchdisc

or scoring,

cracks, nd burning.

Repair r replace s

necessary.

2.

lnspecthecontact urface

f the clutch elease earing

for wearandcracks.

Replacehe clutch over

f crackedor worn.

CLUTCH

DISC

INSPECTION

Note.

Use

sandpaper

l

the

trouble 15mlnor,

1. nspectthe

ining uriaceorburning

ndoilcontamination.

Replace

he

clutch

isc f t s badly

burned r oilsoaked.

2. Inspector

loose acing ivets nd rubbers.

Replacehe clutch

disc f either

s

loose.

3.

Measurehe hicknessf

he ining t a rivet eadon both

sides

withvernier alipers.

ReDlace

heclutch isc f ts hickness

s esshanminimum.

Minimum hickneaa: .3mm

0.012

n)

4. Measure

he clutchdisc

unoutwitha dial ndicator.

Replaceheclutchdisc f

runout s excessive.

Runout:0.7nm

(0.027

n)

max.

H-l1



RELEASE

COLLAR,

PILOT

BEARING'

FLYWHEEL

RELEASE

COLLAR

INSPECTION

Note

.

The

clutch

Eleaae

collar

s a

sealed

bearlngand

musl not be washed in solvent.

Turn he bearing

while

pplying

orce

n the

axialdirection

It

the

bearinq

sticksor

has excessive

esislance,

eplace

t.

PILOT

BEARING

INSPECTION

Turn he bearing

while pplying

orce

n the axial

direction

lf the bearing

ticks

r

hasexcessive

esistance,

eplace

t

FLYWHEEL

INSPECTION

Note

.

Minorscoring

or

burning

should

be

removedwith

emery paPer.

1. nspect

he contact

urface f

the clutch

disc

or scorang,

cracks, nd

burning.

lepair r

replace

s necessary.

2.

nspecthe

ring

gear

eeth

o. wear

anddamage

l neces'

sarv.

eDlace

he

lwheel.

3. '/easurehe

lvwheelunout

witha

dial

ndicator' eplace

the lywheel

f runout

s excessve-

Runout:

0,2mm

0.008

n) max,

t

H-12



J

MANUALTRANSAXLE

tNDEX..................................................,,..- 2

ouTLtNE........,..........,..,....,...,..................- 3

spEctFtcATroNS,...................,........,......

- 3

STRUcTUFAL

tEW,.........,....,..,..............- 4

powERF1OW,...........,..........,..,...,..........

- s

TROUBLESHOOTTNGUTDE......,..............-

6

TRANSAXLEtL,,,,.,.................,.....,.,.,.....- 7

tNSPECTtON......................-......,,,,.........-

7

REPLACEMENT........-.....-.,..................,-

7

TRANSAXLE....,............................,...........

- I

PREPARATtON................................,..,.,..- 9

REMOVA1.................-...---.............,....-r

r

DtSASSEMB1Y..................................,.....

-r4

tNSPECTtON.................--..................,...-27

ASSEM81Y..................,......,,..................-30

|NSTALLAT|ON ......,..,J-56

DtFFERENT|AL................,.,...,...................-59

PREPARAT|ON.,.,....,.........,....,..,.............-59

DISASSEMBLYINSPECIIONASSEI\,lBLY..-50

SHIFTMECHANlStrl...--...-.................,.....-64

ovERHAU1...........,....,.,........................,

-64



J

INOEX

INDEX

BACK.UP

UGHT SWTTCH

SEFIVICE,

ECTION

T

NEUTRAL AIITCH

SEBVICE,SECTION

F

GFADE

: API SEFVICEGI-4

VISCOSIIY:

ALL SEASON

D€xrend'[

or M2C3ilF

aBovE

r8.c

(ocD

saE

75W-80

cAPAclry:

2.5lllsls

2.6

us

qt,

2.2 mp

1.Transaxle

Remova1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

- l 1

Disassemb1y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-14

inspec l ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

27

Assemb|y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age -30

Ins ta | Ia t ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-56

2. Differential

Disassembly

Insp€ction

Assembly

.

page

J-60

3. Shift

mechanism

Overhau| . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .age -64

4. Transaxle

il

Inspection..--................................

age

-

7

Rep|acemel t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-

7

J-2



OUTLINE

J

OUTLINE

SPECIFICATIONS

-

----__

____

Engine

Item

-------

B3

85M-B

Synchronlzation

echanism

Forward:Synchromesh

Bev€rse:S€leclivesliding

Gear

atio

3

454

2nd

1.944

3rd

1.392

1.030

5lh

0.810

3.583

4.058

Speedomeler

ear

atio

(Driv€nearnumber/Drlveearnumber)

o.9112123)

o l

Grade

Dexrono]I r

M2C3&F

Above

-18oC

(0"F)

SAE

75WAO

Capaclty

liters

USqt,

lmp

qt)

2.5

12.6,

.2:)

J-3



J

OUTLINE

STRUCTURAL

IEW

1 Primary

lst

gear

6-

Primary everse

ear

'11.

Secondary

th

gear

2.

Pdmary nd geat 7. Secondaryst gear 12.Secondaryeverse ear

3. Primary

rd

g;ar B.Secoloary

2nd

gear 13 FleveIse

dler

gear

a. Primary

tn

gear

9. Secondary

rd

gear 14 Ditferedial

5. Primary

th

gear

10.Secondary

th

gear

J-4



OUTLINE

J

POWEBFLOW

rsT

3RD

4TH

J-5

2ND

5TH



J

TROUBLESHOOTING

UIDE

TROUBLESHOOTING

UIDE

Page

shilt

lever

won't shlfi

smoothly

or is hatd

ro shlfi

sllcking shiit

ever ball

Stcking change

conllol

rod

oinl

Benl change conlrol

od

J-€4

J-64

J-64

Too much

play

n

shilt lever

Wornchange onlrcl

od bushing

Weakshift everball

sprlng

Worn shitt ever

ball seat

J 6 4

J 6 4

J-64

Difficull to shltl

No

Oreas€

transaxleonlrol

lnsuificieniil

Deteiorationof oil

quality

We or

play

ot shlft

ork or shlft rod

Worn ynchronizer

g

Wom

synchrcnizer

oneor

gear

Bao

conlacr l syrchro_i7Fr

ingandcone

ol

gea'

Excessive

ongiludinsl

ay

ol

gears

Womsynchronlzereysping

Excessiv€

rirnary

halt

gear

bearlng

preload

lmpropeiy djusled

hange

uLde

late

J 6 4

J 6 4

J 7

J,21,24

J

2 1 , 2 4

J

2 1 , 2 4

J

2 1 , 2 4

J

2 1 , 2 4

J-21.

24

J-38

Won't stay

h

gear

Benl change

conlrol rod

Wom

change

conlrol

od

bushing

W€ak shit

lever balL pring

Wofn clutch hub

sleeve

Worn slidingsudace

ol

gear

or shait

Worn steelsllding

groove

ol conlroL nd

Excessivehrusl

clearance

Loos€ engrne

mounl

Tishten

Tghten

J-64

J-64

J-64

J-64

J

2 1 , 2 4

J 1 4

J - 1 4

J-56

Deierloralioni oil

qualty

Wom

sliding

urlace i

gear

or shafl

Danragecl

ear

eeth

Fore

n

materlal

gears

Damaged itferentiaL

ear

or excessve

acklash

J - 7

J - 7

J

21,24

J 2 1 , 2 4

J - 2 1 . 2 4

J-21. 24

J-60

J-6



TRANSAXLEOIL J

TRANSAXLEOIL

INSPECTION

Note

.

Park he vehicleon level

ground.

1 Disconnecthe speedometerableand

remove

he speedo

meter

driven

ear.

2.

Verify

hat

he oil evel s betweenhe

F

and L.

3. Installhe speedometer

riven

ear.

Tightening orque:

7.8-12 Nm

(0.8-t.2

m-kg, 5.8-8.7

tt-lb)

4. Connecthe

speedometerable.

REPLACEMENT

'1.

Disconnecthespeedometerable

nd emove

hespeedo-

meter

driven

ear.

2.

Remove

he draan

lug

and washer.

Drain

he oil ntoa suita-

ble container.

3. nstall new

washer

nd

he drain

plug.

Tightenlng orque:

24-35

N.m

2.4-3.5

m-kg, 7-26 finb)

4.Add henecessarymount f hespecilied il hroughhe

speedometer

riven

ear

hole.

Specifiedoil

Grade:

API serviceGL-4

Viscosity:AlFseasonDexron@n r M2C33-F

Above

-t8"C

(0"D

SAE75W-80

Capacity:2.5

liters

(2.6

US

qr,

2.2 mp

qt)

5.Veritvhe oil

evel.

