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Toyota 2VZ-FE, Manual

The Toyota 2VZ-FE is a reliable and efficient engine used in various Toyota models. To better understand its mechanics and maintenance, download the free user manual from our website. This comprehensive manual provides detailed instructions and diagrams, enabling smooth operation and optimized performance for your vehicle.

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DISASSEMBLY OF CYLINDER BLOCK

(See page 

EM–69

)

1. 

REMOVE REAR OIL SEAL RETAINER
Remove the six bolts and retainer.

2. 

CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.

Standard thrust clearance: 0.150–0.330 mm

(0.0059–0.0130 in.)

Maximum thrust clearance: 0.38 mm (0.0150 in.)

If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crank-
shaft.

3.  REMOVE CONNECTING ROD CAPS AND CHECK OIL

CLEARANCE
(a) Using a punch or numbering stamp, place the

matchmarks on the connecting rod and cap to ensure
correct reassembly.

(b)  Using SST, remove the connecting rod cap nuts.
SST 09011–38121

(c)  Using a plastic–faced hammer, lightly tap the

connecting rod bolts and lift off the connecting rod cap.

HINT: Keep the lower bearing inserted with the connecting
cap.

EM-71

ENGINE MECHANICAL   –   Cylinder Block

Summary of Contents for 2VZ-FE

Page 1: ...ENGINE MECHANICAL EM 1 ENGINE MECHANICAL Description Operation ...

Page 2: ...DESCRIPTION The 2VZ FE engine is a V 6 2 5 liter DOHC 24 valve engine OPERATION EM 2 ENGINE MECHANICAL Description Operation ...

Page 3: ...DESCRIPTION The 2VZ FE engine is a V 6 2 5 liter DOHC 24 valve engine OPERATION EM 2 ENGINE MECHANICAL Description Operation ...

Page 4: ...placement of the shims without removal of the cam shafts The timing belt cover is composed of the resin type No 2 and No 1 above and below the engine RH mounting bracket Pistons are made of high temperature resistant aluminum alloy and a depression is built into the piston head to prevent interference with the valves Piston pins are the semi floating type with the pins fastened to the connecting r...

Page 5: ...ng Compressor 09202 70010 Crankshaft Pulley Holding Tool 09213 54015 Crankshaft Pulley Gear Puller Set 09213 60017 Body with Bolt 09213 00020 Handle 09213 00030 Bolt Set 09213 00060 Crankshaft Pulley Holding Tool 09213 70010 Piston Pin Remover Replacer 09221 25024 Body 09221 00020 Spring 09221 00030 Bushing E 09221 00181 Guide K 09221 00190 Illustration Part No Part Name Note EM 4 ENGINE MECHANICA...

Page 6: ...haft Holding Tool Camshaft timing pulley 09278 54012 TransmissionBearing Replacer Crankshaft front oil seal 09309 37010 CompanionFlange Holding Tool Crankshaftpulley 09330 00021 Oil Pressure Switch Socket Knock sensor 09816 30010 RECOMMENDED TOOLS Illustration Part No Part Name Note EngineAdjust Kit For suspending engine 09200 00010 Plug for vacuum hose fuel hose etc Hose plug Set 09258 00030 Expa...

Page 7: ...alipers SSM SERVICE SPECIAL MATERIALS Part Name Part No Use etc Camshaft bearing cap Seal packing or equivalent 08826 00080 Cylinder head cover Rear oil sear retainer Seal packing 1282B Three bond 1282B or equivalent 08826 00100 Water by pass pipe Adhesive 1324 Three bond 1324 or equivalent 08833 00070 Flywheel or drive plate mount bolt Adhesive 1344 Three bond 1344 Loctite 242 or equivalent 08833...

Page 8: ... 1 and 2 on page CH 5 Standard specific gravity 1 25 1 27 when fully charged at 20 C 68 F INSPECTION OF AIR FILTER See step 3 on page MA 4 INSPECTION OF HIGH TENSION CORDS See page IG 7 Maximum resistance 25 kW per cord INSPECTION OF DRIVE BELT See step 3 on page MA 4 Drive belt tension New belt 175 5 lb Used belt 115 20 lb EM 7 ENGINE MECHANICAL Engine Tune Up ...