6. Install he speedometerriven

gear

and connect he

speedometerable.

Oil seal

Replacement

On-vehicle)

1.Jack up the vehicle nd support

t withsafety tands.

2. Drain he ransaxle il.

3. Removehe

ront

wheel.

4. Femovehe splash hield.

5. Separate

he rontstabilizerrom he

owerarm.

o

l-----.--

J-7



J

TRANSAXLE

OIL

Cautlon

.

Do noi damage

he dust

boots.

6.

Removehe

clinch

oltand

pull

he

ower rmdownward

to seDarate

he

knuckle

rom

he

owe.arm ball

oint.

7 Loosenhenutand

o6connect

he

ie-rod nd

wilh heSST

Caution

.

Ilo not

subiect

he tdPod

olnl

to

shock

when remov'

ing lhe driveshaft.

8. Disconnect

hedriveshaft

rom he ransaxle

y

prying

with

a bar nsened

etween

he

outer

ingand he ransaxle.

9. Suspendhe driveshaft itha rope

10.Removehe

oil seal

witha

screwdriver.

Note

.

Tap n until

he oil seal

nstaller

ontacts

he case.

.

Coat

he

gil

seal

ip wilh ttanaaxle

oil.

11

Tap he newoil

seal nto

he ransaxle

ase

with heSST

12.Replacehe

driveshaft

ndclip

witha

newone-

nserthe

driveshaft

ith

he split

ol the ciip

acing

upward

13.Pull ut

on hedriveshatt

o

veritvhat

t s

held irmlyn

place.

J-8



TRANSAXLE

J

TRANSAXLE

PBEPARATION

ssT

49 GO17 AO

Suppon,englne

49

G017

501

Bar

(Parl

of

49 GO17 A0)

49

G017

Suppod

49 G0175A0)

49 G017 03

Hook

{Pan

of

49

G017 AO)

49

0107

6804

Engine tand

49

DO172A2A

_g

sh,ms€ecro,se,

,fffiililp

../-t

adiuslmenl f

bearing

reload

49 G0190A0

49 F401384

Collar

(Pan

of

49 DOIT2A2A)

adjuslrnent

f

49 G019 01

Body

(Pan

ol

49 G019 A0)

49 F401385

Bar

49 Do17 MA)

49 G019 02

Siay

{Parr

ol

49 GOrg A0)

49 F4013818

Selector

C6o

(Pad

of

49 F401

814)

adjustrnent

t

bearng

preload

49 G019003

F:'"Tr

888

-

9 Gor90A0)

49G019 19

Bolt set

49 Do17 A2A)

49 DO17 01

49

8001 795

J-9



J

TRANSAXLE

49 FTot

361

49 BO27

0024

(Part

ot

49 DO172A2A)

beanng

preload

49 G030

795

49 0180

5108

beaing

prcload

measuing

49

DOIT 241

beanng

beaflng

49 G030797

Body

(Part

ol

49 G030

795)

49 F401

331

Body

(Part

ol

49 D017

A1)

b€aring

49 G030

796

Body

(Pad

of

49 G030

795)

49 DO17

01

/A\

Attachmenl

w|,

(Padof

49D017

A1)

gezl

49 0839 425C

beanng

bearng

49 0710

520

49 0A62 428

bearlng

pullef

(Pan

oi

49 0839

425C)

49 0636

145

49 0a39 426

(Part

ol

49 0839

425C)

beaflng

J-10



TRANSAXLE

J

REMOVAL


attery

able.

2.

Raise

he vehicle

n a

vehicle oist.

3.

Drain he

ransaxle il ntoa suitable ontainer.

4. Removen

the ordershown n the igure, eferringo RemovalNole.

{ !e

CLIP,

01A0JX{02

1.Wheel

nd

ire 10.Driveshafts

2.Splashhield

Bemovalote.............................

age

-12

3.

Battery,

attery arrier 11 Starter

4. Speedometerable 12.

Enginemounting ember

5.Clutch able

Bemoval ote..................... ........

age

-12

6. Back-upightswitch onnector 13.Exhaust

ape

racket

7. Neutral witch onnector

'14.

Stifiner

8.

Extension

ar

15.Transaxle

L Control

od Removalote.............................

age

-13

16.Engine ount

o.2

J-1 1



J

TRANSAXLE

- 1 .

Removd

Note

DrlvEhaft

1. Remove

he

ball

oint

clinch

bolt.

Caution

.

Wrap a

rag around

the

ball

ioint

dusi

boot

to

pro'

lect

h

trom damage.

2.

Pry he ower

arm

rom he

knuckle

witha

pry

bar.

Cautlon

.

Do not

shock

the tripod

ioint

when

removing

the

dtiveshaft.

3. Seoarate

he driveshaft

rom he ransaxle

y

prying

wilh

a bar nserted

etween

he outer

nng and he

ransaxle.

4. Suspendhe driveshaft itha rope.

Engine

mountinE

member

1 Suspend

he engine

with he

SST

2. Remove

he

bolts nd

nuts hown,

nd

emove

heenglne

mounting

ember.

J-12



TBANSAXLE

J

Tranaaxle

1. LoosenheSST

€ngine

uppon)

and ean he

engineo

ward he transaxle.

2. Support he transaxle

with a

jack.

3. Removehe ransaxle

ounting olts.

4. Removehe ransaxle.

J-l3



J

TRANSAXLE

DISASSEi'BLY

Precaution

i.

6t""n

tn"

ttuna""f.

xteriorhoroughly

ilha steam

leane.

r

cleaning

olvent

efore

isassembly'

i.

di;;;

il";,.d;"J

pirti

(except

"-ateb

earings)and

seating

udaces

ith leaning

olvent,

nddry

-

iitiilii,irr""llO

iii

Cteinouiatt

rotes nd

plsiageswitha compressed

ir,

and

checkhat here

re

no obskuctions.

3.Wear yeprotectionhenusing ompressedir o clean omponefis

Housing

Parls

ijGo"inOt"

in the order

shown

n ll"e

igure'

eferringo

Disassembly

Note'

BEPIACE

\-,.,@

a'. \

af

" - / W r

. / F -u t ]

\

xqrqk'

/(t

\

@

REPLACE

@

FEPLACE

g

o

BEPLACE

BEPLACE

J-l4



TRANSAXLE

J

1.

Transaxle

Disassemblyote.......................

age

-16

2. Return pring

3. Clutch ever

4. Clutch elease

ork

5.

Clutch

elease ollar

fnspection.............-......................age -27

6.

Engine ountNo.1

7.

Drain

plug

8.

Plug,

pring,

teelball

9. Back-up

ightswitch

10.Neutral witch

11.Speedometer

riven

ear

assembly

12.Transaxle

aseassembly

'13.

Retaining

ing

14.Crank

ever

shatt

15.Crank

ever

assembly

16.Base

plate

unit

17.Plug,spring, teelball

18.Roll

in

19.Roll

in

20.Shift

ork

(3rd/4th)

fnspection....................................

age

-27

21.Shift

od

(3rd/4th)

Disassemblyote.......................

age

-1

6

22.Shift

od end

(3rd/4th)

23.

Roll

pin

24.Shifl ork

(1sv2nd)

1nspection....................................

age

-27

25.Shift od

(1st/2nd)

Disassemblyote.......................

age

-16

26.Roll

pin

27.Roll

pin

28.Shift ork

sth/Rev)

1nspeciion....................................

age

-27

29.Shift od

(sth/Rev)

Disassemblyote.......................

age

-16

30. nlerlock in

31.Shift od end

(sth/Rev)

32.Ueversedler

gear

33.Feversedlershaft

34.Foll

pin

J5. l.tn

36.Lever etspring

37.Reverseever haft

38. O'ring

39.

Reversehitt ever

40.

nterlock

in

Disassemblyote.......................

age

-16

4'1 Interlockin

Disassembly

ote.......................

age

- 16

42. Primary haft

gear

assembly

43.

Secondary

haft

gear

assembly

44.Difi rential ssembly

45.

Clutch

ousing ssembly

46.Foll

pin

47.

Speedometer

ear

sleeve

48.

O-rin9

49.

Oil

seal

Disassemblyote ......................

age

-16

50.Driven

ear

51.Magnet

J-15



J

TRANSAXLE

Disaasembly

Note

Transaxle

Mount he

ransaxle

n

the

SST.

Shlft

rod

Wiap he

shift

oOwith

a rag

and

urn t

with

plierswhile

pull

ing

t out.

lnterlock

pln

Removehe

nterlock

in

with

a magnet.

Oll seal

iem-dve

tre speeaometer

riven

gear

oil

sealas

shown

n he

figure.

J-16



TRANSAXLE

J

Clulch

Housing

and TaansaxleCase

Components

Caution

.

Do not remove

an oil seal lf not necessary,

1.Disassemble

n the

ordershown n the igure, eferringo DisassemblyNote.

2. nspect ll partsand repairor replace s necessary.

REPLACE

BEPLACE

SELECNVE

AEPLACE

1.Batfle

late

2. Bleeder

3. Roll

pin

4.Change

rm

5.Change od

assembly

7.

Oilseal

change

od)

Disassembly

ote.......................

age

-18

8. Oilseal

primary

haft)

Disassemblyote.......................age

-18

9. Bearing

uter

ace

secondary

haft)

Disassemblyote....................age

-18

10.Funnel

Disassemblyote ......................age -1811.

Oilseal

ditferential)

Disassembly

ote.......................

age

-18

12.Bearing

uter

ace

differential)

Disassembly

ote.......................

age

-19

13.

Oilseal

'14.

Bushing

15.

Clutch ousing

16.

Oil

passage

17.Adjustment

him

18.Funnel

Disassemblyote.......................

age

-19

lO Ra./i^^ ^' d6r /r^6

Disassemblyote ......................

age

-20

20.Adjustmenthim

secondary

haft)

Disassemblyote.......................

age

-20

21.Bearing uter ace

ditferential)

Disassemblyote.......................

age

-19

22.Adjustmenthim

23.

Oil seal

differential)

Disassembly

ote.......................

age

-18

24.

Transaxle

ase

J*17



J

TRANSAXLE

Disassembly

Note

Oil

seal

(change

od)

Caution

.

Do

not damage

he cluich

housing'

Removehe oil sealwitha screwdriver.

Oil

seal

(dlfterential)

Caution

.

Do ngt damage

he clutch

housing.

Remove he oil seal

with

a screwdrver'

Oil seal

(p

mary shafl)

Cautlon

.

Do noi

damage

he clutch

housing.

Removehe oil seal

witha

screwdriver'

Funneland bearing

outer race

(secondary hatt)

Noie

.

Remove

he bearing

outer

racewith

a acrewdriver

it neces-sary.

I ) naerta screwdrive.

etween

he clutch

housing

and bearlngouter race.

2)Pry

the bearlng

outer race

flee.

Removehe bearing

uter

aceby

ifting ut

he unnel nd

race together.

\ r

l < ,

J-l8



TRANSAXLE

J

Funnel

Removehe unnel

with

pliers.

Bearlngouter race

(differential)

1.

nstallhe

SST

o the bearing uter ace.

2. Turnover he clutch

housing.

3. Removehe bearing

uter acewitha su,table

Bearingouler

raaeand adiustmentshim

(difierential)

1. nstallhe SST o

the bearing uter ace.

2.

Turn

ver he

clutch ousing.

3. Tap heSSTwith

a

pipe

hroughhe driveshatt

ole o re-

move he bearino uter

ace.

prpe.

.'-/l

l\).r-

.<

-t,'.-,t )-P

J-19



J

TRANSAXLE

Bearing

outel

race and

adluslment

shin

(seqondary

shalt)

i.

putt

out tre

beaiing

uter

aceas

shown

n the

igure.

2. Remove

he adiustment

him

J-20



TRANSAXLE

J

PrlmaryShaft Assembly

1. Measurehe hrust learancest all

gears

betore isassembly,

eferringo

Preinspection.

2. Disassemblen the ordershown n the igure, eterring

o Disassembly ote.

FEPLACE

E

FEPLACE

1.Retaininging

2. Bearing

sth)

Disassemblyote.......................age -22

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-28

3. Spacer

4. Steel

all

5. sth

gear

Disassemblyote ......................

age

-22

Inspect

ear

eeth

or

damage,

wear,

and

cracKs

6.

4th

gear

Disassemblyote ......................

age

-22

Inspection....................................

age

-28

7.

Synchronizer

ing

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-27

8. Retaininging

9. Clutch ub assembly

3rd/4th)

Disassemblyote ......................

age

-22

Inspection....................................

age

-29

10.Synchronizer

ing

Disassemblyote

......................

age

-22

Inspection....-...............................age 27

11.3rd

gear

Disassembly

ote ......................

age

-22

Inspection....................................

age

-28

12.Bearing

Disassembly

ote.......................

age

-22

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

28

13.Primary haft

Inspection....................................

age

28

14.Synchronizer

pring

'15.

Clutch

ub sleeve

3rd/4th)

1nspection....................................

age

-27

16.Synchronizer

ey

17.Clutch ub(3rd/4th)

J-21



J

TBANSAXLE

Preinspection

3rd

qear

thrusl

clearance

1 M;-asurehe clearance

etween

rd

qear

and

2nd

gear'

Clearance:

.06-0.41mm

(0.002-0.016 n)

llaximum

: 0.46mm

0.0'18n)

2. lf heclearance

xceeds

he maximum,

heck

he

contact

surfaces

fthe3rd

gear,2nd

ear,

ndclutch

ub

3rd/4th).

Replace

ornor

damaged

arts

4th

qear

hrust clearance

t. MEasure

he clearance

etween

th

gear

and

the ball

bearing.

Clearance:

.22-0.52mm

(0.009-0.020 r)

Maxlmum:

0,57mm

0.022

n)

2.

lf theclearance

xceeds

he

maximum,

heck

hecontact

surfaces

f the

4th

gear,

ball

bearing,

nd clutch

hub

(3rd/4th).

eplace

ornor

damaged

arts

Disassembly

Noie

Bealing

(sth)

1

Place he

primary

hafl

gear n

a

vrse

Noie

.

Use

protectfue

Plates

n the

iaws

ot

lhe vlse'

2.

Removehe

bearing

with

he SST.

4ih

gear

and

5th

geat

1 lnsrallhe 4th oear

wrth he

SST.

Cauilon

.

Hold he shaft

with

one hand

so that

t does

not all'

2. Flemovehe 4thgearand sth gearwith heSST

Clutch

hub

assembly

3rd/4lh),

ynchronizer

ing

(3td)

and 3rd

gear

Caution

.

Hold he shaft

with

one

handso

that t

doesnot all.

1.Bemovehe retaininging.

2. Remove

he clutch

hubassembly

3rd/4th)'ynchronizer

ring

3rd)

and 3rd

gear

with he

SST

J-22



TRANSAXLE J

Bea ng

Note

.

Use

protectlve plalea

In ihe

laws

ol the v|se.

Removehe bearing

with

he SST.

J-23



J

TRANSAXLE

Secondary

Shaft Assembly

1.

Measute

he thrust learance

f

2. Disassemble

n the order

shown

gear,

and sth

gear,

elerring

o Preinspectlon.

referringo Disassembly

ote.

1st

gear,

2nd

in the igure,

NEPLACE

N€PLACE

1. Bearing

nne. ace

5th)

Disassembly

ote

......................

age

-25

Inspect

or damage nd

rough otation

2.

Retaining

ing

3.

Washer

4.

Clutch

ub assembly

5th)

Disassembly

ote

...............

......

age

-26

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . .age -29

5.Synchronizer

ing

fnspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-27

6.

sth

gear

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

29

7. Retaining

ing

8. Bearing

nner ace

1st)

Disassembly

ote ......................

age

-26

lnspector damage nd

rough otatpn

L Pinion

ear

Disassembly

ote.......................

age

-26

Inspect

ear

eeth

or

damage,

wear,and

cracks

10.

1st

gear

Disassembly

ote.......................

age

-26

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-29

11.Retaining

ing

J-24

12.Synchronizer

ing

Disassembly

ote.......................

age

-26

1nspection....................................

age

-27

13.Clutch

ub assembly

1sv2nd)

Disassembly

ote.......................

age

-26

Inspection.......-............................

age

29

14.Synchronizer

ing

Disassemb|y................................age -26

1nspection....................................

age

-27

15.2nd

gear

Inspection.....................-..............

age

-29

16.Synchronizer

pring

17.Clutch

ub sleeve

sth)

Inspection..................................

a]e

J 27

18.Synchronizer

ey

19.

Clutch

ub

(sth)

20.Synchronizer

pring

21.Clutch

ub sleeve

1st/2nd)

fnspection....::...............................

age

-27

22.Synchronizerey

23.Clutch

ub

(1sv2nd)

24.Secondary

haft

Inspect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

29



TRANSAXLE

J

Prelnspectlon

lsi

gear

hrust clearance

1. Measurehe clearance etween st

gear

and he

pinion

gear.