Page 9: ...k as above 4 ADJUST VALVE CLEARANCE a Check only those valves indicated in the figure Using a feeler gauge measure the clearance between the valve lifter and camshaft Record out of specification valve clearance measurements They will be used later to determine the required replacement adjusting shim Valve clearance Cold Intake 0 13 0 23 mm 0 005 0 009 in Exhaust 0 27 0 37 mm 0 011 0 015 in b Turn ...

Page 10: ...he thickness of a new shim so that the valve clearance comes within specified value T Thickness of used shim A Measured valve clearance N Thickness of new shim Intake N T A 0 18 mm 0 007 in Exhaust N T A 0 32 mm 0 013 in Select a new shim with a thickness as close as possible to the calculated values HINT Shims are available in seventeen sizes of 0 05 mm 0 0020 in from 2 50 mm 0 0984 in to 3 30 mm...

Page 11: ...E Intake valve clearance Cold 0 13 0 23 mm 0 005 0 009 in EXAMPLE The 2 800 mm 0 1102 in shim is installed and measured clearance is 0 450 mm 0 0177 in Replace the 2 800 mm 0 1102 in shim with a No 22 shim EM 10 ENGINE MECHANICAL Engine Tune Up ...

Page 12: ...UST Exhaust valve clearance 0 27 0 37 mm 0 011 0 015 in EXAMPLE The 2 800 mm 0 1102 in shim is installed and measured clearance is 0 450 mm 0 0177 in Replace the 2 800 mm 0 1102 in shim with a No 18 shim EM 11 ENGINE MECHANICAL Engine Tune Up ...

Page 13: ...properly connected f EFI system wiring connectors fully plugged in g Transmission in neutral h Tachometer and HC CO meter calibrated aud close at hand 2 START ENGINE 3 RACE ENGINE AT 2 500 RPM FOR APPROX 2 MINUTES 4 INSERT HC CO METER TESTING PROBE INTO TAILPIPE AT LEAST 40 cm 1 3 ft 5 CHECK HC CO CONCENTRATION AT IDLE Complete the measuring within three minutes HINT When performing the 2 mode 2 5...

Page 14: ...properly connected f EFI system wiring connectors fully plugged in g Transmission in neutral h Tachometer and HC CO meter calibrated aud close at hand 2 START ENGINE 3 RACE ENGINE AT 2 500 RPM FOR APPROX 2 MINUTES 4 INSERT HC CO METER TESTING PROBE INTO TAILPIPE AT LEAST 40 cm 1 3 ft 5 CHECK HC CO CONCENTRATION AT IDLE Complete the measuring within three minutes HINT When performing the 2 mode 2 5...

Page 15: ...lves 5 L k li d y 5 Leaky cylinder High Low Rough idle 1 Vacuum leak High Low Rough idle Fluctuating HC reading 1 Vacuum leak D PCV hose g g D EGR valve D Intake manifold Intake manifold D Air intake chamber Air intake chamber D Throttle body D Throttle body D ISC valve D ISC valve D Brake booster line D Brake booster line 2 Lean mixture causing misfire High High Rough idle 1 Clogged air filter Hi...

Page 16: ...s measurement must be done in as short a time as possible Compression pressure 12 5 kg cm2 178 psi 1226 kPa or more Minimum pressure 10 0 kg cm2 142 psi 981 kPa Difference between each cylinder 1 0 kg cm2 14 psi 981 kPa or less e If the cylinder compression in one or more cylinders is low pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a through c f...

Page 17: ... position and the negative termi nal cable is disconnected from the battery 2 REMOVE SUSPENSION UPPER BRACE See step 7 on page EM 63 3 REMOVE CRUISE CONTROL ACTUATOR See step 15 on page EM 64 4 REMOVE PS OIL RESERVOIR TANK WITHOUT DISCONNECTING HOSES See step 36 on page EM 67 5 REMOVE RH FRONT WHEEL 6 REMOVE ALTERNATOR DRIVE BELT 7 REMOVE RH FENDER APRON SEAL 8 REMOVE PS DRIVE BELT EM 15 ENGINE ME...