Clearance: .22-0.62mm

(0.008-0.024

n)

Itaximum:0.67mm 0.026 n)

2.

lf

theclearancexceedshemaximum,heckthe

ontact

surfaceslthe stgear,

pinion ear

ofthesecondary

haft

gear,

ndclutch ubassembly

1sv2nd).

eplace orn

or

damaged

arts.

2nd

gear

hrusi clearance

1. Measureheclearanceetween nd

gear

andsecondary

3rd

gear.

Clearance:

.06-0.2lmm

(0.002-0.008

n)

Maximum: .26mm 0.010 n)

2. lf

theclearancexceedshemaximum,heck hecontact

surtaces l the2nd

gear,

econdaryrd

gear,

and

clutch

hubassembly

1sy2nd).

eplace ornor damaged

arls.

slh

gear

lhru9t clearance

1. Measure

he

clearance

etween th

gear

and secondary

4th

gear.

Clearance: .06-0.2lmm

(0,002-0.008

n)

Maximum: .26mm

0.010

n)

2. lf theclearancexceedshemaximum,heck

hecontact

surfaces

f

the sth

gear,

econdary th

gear,

and clutch

hub

assembly

sth).

Replace

ornor damaged

arts.

Disassembly Note

Bearing nner race

(5th)

Caution

.

Hold he

shaft

with one hand

so that

t

doesnot all.

1.Set he SST o the sth

gear.

2. Removehe bearing uter acewitha suitable

ipe.

Pipe diameter:20mm

0.79

n)

J-25



J

TRANSAXLE

Clutch

hub

assembly

(sth)

Nole

.

Remove

he clulch

hub assembly

sth)

as

lollows

ll

necessary.

1- nstallhe SSTas shownn the igure.

2.

Remove

he clutch

ub

assembly

sth)

usinga

press

Bearlng

nner

race

(lsl),

pinion

gear'

l3l

gear

Caullon

.

Hold

the shaft

with

one hand

so

that lt does

not tall.

'1

. Set

he SST

o the

1st

gear'

2. Remove

he b€aring

nner ace

witha

suiiable

ipe

Plpe diameter:

20mm

0'79

n)

Clutch

hub assembly

lsu2nd), synchronizer

ing

Note

.

Remove

he

cluich

hub assembly

15u2nd) s

tol-

lows

if necessary.

1.lnstallheSST as

shown

n the igure

2. Remove

he

clutch

ubassembly1s 2nd)using press

J-26



TBANSAXLE

J

INSPECTION

Inspect

ll

parts

and

repair

r

replace

s

necessary.

Clutch release ollar

Inspect

heclutch

elease

ollar

or roughness

r

noisewhile

turning.

Synchronizer ing

Note

.

Set he synchronizering squarely

n he

gean

hen

measurearound he clrcumlerence,

1. \,leasurethelearanceetweenhesynchronizeringand

lianksurface f the

gear.

Standard learance: .5mm

0.059

n)

Minimum:

.8mm

0.015

n)

2. Inspectthe

ynchronizer

ing

eeth

ordamage, ear,

nd

cracks.

3. lnsoecthe aoersurfaceor wearor cracks.

Shift tork, clulch hub

sleeve

1. Measurehe

clearance etween

he shift ork andclutch

hub

sleeve

roove.

Standard

lealance

(1st/2nd):

0.100-0,358mm

0.004-0.014

n)

(3rd/4th)

0.150-0.458mm

0.006-0.018

n)(5th)

: 0.150-0.458mm

0.006-0.018

n)

Maximum

1st/2nd):

.408mm

0.0i6

in)

(3rd/4th):

0.508mm

0.020

n)

(sth)

:0.508mm

(0.020

n)

J-27



J

TRANSAXLE

3FD

GEAB

Pdmary Shatl

Note

.

ll

the

prlmary

shaft

is replaced,

adiust

the bearing

pretoad. Reler o

Page

J-39.)

1. nspecthe primary haft unout

Maximum

unout:

0.0lsmm

(0.0005

n)

2.

Inspecthe splines

or

damage

nd

wear.

3. Insbect

he

gear

eeth

or damage'

wear,and cracks

4.

Inspecthe oil

passage

or blockage.

3rd

gear,

4th

gear

'1.

l\,leasurehe clearance

etween

he shaft

nd

gears

B A

2.

Inspecthe

synchronizer

ones

or

weat.

3.

Inspecthe

gear

eeth

or damage,

wear'

andcracKs.

4.

Insbecthe

Contacturfaces

f the synchronizer

ingand

the 3rd/4th

ear

or wear

and cracks

Bearing

Insoecthe

bearing

or damage

r

rough

otation.

0rFoJx063

J-28

mm

.n)

Shaft

srde

(outer

diameleo

Ge side

(inner

iamelet

3rdgearsideA

32.945-32.970

(1 297-1 298)

33.000-33.025

(1.299-1.30O)

4th

geff

side

B

2A.545-28.570

0

.123-1

125)

[email protected]

l1

126-1

127



TRANSAXLE J

Seaondary

Shafl

Nole

.

ll the secondary shatt is replaced, adiust the bear-

ing

preload.

Reter

o

page

J-39.)

1. nspecthe secondaryhaft unout.

Maximum unout: 0.015mm

0.001

n)

2. Inspecthe splinesor damage nd wear.

3.

Inspect

he

gear

eeth

or damage, ear,and cracks.

4. Inspecthe oil

passage

or blockage.

1st

gear,

2nd

gear,

sth

geal

1. Measurehe clearance

etweenhe shaft nd he

qear.

2. Inspect

he synchronizer

ones or wear.

3-

Inspect

he

gear

eeth or damage, ear,and cracks.

4. Inspecthe contact urfaces

l the synchronizeringand

the l st/2nd nd sth oear or wearand cracks.

Clutch hub aaaembly

1. nspecthe clutchhubsleeve nd

hub operation.

2. Inspect

he

gear

eeth or damage,

ear,

and cracks.

3.

Inspecl

he

synchronizerey or damage,

wear,and

cracks.

mm

(in)

Shalt ide

(olter

diameled

Gear ide

(nner

diameter)

32.945-32.970

112971 .294)

33.000-33.025

(1 299-1 .30O)

2nd

gear

side

B

39.945-39.970

(1

573-1 .574)

40.000-40.025

(1.575-1.576)

sth

seff

side C

28.545 28.570

11

124- t 125J

24.604-24.62-l

lt.126-1.127)

J-29



J

TRANSAXLE

ASSEIIIBLY

Precaution

i. lil-O;i;a.

and

gaskets

must

be replaced

ith

he new

ones

ncluded

n the overhaul

it '

2.

Verity

hatall

pans

are

completely

lean

before

assembly

3. Assehbboans

within

10

minutes fter

applying

ealant

"

;ffi;il

"A;;ti;cure

at

least

go

minuies ftEr ssembrv

e{ore

illing

he ransaxle

nhoil'

4.A bearing uter aceandbearingnner acemuslbe replaced san assemDly

olEoJx.o6s

Clutch

hub assembly

Note

.

Synchlonizer

ing diametels

are

as follows.

mm

(ln,

--_=_-

@

1st

55.7

2.r93)

?nd

55.7

{2.193)

3rd and

4lh

49.7

r.954

5th

43.7

172O)

.

Synchronizer

ey

dlmensions

are as

tollows.

o

@

1sv2nd

17.00

0.669)

4

25

0.r67) 5.00

0.

97)

3tdl4th

14.00

0.551)

4.25

0.164 5.00

0.197)

14.00 0.551)

4 25 0.16n

5.00

0194

1. nstall

hesvnchronizer

eysprings

n theclutch

hubwith

thehooks

n he

grooves

o hold

he hree

ynchronizer

eys

In

p|ace.

SYNCHRONBEB

RING

SYNCHRONIZEF

EY

2.

Align he

synchronizer

ing

grooves ith he

synchronlzer

key

during

assembly.

J-30



TRANSAXLE

J

secondaryShaft Assembly

Assemblen the ordershown

n

the

igure, eierringo Assembly

Note.

'1-

Secondaryhaft

2. Clutch

ub

(1sv2nd)

3-Synchronizer

ey

4. Clutch ub sleeve

5. Synchronizereyspring

6. Clutch ub

7.