Page 18: ...INTAKE CHAMBER See step 1 to 14 on pages FI 28 and 29 13 REMOVE SPARK PLUGS See page IG 7 14 REMOVE NO 2 TIMING BELT COVER Remove the eight bolts timing belt cover and gasket 15 REMOVE ENGINE RH MOUNTING BRACKET Remove the three bolts and mounting bracket 16 IF RE USING TIMING BELT CHECK INSTALLATION MARKS ON TIMING BELT Check that there are four installation marks on the timing belt by turning th...

Page 19: ...BELT TENSIONER Remove the two bolts tensioner and dust boot 19 REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEY HINT Re using timing belt If the installation marks have disappeared before removing the timing belt place new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys a Using SST loosen the tension between the LH and RH camshaft timing pulleys by slig...

Page 20: ... place new installation mark on the timing belt to match the end of the No 1 timing belt cover 20 REMOVE CAMSHAFT TIMING PULLEYS Using SST remove the bolt timing pulley and knock pin Re move the two timing pulleys SST RH 09249 63010 and 09278 54012 LH 09278 54012 HINT Arrange the RH and LH pulleys 21 REMOVE NO 2 IDLER PULLEY Remove the bolt and idler pulley EM 18 ENGINE MECHANICAL TimingBelt ...

Page 21: ...n the crankshaft pulley bolt is loosened the position of the timing mark of the crankshaft pulley and also the installation mark may slip so check and align them again b Using SST remove the pulley SST 09213 60017 23 REMOVE NO 1 TIMING BELT COVER Remove the four bolts timing belt cover and gasket 24 REMOVE TIMING BELT GUIDE EM 19 ENGINE MECHANICAL TimingBelt ...

Page 22: ...to match the drilled mark of the crankshaft timing pulley 26 REMOVE NO 1 IDLER PULLEY Using a 8 mm hexagon wrench remove the bolt idler pulley and plate washer 27 REMOVE CRANKSHAFT TIMING PULLEY If the pulley cannot be removed by hand use two screw drivers HINT Position shop rags as shown to prevent damage EM 20 ENGINE MECHANICAL TimingBelt ...

Page 23: ...wn in the figures check the fol lowing points a Premature parting Check for proper installation Check the timing cover gasket for damage and proper installation b If the belt teeth are cracked or damaged check to see if either camshaft is locked c If there is noticeable wear or cracks on the belt face check to see if there are nicks on the side of the idler pulley lock and water pump d If there is...

Page 24: ...ually check tensioner for oil leakage HINT If there is only the faintest trace of oil on the seal on the push rod side the tensioner is all right If leakage is found replace the tensioner b Hold the tensioner with both hands and push the push rod strongly against the floor or wall to check that it doesn t move If the push rod moves replace the tensioner c Measure the protrusion of the push rod fro...

Page 25: ...350 kg cm 25 ft lb 34 N m c Check that the pulley bracket moves smoothly 3 TEMPORARILY INSTALL TIMING BELT NOTICE The engine should be cold a Remove any oil or water on the crankshaft timing No 1 idler and water pump pulleys and keep them clean b Align the installation mark on the timing belt with the drilled mark of the crankshaft timing pulley c Install the timing belt on the crankshaft timing N...

Page 26: ... outward b Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley and install the knock pin c Using SST install and torque the bolt SST 09278 54012 Torque 1 100 kg cm 80 ft lb 108 N m 9 SET NO 1 CYLINDER TO TDC COMPRESSION a Crankshaft Position Turn the crankshaft pulley and align its groove with the O timing mark of the No 1 timing belt cover b RH Camshaft Pulley ...

Page 27: ...mshaft timing pulley SST 09278 54012 d Using SST align the timing marks of the LH camshaft pulley and No 3 timing belt cover SST 09278 54012 e Check that the timing belt has tension between the crankshaft timing and LH camshaft timing pulleys 11 INSTALL RH CAMSHAFT TIMING PULLEY AND TIMING BELT a Remove any oil or water on the RH camshaft timing and No 2 idler pulleys and keep them clean b Align t...