Synchronizer

ey

8. Clutch

ub

sleeve

5th)

9. Synchronizer

ey

spring

10. nd

gear

Assembly

ote............................

age

-32

11.Synchronizering

Assembly ote...................... ......

age

-32

12.Clutch ubassembly1sl2nd)

Assembly ote...................... ......

age

-32

13.Synchronizering

Assembly ote...................... ......

age

-32

14.Relaininging

15.1st

gear

Assembly

ote............................

age

-32

16.Pinion

ear

Assembly

ote............................

age

-32

17.Bearingnner ace

1st)

Assemblyote...............

....

page

-32

18.Retaining

ing

Assembly

ote............................

age

-33

19.5th

ear

20.Synchronizer

ing

21.Clutch ub assembly

sth)

Assemblyote........................

..

page

-33

22.Washer

23.Retaininging

24.Bearing

nner ace

sth)

Assembly

ote............................

age

-33

BEAFINQ

NNEFRACE,

YI

ETAINING

FIING,NEW

@

@E

AEAFINGNNER

J-31



J

TRANSAXLE

Assembly

note

2nd

gear,

synchronlzer

ino

1.

Asaemblehe

2nd

gear

o the secondary

haft s

shown

in the

igure.

2.

Assemble

he synchronizer

ing.

Clutch

hub as€embly

lsu2nd), synchronizer

ng

1.Assemblehe

clutch ub

assembly

o hesecondary

haft

as shown n

the igure.

2.

Assemblehe

synchronizer

ing.

Caution

.lnstall the clutch hub assembly lsi/2nd) wlth a

presa

It necessary.

.

Align

the synchlonizer

drg

gloove

and

leverse

gear

key

groove

when installing.

1st

gear

Assemblehe

1st

gear

o he

secondary

haft s

shownn he

figure.

Caulion

.

Align he synchronizer

ing

groove

and

clutch

hub

assembly ey when Installing.

Pinion

gear,

bearing

nner race

(lst)

Caution

.

Replace

he bearing

inner

race lf

removed.

1.

Support

he

4th

gear

of

the secondary

hatt.

2. Inslallhe olain

end ol

pinion ear

with he bonom

up.

3. Set

heSST o

henewbearing

nner

aceasshown

n he

fagure.

I

&

Y

J-32



TRANSAXLE

J

Rstaining lng

Cautlon

.

Roplace he retalning ng ll removed.

1. nstall

he

retaininging.

2. Measurehe clearance etweenhe retainino

secondaryhaft

groove.

Clearance: -0.1mm

(0-0.004

in)

ringand

3. l notasspecilied,electhe

proper

etaininging rom

he

chart

belowand

nstallt.

Retaining ing

thickness:

mm

(in)

2.0

0.079)

|

2.1

0.082)

2.2

0.086)

|

2.3

O.O9O)

|

24

(0.094)

Clutch

hub assembly

5th)

Install

he clutch

hub

assembly nto he secondaryhaft.

Note

.

Installthe clutch hub

assembly

sth)

wilh

a

press

it necessary.

Bearlng

Inner race

(5th)

Cautlon

.

Replace

the bearlng Inner race it

removed.

1.Supporthe st

gear

of

hesecondaryhaft nd

press

he

bearingnner aceon.

2. Installthe

ewbearingnner

ace

usingthe STand

press,

as shown n the igure.

3. vleasure

he clearance etween

st

gear

and he

pinion

gear.

Clearance: .22-0.62mm

(0.008---{t.024

n)

Maximum:

.57mm

0.025

n)

J-33



TBANSAXLE

4. Measure

he clearance

etween

nd

gear

and he

secon-

dary

3rd

gear.

Clearance:

.06---0.2lmm

0.002-0.008 n)

Itaxlmum: 0.26mm

0.010

n)

5. Measure

he clearance

etween th

gear

and

he secon'

dary

4th

gear.

Clearance:

.06-0.21mm

(0.002-0.008

n)

Itaxlmum: 0.26mm

0.010

n)

J-34



TRANSAXLE J

Prlmary

Shaft

Assembly

As.semblen

the

ordershown n

the

igure, eferring

o Aasembly

Note.

RETAININGFIN6,NEW

1.

Clutch

ub

(3rd/4th)

2. Synchronizerey

3.

Clutch

ub sleeve

4.

Synchronizer

ey

spring

5.

Primary

haft

6. Bearing

'1st)

Assembly ote....................... .....

age

-36

7. 3rd

gear

8. Synchronizering

9. Clutch ub assembly

3rd/4th)

Assembly ote....................... .....age -36

10.Retaininging

11.

Synchronizering

Assembly ole................... .........

age

-36

12.4th

gear

Assemblyote............................

age

-36

13.sth

gear

Assemblyote............................

age

-36

'14.

Sleelball

Assemblyote............................

age

-37

15.

Spacer

Assemblyote............................

age

-37

16.Bearing

sth)

Assemblyote............................

age

-37

17.Retaininging

Assemblyote............................

age

-37

J-35



J

TRANSAXLE

---

t-

Asssmbly

lote

Bearing

lst)

Installhe

bearing

th

a

Press

il ,1

\

OIL

GFOOVE

Clutch

hub assembly

3rd/4th)

i. Fress he

clutch

hu6 assembly

nto

he

primary haft

Caution

.

lliqn

the svnchronlzer

ing

grooveand

clutch

hub

assiembly

ieys

(3rd,/4th) hen

Installing'

2. Align

e clutch

uband

halt

ear

pline

nd

hen

nstalling'

*re@69

Synchronizer

ing,

4th

gear

1.

Install

he synchronEer

ng

(3rd/4th).

2. Install

he 4th

gear.

and

clutch

hub assembly

5th

gear

Caution

.

ltion tne

svnctrronizel

ing

grooveand

clutch

hub

ass;embly

eys

(3rd/4th)whsn

installlng'

'1.

Align

he clutch

hub and

primary haft

splines'

2. Presshe sthgearon

J-36



TRANSAXLE

J

Steel ball, spacer

Hold he steel allwitha finger, nd nstallhe spacer.

Bearing

sth)

C€ution

.

Replace he ball

Installhe ballbearing

bearing f removed,

with he SST and a

press.

2.0

0.079)

I

2

r

(0082

|

22

(0.086)

|

2.3

0.090)

|

2.

(0

094)

Retaininging

Caution

.

Replacehe relaining

ing

t

removed,

1. nstallhe retaininging.

2. Measureheclearanceetweenetainingingand hepri-

maryshatt.

Clearance: -0.1mm

(0-0,004

in)

3. f not

asspecified,elect

he

proper

etaininging rom

he

chartbelowand

nstallt.

Fetaining ing

mm

(in)

Note

.

The ollowing nspectlons to verity

proper

assem.

bly

ol

lhe

primary

shatt.

.

ileasure the clearance etween he 3rd

gear

and

2nd

geal. (Reter

o

page

J-22.)

.

Measure he clearancebetween he 4th

gear

and ball

bearing.

Refer

o

page

J-22.)

J-37



J

TRANSAXLE

Clutch

Housinq

and

Tlansaxle

CaseComponents

L

select

he

adiusiment

him(s).

eterrrngo

Bearlng

PreloadAdiustmenl

2.

Assemble

n

ihe order

shown

n the

rgule reterring

o Assembly

Note

1-Transaxle

ase

2.Adjustment

hrm

Assembly

o ie . . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

'45

3.Bearing uter ace differential)

Assembly

ote. . . . . . . . . . . . . . . . . . . . - . . . . . . .

age

45

4. Oil

seal

difierential)

Assembly

ote....................

.......

age

-45

5.

Adjustmenthim

Assemblyote............................

age 45

6. Bearing

uter ace

secondaryhaft)

Assembly

ote............................

age

-45

/ FUnnel

Assembly

ote.... . . . . . . . . . . .

. . . . . . . . . . . .

age

J-46

8. Adjustmeni

hrm

.

Assembly

ote.... . . . . . . . . . . . . . . . . . . . . .- . .

age

J-46

9. Oil passage

10.Clutch

ousing

11.Bushang

12.Oilseal

J-38

13.Bearing

uter

ace

dilterential)

Assembly

ote............................

age

-46

14.Oil

seal

ditferential)

Assemblyote.........................age -46

15.Funnel

Assembly

ote............................

age

-47

16.Bearing

uter

ace

secondaryhatt)

Assembly

ote............................

age

-47

'17.

Oil seal

primary

haft)

Assembly

ote.....................

....

age

-47

18.Oil seal

change

od)

Assembly

ote.............-..............

age

-47

19.Boot

Assembly

ote..........................

.

page

-47

20.Change

od

21.Changerm

22.Roll

in

Assembly

ote............................

age

-48

23.

Bleeder

24.

Batfle

late



TRANSAXLE

J

0

30 (0.012)

I

0

40 (0.016)

|

0 50

10

r9)

Adiustmeni

shim selection

Selecthe shim(s)

s follows.

Primary

shaft assembly

1.Set he

primary

haftassembly

nto

he clutch

housing.

2. Installtheransaxlease o theclutch ousing nd ighten

theboltso the soecifiedorque.

Tightening orque;

19-26 N.m

1.9-2.6

m-kg, 14-19 ftlb)

3. l\4ount dial ndicaloro the ransaxle

anoer

ndmeas'

ure he

primary

hatl hrust

learance.

Clearance: -0.lmm

(0-0.004

In)

Caution

. Do nol usemore han three(3)shims.

4. Selectheclosesl himon the hinside rom he able

or

adiustment

f the

primary

hatt.

Adiustmenlshim hickness:

Secondary halt assembly

Caution

.

Do nol install

he

secondary

hafl shim.

.

Apply

petroleum

elly

o

prevent

he

shim lom

fall-

ing when installinE

i.

1-Removehe ransaxleaseand nstallheproper djust'

mentshim or the orimarv hafi.

2. nstallhe

primary

haft

ear

assemblynd hesecondary

shaft

gear

assembly.

Do not nstallhe secondary haft

hlmat his ime.

3. Shifl he

gears

o 4th

gear.

J-39



J

TRANSAXLE

d.F

\ i c

4. nstall

he

ransaxle

ase

o he

clutch

ousing

nd ighten

the

bohs

o the specified

orque

Tiohteninq

orque:

ig-zs-Hm i.s-z.s

m-rs,

14-19

t'lb)

5.Set

heSST

onto

he

primary

haft nd

measure

hestad-

ing

orque

witha

torque

wrench

Sta

inq torque:

o-ra7

N.m

o-15

m-kg,

o-1oB

fi-lb)

6.

Remove

he ransaxle

ase

and the

bearing

uter

ace'

7. nstallthe

him

emoved

uring

isassembly

ndthe

bear'

ino outer

ace.

Caution

.

Verifv

hal

the

primary

hatt can

be

urnedby

hand

atteriightenina

he transaxle

case

bolts'

8. Usino he

SST

measure

he

starting

orque

witha torque

wren;hand

select

he

proper

him

f hestading

orque

s

greaterhan n SteP .

Caulion

.

oo not

use mote

than two

(2)

shims.

Adlustment

him

lhickness:

mm

(in)

0.30

0.011) 0.35

0.013) 0.40

0.016) 0.45

0.0r8)

0.50

0.020)

0.55

0.021) 0.60

{0.023)

I

6

A

\ ,1-

J-40



TRANSAXLE

J

Dltterenllal

'1.

Removehe bearing uter aces rom he ransaxlease

and removehe adjustmenthims.

Note

.

Turn A

and

B untilthe

gap

(anow)

n lhe tigu.e is

eliminated,

2. Install

he differential

idebearing

uter

ace o the

SST

(selector).

3. Set he bearingouter aceand diiferentialssemblynto he

clutchhousino.

4. Set he bearingouter aceand SST onto he differential s-

sembly s shown n the agure.

5. Slide he ransaxleaseover he ditferentialssemblv

J-41



J

TRANSAXLE

6. Set he

SST

(collals)

between

he

ransaxlease

andclutch

housing

n the

positions

hown

n the

igure.

7. Tighten

he SST

(bolt

set)

o the

specjfied

orque

Tiqhtenlnq

orque:

ls-ze-Nm

(i.9-2.6

m-kg,

14-19

fi ' lb)

Note

.

Turn the bars

until the

SST

(seleclor)

no longer

iurns,

8.

Mountthe

arson

parts

@

and

@

of

heselector,

nd urn

the

selsctor o

he

gap

s widened.

9.Turn n the reverse irection

ntil he

gap

s eliminated.

01EoJX,115

10.

nstallhe SST

o the

difterential

inion

haft

hrough

he

transaxle

ase.

J-42



TRANSAXLE

J

@t@

@

Note

.

Procedurework with a

pull

scale.

.

Procedure12 work wilh

a

torque wnench.

11.Turn he

SST

witha

pull

scale.

Adjusi he

SST

preload

adapter)

until

he specified

reload.

Preload:0.5--0.7 N.m

5-7.6

cm-kg, 4.3-6.6 inlb)

Puffscafe:500-760

g

(17.7-26.8

ozl

12.Turnthe STwith

atorquewrench.

djustheSST

selec-

lor)

with he

barsuntil he

specified

reload

s obtained.

Preload:0.5-0.7 N.m

5-7.6

cm-kg, 4.3-6.6 In-lb)

13.BemoveheSST.

14.

Measurehe

gap

around

he

entire ircumference

f the

SST

(seleqtor).

15.Selecthe

proper

adjustmenthim(s)o be used

or the

ditferentialy referringo the ableand selectingheshim

whichsnearest

onthethick

ide)o he argestmeasured

clearance

n the selector.

Adiustment

shim hickness:

16.

RemoveheSST

(bolts).

17.Removehe

ransaxle

aseand

he

SST

(collars).

'18.

Removehebearing uter ace rom heSST

selector).

Installhe selected him(s) nd

transaxle

ase.

bearing uter ace o

the

t9

0-25

0.010)

.10

0.004)

0.35

0.014)

0.80

0.031)

J-43



J

TRANSAXLE

01E0JX-121

20. Measure

he

preload

as ollows.Set

he differential

ssem-

bly

nto he clutch

housing.

21. nstallhe

kansaxle

aseonto

he clutch

housing

Tlght€ning

orque:

t9-26 N.m

1.9-2.6

m-kg, 14-19

ft-lb)

22.

Installhe SST o

he differential

ide

gear

hrough

he rans-

axle case.

Note

.

Procadurc 23

work wilh

a

pull

scale'

.

Prccedure24

work

with a iorque

wrsnch.

23.

Turn he SST

(preload

anachmet

)

witha

pull

scale

Readjust he SST

(prsload

adaptor)

until

he specified

preloadwhennotapply.

Preload:0,5-0.7

Nm

(5-7.6

cm-kg,

4'3-6.6

innb)

Pull scale: 500-760

g (17.7-26'8 oz)

24.Turn he

SST witha

torque

wrench.

Readjusthe

SST

(Preload

adaptor)

until

the specified

preload

when

not aPPlY.

Pleload:0.5-0.7

l,l'rn

5-7.6

cm-kg,

4.3-6'6 in'lb)

25.Removehe SST.

26. Remove

he transaxle

ase

and then

the ditferential

s-

semory.

:1

t/

@

J-44



TRANSAXLE

J

Assembly Noie

Adiustmer

shlm

and bearing outer racc

(dltferential)

1. Set he adjustment

himand newbearing uter ace

nto

the lransaxle

ase.

2.Aftermountingthelutch ousing nto

he ransaxle

ang-

er, tap in the diffe.ential earingouter raceswith a ham-

mer

until

t is lushwith he

end

of the ransaxlease.

Pipediametsr:59mm

2,32

n)

Oll seal

(ditterential)

Caution

.

Apply transaxleoil to the outet circumfercnceol the

oil seal,

lnstallhe newoil sealwith he SST.

Adiustment shim,

bearlng ouier race

(secondary

shaft)

1. nstallthedjustment

himandbearing uter ace nto he

clutch

housing.

2. Aftermountingheclutch ousing nto he

ransaxle

ang-

er, tap

in

the

difterential earingouterraceswith a ham-

meruntil t is

flushwith he end ol the clutchhousinq.

Plpedlametel:47mm

1.85

n)

\

J-45



J

TRANSAXLE

Adlustment

shim

and tunnel

(Primary

haft)

1. nstail

he unnel

nto he ransaxe

ase

Pipediameter:

40mm

(1.57

n)

2. Install

he adjustment

him(s).

Oll seal

(ditlerential)

Caution

.

Apply

transaxle

oil

to lhe outer

clrcumGl€nce

of

the

oll seal.

lnstallhe newoil sealwith he SST.

Bearlng

outer

race

(differential)

1.

nstai he bearing

uter

ace nto

he clutch

housing-

2.

Aftermounting

he

clutch ousing

nto he

ransaxle

ang'

er,

ap n

the differentialearing

uter

aces

witha ham-

meruntil t is

flushwith he

end of the

clutch

housing

Pipediameter:

59mm

2.32

n)

-4

r-J

lr_:

--\R

\

$,\o,-

\m#

4PY

J-46



TRANSAXLE

J

Funnel

and

bea.ingouter race

(secondary

hafl)

Note

.

lnstall he tunnel which

has the

extra

hole.