Page 28: ...NG BELT TENSIONER a Place a plate washer between the tensioner and a block b Using a press slowly press in the push rod using 100 1 000 kg 220 2 205 lb 981 9 807 N of pressure c Align the holes of the push rod and housing pass a 1 27 mm hexagon wrench through the holes to keep the setting position of the push rod d Release the press e Install the dust boot to the tensioner 13 INSTALL TIMING BELT T...

Page 29: ...timing belt and reinstall it 15 INSTALL ENGINE RH MOUNTING BRACKET Install the mounting bracket with the three bolt Torque 410 kg cm 30 ft lb 39 N m 16 INSTALL NO 2 TIMING BELT COVER a Install the gasket to the timing belt cover b Install the timing belt cover with the eight bolts HINT Use the bolts indicated by A B and C 17 INSTALL SPARK PLUGS See page IG 8 Torque 180 kg cm 13 ft lb 18 N m 18 INS...

Page 30: ...ts Torque the bolts Torque 530 kg cm 38 ft lb 52 N m b Install the No 2 mounting stay with the bolt and nut Torque the bolt and nut Torque Bolt 670 kg cm 48 ft lb 66 N m Nut 530 kg cm 38 ft lb 52 N m 22 INSTALL PS PUMP DRIVE BELT Adjust the drive belt Drive belt tension New belt 125 20 lb Used belt 80 25 lb 23 INSTALL ALTERNATOR DRIVE BELT Adjust the drive belt See pages MA 4 Drive belt tension Ne...

Page 31: ...CYLINDER HEADS COMPONENTS EM 29 ENGINE MECHANICAL Cylinder Heads ...

Page 32: ...tep 15 on page EM 64 7 REMOVE AIR CLEANER HOSE a Disconnect the following hoses 1 ISC valve air hose 2 Vacuum pipe hose b Remove the air cleaner hose 8 REMOVE ENGINE RH UNDER COVER 9 REMOVE SUSPENSION LOWER CROSSMEMBER See step 27 on page EM 65 10 REMOVE FRONT EXHAUST PIPE See step 28 on page EM 65 11 REMOVE ALTERNATOR See page CH 8 12 REMOVE ISC VALVE See steps 3 to 5 on pages FI 44 and FI 45 13 ...

Page 33: ... 21 REMOVE AIR INTAKE CHAMBER a Disconnect the following hoses 1 PCV hose 2 Vacuum sensing hose 3 Fuel pressure VSV hose 4 A C control valve vacuum hose 5 CALIF only EGR gas temperature sensor connector b Remove the four bolts and two intake chamber stays c Remove the two bolts two nuts intake chamber and two gaskets 22 REMOVE DELIVERY PIPES AND INJECTORS See steps 15 to 19 on pages FI 29 and 30 2...

Page 34: ...o bolts and crossover pipe heat insulator from the water by pass outlet 25 REMOVE CYLINDER HEAD REAR PLATE Remove the two bolts and rear plate 26 REMOVE INTAKE MANIFOLD a Remove the two bolts and No 2 idler pulley bracket stay b Remove the eight bolts four nuts intake manifold and two gaskets 27 REMOVE RH EXHAUST MANIFOLD a Disconnect the main oxygen sensor connector b Remove the three nuts and ou...

Page 35: ...30 REMOVE TIMING BELT CAMSHAFT TIMING PULLEYS AND NO 2 IDLER PULLEY See steps 3 to 19 on pages EM 15 to 18 31 REMOVE NO 3 TIMING BELT COVER Remove the six bolts and timing belt cover NOTICE Support the belt so the meshing of the crankshaft timing pulley and timing belt does not shift Be careful not to drop anything inside of the timing belt cover Do not allow the belt to come into contact with oil...