1.Setthefunnelandearinguter

acentoheclutch ousing.

2.Tap hebearing uter acewitha suitable

ipe

untilit sful

ly seatedn the clutchhousing.

Plpe diameter:50mm

('1,97

n)

Oil seal

(primary

shalt

gear)

Caution

.

Apply transaxleoil to lhe outer

qircutnlerenca

ol lhe

oil seal.

lnstallhe newoil sealwitha suitable ipe.

Pipe diameter:38mm

1.50

n)

Oil seal

(change

od)

Cautlon

.

Apply transaxleoil to ihe outer

circumferenceol the

oil seal.

Tap henewoil seal n until t is ullyseated.

Change

rod

and boot

1. nsEll he change od and boot

nto he ransaxle.

2. Fit he

boot

over he seal.

Cautlon

.

lnstall the boot wlth the air bleed

downwardas

shown in the ligure.

e \ r

< - , 2

l \

\

\ t -

u .\-- -J,,-

J-47



,J

TRANSAXLE

Roll

pln

lnsiali

he

new roll

pin

as shown

n the

igure.

J-48



TRANSAXLE

J

i,EMO

J-49



J

TRANSAXLE

Housing

arts

ljsemo-te

n the

order

hown

n he

igure

eferring

o Asaembly

ote

q

(2.0-3.0,

NEW

r20-29

(2.oJ,0,1s-22)

(3.6-5.3,

t i

fl e-^

{\\

q02.-r5

\

(2..--3.€r

@

17__61

J-50



TRANSAXLE J

1.Clutch

ousing ssembly

2.

Diff rential ssembly

3.

Primary haft

gear

assembly

Assembly

ote............................

age

-52

4. Secondary

haft

gear

assembly

Assemblyote. . . . . . . . . . . . . . . . . . . . . . . . . . . .

age

-52

5. Reverse hitt ever

Assembly

ote..........

page

52

6. Oring

7. Reverse

evershalt

Assembly ote..........

page

52

tJ Htn

9.Roll

in

10.Reversedlershaff

'11.

Reversedler

gear

Assembly ote........................ ....

age

-52

12.Lever

et sprrng

13.

Shift

ork

1sv2nd)

Assembly ote...........................age -52

14.Shift

od

(1st/2nd)

Assembly ote........................ ....

age

-52

15.Boll

pin

Assembly

ote..........

Page

-52

16. nterlock

in


page

-52

17.Shift

ork

(sth/Rev)


page

53

18.Shift od end

(sth/Rev)

Assembly

ote..........

Page

-53

19. nterlock

in


page

-53

20.Shift od

(sth/Rev)


page

-53

21.

Foll

pin


page

53

22.Roll

in

Assembly

ote..........

page

-53

23.lnterlock

in

Assembly

ote..........

page

-53

24.Shitt

ork

(3rdi4th)

Assembly

ote..........

Page

-53

25.Shiti

od

end

(3rd/41h)

Assembly ote....................... .....

age

53

26.Shift od

(3rd/4th)

Assemblyote............................

age

53

27.

Roll

in

Assemblyote............................

age

-53

28.Roll in

Assemblyote............................

age

-53

29.Plug, pring

3rd/4th),

teelball

30.Base

plate

unit

31.Crankever ssembly

32.Crank

ever haft

33.Retalninging

Assembly ote...................... ......

age

-54

34.

N4agnet

35.

Transaxle

ase

assembly

Assembly ote...................... ......

age

-54

36-

Engine ountNo.1

37.Plug, pring 'lsv2nd, th/Bev), teel all

Assembly ote...................... ......

age

-54

38.

Drain

plug

39.Back-up

ightswitch

40.Neutrai witch

41.Oilseal

Assembly

ote............................

age

55

42.Speedometer

ear

sleeve

43.OJing

44.Driven

ear

45.Roll

in

Assemblyote...........................

age

-55

46.

Speedometer

riven

gear

assembly

47.Clutch elease ollar

Assemblyote............................

age

-55

48.Clutch

eleaseork

Assemblyote..........

.................

age

-55

49.Clutch ever

Assemblyote............................

age

-55

50.Return pring

51.

Transaxle

J-51



J

TRANSAXLE

Assembly

Note

Primary

ahalt

gear

assembly

and

secondary shatt

gear

assembly

Inslallhe

bdmary

hatt

gear

assembly

nd he secondary

haft

gear

assembly

ogether.

Reverse shift

lever,

reverse

lever shalt

1.

Apply ransaxle

il o the

newO-ring

nd hen

nslallhe

reverseevershalt.

2.

Installtheeverse

hift ever

nd hen

nstallthe

eversee-

ver shaft.

3.

nslallhe new

pin.

Reverse

dler

gaar

Installhe

reverse

dler

gear

and

he reverse

dlershalt.

Shift

rod

(l

sU2nd),shift

fork

(l

su2nd),

roll

pin,

interlock

pin

Caution

.

The

mark

0ndicated

by the

atrow in the

llgure) and

theshin

rod end mountlng

bolt

holemust be

n the

aame

direction.

'l.

,nstallhe shitt

ork and

he shift od.

Caution

.

When

nstalling

he roll

pin,

be caretul

not to dam'

age the

shlft

rod.

2.

Installhe new

oll

pin.

3. Install

he nterlock

in.

J-52



TRANSAXLE

J

Shift

rod

(slvRev),

shitt fork

(sth/Rev),

shltt

rod

end

(5th/Fev),

oll

pin,

inte

ock

pin

Caution

.

lnstall

he

intedock

pln

nto he holeof clutch

hous-

ing as shown

in the flgure.

1. nstallthenterlock intothe

hift odand nstallthehifl od.

Cautlon

.

When nstalling he roll

pin,

becaretul not to dam-

age the shift

rod.

Note

2. Installhe

new roll

pin.

3. lnstall

he nterlock

in.

Shift rod

(3rd/4th),

shift

lork

(3rd/4th),

shift

rod end

(3rd/4th),

oll

pin

Caution

.

Install he nterlock

pin

nlo he holeot clutchhou&

ing

as

shown in lhe llgure.

1 Installthenterlock

in

o te shift odand nstallthehift od.

Caution

.

When nstalling

he roll

pin,

be caletul not to dam-

age he shift rod.

2. Installhe new roll

pin.

Diameter Length

Shifl

lork

{sth/Rev)

s.0

0.20)

22

9.8n

Shifl

rod end

(slh/Rev)

s.0

0.20)

20

(0.79)

J-s3



J

TRANSAXLE

Retaining

ing

1. nstall

he crank

everand

nstallhe

crank

evershaft.

Caution

.

Verify

he

in3talling

a retalning

ing 6urely.

.

lnstal

the

groove

of crank

ever shalt

to the diftereF

tlal end.

2.

Installhe

new etaining

ing.

3. Shift he

gears

o 3rd

gear

and

hold he shift

odwithone

handso

that t does

nol

all.

Transaxle

ase

assembly

Note

.

Tighten he

bolts to

the specified

orque.

1. Applysealant

nd

nstallhe

ransaxle ase.

Caution

.

When

nstalling

he transaxle

case,

nstall he en-

glne

mount

No.l.

2. nstallhe

ransaxle

ase o the

clutch

housing.

Tlghtening orque:

i9-26 N.m

1.9-2.6 m-kg, 14-19 ft-lb)

Plug, spring,

steel

ball

'1

. Applysealant

o the

Plugs.

2.

Installhe

geel

balls, prings

nd

plugs

Tiqhtenlnq

orque:

20-2tN.m

i2.O-3.0

m-kg, 14-22

ftlb)

3. Contirm

hat

he ransaxle

perates

moothly

hen hitted.

If not, eassembly

he

ransaxle.

ENGINEMOUNT No.l

sp

ng

Oiameter

mm

{in)

Lensh

mm

(n)

@

7.2

O.2A)

22.5

(0.89)

7.2 10.28)

33.2

r.31)

o

7.2

/{0.28)

22.5

0.89)

J-54



TRANSAXLE

J

Oil seal

1. Place hespeodometer

ear

sleeven a vice.

2. Tap he new oil seal nto he speedometer

ear

sleeveus-

ing a suitable

ipe.

Pipe

diameter:15mm

0,59

n)

Folt

pln

Install

he new oll

pin

as

shown n the igure.

Clulch

release ork, clutch releaae olol

Apply

grease

s

shown n the igure.

Clutch ever

1.Apply

grease

o the bushing.

2. nstallhe clutch ever o the clutch elease

ork.