Page 36: ...following steps should be carried out A Remove exhaust camshaft of RH cylinder head a Align the timing marks two pointed marks of the camshaft drive and driven gears by turning the camshaft with a wrench b Secure the exhaust camshaft sub gear to the driven gear with a service bolt Recommended service bolt Thread diameter 6 mm Thread pitch 1 0 mm Bolt length 16 20 mm 0 63 0 79 in HINT When removing...

Page 37: ...vice bolt Recommended service bolt Thread diameter 6 mm Thread pitch 1 0 mm Bolt length 16 20 mm 0 63 0 79 in HINT When removing the camshaft make certain that the torsional spring force of the sub gear has been eliminated by the above operation c Uniformly loosen and remove the eight bearing cap bolts in several passes in the sequence shown d Remove the four bearing caps and exhaust camshaft D Re...

Page 38: ...bolt A into the service hole of the camshaft sub gear c Using a screwdriver turn the sub gear clockwise and remove the service bolt B NOTICE Be careful not to damage the camshaft d Using snap ring pliers remove the snap ring e Remove the following parts 1 Wave washer 2 Camshaft sub gear 3 Camshaft gear spring HINT Arrange the camshaft sub gears and gear springs RH and LH EM 36 ENGINE MECHANICAL Cy...

Page 39: ...racking could result from re moving bolts in an incorrect order c Lift the cylinder head from the dowels on the cylinder block and place the two cylinder heads on wooden blocks on a bench HINT If the cylinder head is difficult to lift off pry with a screw driver between the cylinder head and cylinder block NOTICE Be careful not to damage the contact surfaces of cylinder head and cylinder block EM ...

Page 40: ... 2 REMOVE VALVES a Using SST compress the valve spring and remove the two keepers SST 09202 70010 b Remove the spring retainer valve spring valve and spring seat HINT Arrange the valves valve springs spring seats and spring retainers in correct order c Using needle nose pliers remove the oil seal EM 38 ENGINE MECHANICAL Cylinder Heads ...

Page 41: ...ct your eyes when using high pressure compressed air 2 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gasket material from the cylinder block contact surface NOTICE Be careful not to scratch the surfaces 3 CLEAN COMBUSTION CHAMBERS Using a wire brush remove all the carbon from the combus tion chambers NOTICE Be careful not to scratch the cylinder block con tact surface 4 CLEAN VALVE ...

Page 42: ...S Using a dye penetrant check the combustion chamber in take ports exhaust ports and cylinder block surface for cracks If cracked replace the cylinder head 8 CLEAN VALVES a Using a gasket scraper chip off any carbon from the valve head b Using a wire brush thoroughly clean the valve 9 INSPECT VALVE STEMS AND GUIDE BUSHINGS a Using a caliper gauge measure the inside diameter of the guide bushing Bu...

Page 43: ...0026 in Maximum oil clearance Intake 0 08 mm 0 0031 in Exhaust 0 10 mm 0 0039 in If the clearance is greater than maximum replace the valve and guide bushing 10 IF NECESSARY REPLACE VALVE GUIDE BUSHINGS a Insert an old valve wrapped with tape into the valve guide bushing and break off the valve guide bushing by hitting it with a hammer NOTICE Be careful not to damage the valve lifter hole b Gradua...

Page 44: ... the bushing bore diameter of the cylinder head is greater than 11 077 mm 0 4361 in replace the cylinder head f Gradually heat the cylinder head to 80 1005C 176 2125F g Using SST and a hammer tap in a new guide bushing until the snap ring makes contact with the cylinder head SST 09201 70010 h Using a sharp 6 mm reamer ream the guide bushing to obtain the standard specified clearance See page EM 41...

Page 45: ...lace the valve NOTICE Do not grind off more than the minimum 12 INSPECT AND CLEAN VALVE SEATS a Using a 45 carbide cutter resurface the valve seats Remove only enough metal to clean the seats b Check the valve seating position Apply a thin coat of prussian blue or white lead to the valve face Lightly press the valve against the seat Do not rotate the valve c Check the valve face and seat for the f...

Page 46: ...an abrasive compound e After hand lapping clean the valve and valve seat 13 INSPECT VALVE SPRINGS a Using a steel square measure the squareness of the valve spring Maximum squareness 2 0 mm 0 075 in If squareness is greater than maximum replace the valve spring b Using vernier calipers measure the free length of the valve spring Free length 42 6 mm 1 677 in If the free length is not as specified r...

Page 47: ...am shaft B Inspect cam lobes Using a micrometer measure the cam lobe height Standard cam lobe height Intake 39 510 39 610 mm 1 5555 1 5594 in Exhaust 38 960 39 060 mm 1 5339 1 5378 in Minimum cam lobe height Intake 39 36 mm 1 5496 in Exhaust 38 81 mm 1 5279 in If the cam lobe height is greater than maximum replace the camshaft C Inspect camshaft journals Using a micrometer measure the journal diam...

Page 48: ...re the Plastigage at its widest point Standard oil clearance 0 035 0 072 mm 0 0014 0 0028 in Maximum oil clearance 0 10 mm 0 0039 in If the oil clearance is greater than maximum replace the cam shaft If necessary replace the bearing caps and cylinder head as a set g Completely remove the Plastigage G Inspect camshaft thrust clearance a Install the camshafts See step 4 on pages EM 52 to EM 55 b Usi...

Page 49: ... clearance 0 015 0 046 mm 0 0005 0 0018 in Maximum oil clearance 0 07 mm 0 0028 in If the oil clearance is greater than maximum replace the lifter If necessary replace the cylinder head 16 INSPECT INTAKE MANIFOLD EXHAUST MANIFOLDS AND AIR INTAKE CHAMBER a Intake Manifold Using precision straight edge and feeler gauge mea sure the surfaces contacting the cylinder head and air intake chamber for war...

Page 50: ...new spark plug tube until there is 45 5 45 9 mm 1 791 1 807 in protruding from the cam shaft bearing cap installation surface of the cylinder head NOTICE Avoid pressing a new spark plug tube in too far by measuring the amount of protrusion while pressing 2 INSTALL VALVES a Using SST push in a new oil seal SST 09201 41020 b Install the following parts 1 Valve 2 Spring seat 3 Valve spring 4 Spring r...

Page 51: ...c Using a plastic faced hammer lightly tap the valve stem tip to assure proper fit 3 INSTALL VALVE LIFTERS AND SHIMS Check the valve lifter rotates smoothly by hand EM 49 ENGINE MECHANICAL Cylinder Heads ...

Page 52: ... e If any bolts is broken or deformed replace it a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts b Install and uniformly tighten the cylinder head bolts in several passes in the sequence shown Torque 350 kg cm 25 ft lb 34 N m If any one of the bolts does not meet the torque specification replace the bolt c Mark the front of the cylinder head bolt he...

Page 53: ...orque 185 kg cm 13 ft lb 18 N m 2 INSTALL LH ENGINE HANGER Torque 380 kg cm 27 ft lb 37 N m 3 ASSEMBLE EXHAUST CAMSHAFTS a Install the following parts 1 Camshaft gear spring 2 Camshaft sub gear 3 Wave washer b Using snap ring pliers install the snap ring c Mount the hexagonal wrench head portion of the camshaft in a vise NOTICE Be careful not to damage the camshaft EM 51 ENGINE MECHANICAL Cylinder...

Page 54: ...d If the camshaft is not level the portion of the cylinder head receiving the shaft thrust may crack or be damaged causing the camshaft to seize or break To avoid this the following steps should be carried out A Install intake camshaft of RH cylinder head a Apply MP grease to the thrust portion of the camshaft b Place the intake camshaft at 905 angle of timing mark two pointed marks on the cylinde...

Page 55: ...n gears c Place the exhaust camshaft on the cylinder head d Install the four bearing caps in their proper locations e Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts f Install and uniformly tighten the eight bearing cap bolts in several passes in the sequence shown Torque 160 kg cm 12 ft lb 16 N m g Remove the service bolt B C Install intake camshaft of...