Tightening orque:

35-41

Nm

(3.6-4.2

m-kg,

26-30 fi-lb)

J-55

1 -

"=



J

TRANSAXLE

INSTALLATION

1. Raise

he

vehicle nd

support

withsalety tands

2.

Install

n the order

shown

n the

ighre. eflerringo

Installation

Nole

3.

Ado

he specitied

mount

l the specitied

ransaxle

jl

(Refer

o

page

J-7

)

a. Warm

up ihe engine

nd

ransaxle, nd

nspector oil

eakage nd

rasaxle peration

3r

--45

(4.2-4,7,

23--.34)

huz

€ t

32-56

(3.4-s.7,

&-trif"l',.'-."

6a--a,

--:6

J-56



TRANSAXLE J

1.

Engine ountNo.2

2. ransaxle

lnstallation

ote........

page

J-57

3. Stittner

4. Exhaust

ipe

bracket

5. Enginemountmember

installationNote........ pageJ-57

6. Staner

7. Driveshatt

Installat ionote..........................

age

-58

8. Control od

lnstallat ionote .........................

age

-58

9.

Extensionar

lnstallat ionote..........................

age

-58

10.

Neutral

witch onnector

11.Back-upightswitch onnector

'12.

Clutch able

lnstallat lonote..........................

age

-58

11

qno6.l^mal6r

^.h16

lnstal lat ionote.... . . . . . . . . . . . . . . . . . . . . . .

age

J-58

14.

Battery,

battery arrier

15.Splashshied

16.

Wheel

and

trre

Installation Note

Transaxle

1.Set he ransaxle

n a

jack

and ift t into

place.

2. nstallhe ransaxle olts.

Tightening orque

A: 64-89

N.m

6.5-9.1

Bt 7.3-11 N.m

0.8-l.l

m-kg, 47-66 ft-lb)

n-kg, 5.8-8.0

ft-lb)

Enginemount member

1.

nstall

he

boltsand nutsas shown.

Tightenlng orque

@:

64-89 N.m

6.5-9.1

m-kg,47-66 ft-lb)

@:

37-52

N.m

3.8-5.3

m-kg,28-38 ft-lb)

Caution

. BetoF installhe enginemountmember, ul engine

mount No.1and

No.2

studs

n the installlnghole.

2. Removehe SST

(Eqine

support).

@rj&{r@

J-57



J

TRANSAXLE

f\rt")

Ddveshaft

Cautlon

.

Verlty hat

the oil seal

s not damaged.

.

Do not damage

he oil seal.

'1. Inserthenewclip withheend-gap t he op ot hegroove

2.

Apply transaxle

il around

he oil

seal ip

lnstall he

driveshaft.

3.

Verityhat hedriveshaft

s correctly eated

y

pulling

n

the shaft.

4. Connecthe

ower rm

o heknuckle nd

ightenhe

clinch

bolt.

Tightening orque:

43-54

N.m

4.4-5.5

m-kg,

32-40

tt-lb)

Extenslon

bar and conlrol

rod

1. nstallhe

extensionar

o the ransaxle.

Tightenin9 orque:

31-46

Nfl

(3.2-4.7

m-kg,

23-34

fr'b)

2. Installhe change ontrolod o the ransaxle.

Tightening

orque:

16-23

N.m

1.6-2.3 m-kg,

2-17 ft'lb)

Clulch cable

Installhe

clutch able.

Refer

o Section

H.)

Speedometer

able

1. Add the sDecified

mount

i the

specified

ansaxle il

thoughthe

speedometer

riven

gear

nsiallation

ole

2. nstallhe

speedometer

riven

ear.

Tightening

orque:

7.8-12 Nm

(0.8-1.2

m-kg, 5.8-8.7

ft-lb)

3.

Connecthespeedometer

able o the

speedometer

riv'

en

gear.

*

<\

J-58



DIFFERENTIAL

J

DIFFERENTIAL

PNEPARATION

SST

49 8017 2A0

@

@@@

@@@

49 DO27 02

(Part

of

49 8017

2A0)

bearins

49 F40l 366A

49 8017

2A0)

oeafrng

49 0839 425C

beanng

49 0439 428

bearing

puller

49 0839 425C)

49

0862

426

bearing

uller

49 0839425C)

49

D017

241

49 F401 3374

49 D0172Al )

J-59



J

DIFFERENTIAL

DISASSEMBLY

INSPECTION

ASSEMBLY

Caqtion

.

Do not

remove the

inner race

il not neoessary'

'1.

Before

isassembly,

nspecthe

backlash l

side

gears'

eferflng

o

Preln6P€ctlon

2.Disassemblen the ordershownn the igure. ete(ing o Disa$embly Note'

3.

Inspect ll

parts

and

repairor

replace s

necessary

4.

Me;sure

he backlash

fterassembly,

eferringo

Backlash

ol

Pinlon Geara

'1.Sidegear

lnspector

wearand

cracks

2.

Washer

3.

Roli

pin

Disassembly

ote.......................

age

-61

4.

Pinion haft

5.

Thrustwasher

6. Pinion ear

Inspect

or

wearand cracks

7. Side

bearing

nner

ace

Disassembly

ote...........

........

page

-61

Inspect

or wearand

cracls

8.

Speedometer

rive

gear

9. Ring

gear

and

gear

case

Inspect

or wear and cracl$

'wa

..-'4b,

Tffi.

J-60



DIFFERENTIAL

J

v€LocK

Preinspection

Backlash

ol

pinion geals

Measurehe backlash s

follows.

1. nstallhe eftand rightdriveshafts

nto he ditferential

s-

semDly.

2.

lMeasurehe backlash l both

pinion ears.

Backlash 0-0,1mm

(0-0.004

in)

Maximum: .5mm

0,020

n)

3.

f the

backlash

s notas soeciiied,eplacehedifierential

as an assemoty.

DisassemblyNote

Roll oin

Caution

.

use

prolectiveplates

n

the

vbe.

.

Insen he

punch

nto he roll

pin

hole lom the rlng

gearslde.

Securehe

gear

case

n

a

vice

and

ap out he roll

pin.

Slde bearing nner

race

Cautlon

.

When

eplacinga bearing, eplac€

he inner

and out-

er

taces as a set,

1. Removehe bearingnner ace

speedometer

rive

gear

side)with he

SST.

2. Removehe bearing

nner ace

ringgear

side)wilhhe SSI.

1EoJXj75

BEABING

NNER

J-61



J

OIFFERENTIAL

Assembly

1. nstallthe peedometer

rive

gear

as

shown

n he igure

Cautlon

.

Wtlen

replacing

a bearing,

eplace

he

inner and out-

er

races as a

set.

2.

Installhe new

beanng

nner

ace.

(1)

Installthe

ew

bearing

nner ace

speedometerrive

gear

sjde)

witha

Press

nd he

SST

(2)

Installhe

newbearing

nner

ace

(ring

ear

side)with

a

press

nd

he SST.

3. Set

he

pinion ears

nd hrust

washer

nto

he

gear

case

4.

Inserthe

pinion

haft.

J-62



DIFFERENTIAL

J

5.

Install

a new

roll

pin

and stake he case o

prevent

t from

workino ut.

6.

Install

he sideoearsand washers.

Backlash

of PinionGears

Recheck

he backlash l the

pinion ears.

(Refer

o

page

J-61.)

J-63



J

SHIFT

IECHANISM

SHIFT

MECHANISM

OVERHAUL

1.

Disassemble

n the ordershown

n the igure.

2.

Inspect

ll

parts

and

repairor replace s

necessary.

3.

Assemble

n the reverse rder

of disassembly,

eferringo

AssemblyNote

16-26

0.6-2.3,

t2-t4

J-64



SHIFTMECHANIS]II

1.Shift

everknob 18.Washer

2.

Ashtray 19.Pipe

3. Front onsole

20.

Bushing

4. Boot Insp€ctor wear

and

damage.

5. Nut

21.

nsulator

6.Washer Inspector

damage ndcracks

7.Bolt 22. Bushing

8. Nut Inspector wearand damage

9. Bolt

23.

Boot

10.

Control

od Insp€ct

or damage

Inspector

bending 24.Spring

Assembly

ote............................

age

J-66

Inspector

damage

nd weakness

11.Bushing Assemblyote............................

age

-66

Inspect or wear and

damage 25. Ball seat

upper)

12.Nut

26. Boot

13.Washer Inspector wear

and damage

14.Washer

27. Holdel

15. Nut

28. Ball seat

bwer)

'16.

Washer 29.Shift ever

17.Extensionar olEoJxr86

Inspector bending

Assembly ote......................... ...

age

-66

J

mazda 121, kia pride repair manual vol 1

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