Page 56: ...Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown Torque 160 kg cm 12 ft lb 16 N m D Install exhaust camshaft of LH cylinder head a Apply MP grease to the thrust portion of the camshaft b Align the timing marks one pointed mark of the camshaft drive and driven gears c Place the intake camshaft on the cylinder head d Install the four bearing caps in the...

Page 57: ... 5 CHECK AND ADJUST VALVE CLEARANCE See page EM 9 Turn the camshaft and position the cam lobe upward and check and adjust the valve clearance Valve clearance Cold Intake 0 13 0 23 mm 0 005 0 009 in Exhaust 0 27 0 37 mm 0 011 0 015 in 6 INSTALL CAMSHAFT OIL SEALS a Apply MP grease to a new oil seal lip b Using SST tap in the oil seals SST 09223 46011 7 INSTALL SPARK PLUG TUBE GASKETS Install the si...

Page 58: ...e two cylinder head covers Torque 60 kg cm 52 in lb 5 9 N m 9 INSTALL NO 3 TIMING BELT COVER Install the timing belt cover with the six bolts Torque 75 kg cm 65 in lb 7 4 N m 10 INSTALL NO 2 IDLER PULLEY CAMSHAFT TIMING PULLEYS AND TIMING BELT See steps 7 to 26 on pages EM 24 to 28 11 INSTALL SPARK PLUGS See page IG 8 Torque 180 kg cm 13 ft lb 18 N m 12 INSTALL RH EXHAUST MANIFOLD a Install the in...

Page 59: ...L LH EXHAUST MANIFOLD a Install a new gasket and the exhaust manifold with six new nuts Uniformly tighten the nuts in several passes Torque 400 kg cm 29 ft lb 39 N m b Install the heat insulator with the two nuts 14 INSTALL INTAKE MANIFOLD a Install two new gaskets and the intake manifold with the eight bolts and four nuts Uniformly tighten the bolts and nuts in several passes Torque 180 kg cm 13 ...

Page 60: ...he three nuts Torque 200 kg cm 14 ft lb 20 N m c Connect the following connectors and hose 1 Heater water by pass hose 2 Cold start injector time switch connector 3 Water temperature switch 17 INSTALL WATER OUTLET a Install a new gasket and the water outlet with the three nuts Torque 85 kg cm 73 ft lb 8 3 N m b Connect the following hose and connector 1 Radiator upper hose 2 Water temperature sens...

Page 61: ...CONNECTOR 22 INSTALL EXHAUST CROSSOVER PIPE a Install new two gaskets to the RH and LH exhaust manifolds b Install the crossover pipe with the six nuts and two bolts Torque Nut 400 kg cm 29 ft lb 39 N m Bolt 350 kg cm 25 ft lb 34 N m 23 INSTALL DISTRIBUTOR See page IG 11 24 INSTALL VACUUM PIPE a Install the vacuum pipe with the two bolts b Connect the following hoses 1 Four BVSV vacuum hoses 2 A C...

Page 62: ...INSTALL CRUISE CONTROL ACTUATOR See step 27 on page EM 97 34 INSTALL ACCELERATOR CABLE AND ADJUST IT 35 A T CONNECT THROTTLE CABLE AND ADJUST IT 36 INSTALL SUSPENSION UPPER BRACE See step 35 on page EM 98 37 FILL WITH ENGINE COOLANT See page CO 5 38 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 39 START ENGINE AND CHECK FOR LEAKS 40 ADJUST IGNITION TIMING See on page IG 13 Ignition timing 10 BTDC ...

Page 63: ...CYLINDER BLOCK REMOVAL OF ENGINE EM 61 ENGINE MECHANICAL Cylinder Block ...

Page 64: ...EM 62 ENGINE MECHANICAL Cylinder Block ...

Page 65: ...MOVE BATTERY Disconnect the ground strap 4 REMOVE ENGINE UNDER COVERS 5 DRAIN ENGINE COOLANT See page CO 5 6 DRAIN ENGINE OIL 7 REMOVE SUSPENSION UPPER BRACE Remove the four bolts and upper brace 8 REMOVE IGNITION COIL IGNITER AND BRACKET ASSEMBLY a Disconnect the following cord and connectors 1 Igniter connector 2 Noise filter connector 3 High tension cord b Remove the two bolts the ignition coil...

Page 66: ...et d Disconnect the vacuum pump connector e Remove the three bolts vacuum pump and bracket 16 REMOVE AIR CLEANER ASSEMBLY a Disconnect the following connector and hoses 1 Air flow meter connector 2 ISC valve air hose 3 Vacuum pipe air hose b Disconnect the four air cleaner cap clips c Disconnect the air cleaner hose and remove the air cleaner cap hoses and air flow meter assembly d Remove the air ...

Page 67: ...ainer 22 M T REMOVE STARTER 23 M T REMOVE CLUTCH RELEASE CYLINDER AND TUBE CLAMP WITHOUT DISCONNECTING TUBE 24 DISCONNECT SPEEDOMETER CABLE 25 DISCONNECT TRANSAXLE CONTROL CABLE S 26 DISCONNECT ENGINE WIRE FROM CABIN a Remove the under cover b Remove the glove compartment box c Disconnect the following connectors 1 Three engine ECT ECU connectors 2 Circuit opening relay connector 3 Cowl wire conne...

Page 68: ... support with a string 30 REMOVE DRIVE SHAFTS See pages SA 23 to 25 31 REMOVE PS PUMP WITHOUT DISCONNECTING HOSES HINT Put aside the pump and suspend it to the cowl with a string 32 REMOVE ENGINE MOUNTING CENTER MEMBER Remove the eight bolts two nuts and center member 33 REMOVE FRONT ENGINE MOUNTING INSULATOR AND BRACKET a Remove the nut through bolt and mounting insulator b Remove the three bolts...

Page 69: ...ITHOUT DISCONNECTING HOSES Remove the two bolts and reservoir tank Disconnect the ground strap 37 REMOVE ENGINE RH MOUNTING STAYS a Remove the three bolts and No 1 mounting stay b Remove the bolt nut and No 2 mounting stay 38 REMOVE ENGINE LH MOUNTING STAY M T Remove the bolt two nuts and mounting stay A T Remove the three nuts and mounting stay EM 67 ENGINE MECHANICAL Cylinder Block ...

Page 70: ... LH mounting insulator e Remove the three bolts and LH mounting bracket f Lift the engine out of the vehicle slowly and carefully NOTICE Be careful not to hit the PS gear housing or neutral start switch g Make sure that the engine is clear of all wiring hoses and cables h Place the engine and transaxle assembly onto the stand 40 A T REMOVE STARTER See page ST 5 41 SEPARATE ENGINE AND TRANSAXLE See...

Page 71: ...COMPONENTS EM 69 ENGINE MECHANICAL Cylinder Block ...

Page 72: ...BELT AND PULLEYS See pages EM 16 to 20 8 REMOVE CYLINDER HEADS See pages EM 30 to 37 9 REMOVE WATER PUMP See page CO 6 10 REMOVE OIL PAN AND OIL PUMP See page LU 8 11 REMOVE OIL FILTER See page LU 6 12 REMOVE KNOCK SENSOR Using SST remove the knock sensor SST 09816 30010 13 REMOVE WATER BY PASS PIPE Remove the two bolts two nuts and by pass pipe 14 REMOVE NO 2 IDLER PULLEY BRACKET Remove the three...

Page 73: ...f the thrust clearance is greater than maximum replace the connecting rod assembly If necessary replace the crank shaft 3 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Using a punch or numbering stamp place the matchmarks on the connecting rod and cap to ensure correct reassembly b Using SST remove the connecting rod cap nuts SST 09011 38121 c Using a plastic faced hammer lightly tap the co...

Page 74: ...earing is damaged replace the bearings If necessary grind or replace the crankshaft g Lay a strip of Plastigage across the crank pin h Install the connecting rod cap with the two nuts See step 6 on pages EM 89 and 90 Torque 1st 250 kg cm 18 ft lb 25 N m 2nd turn 90 NOTICE Do not turn the crankshaft i Remove the two nuts and connecting rod cap See procedure b and c above EM 72 ENGINE MECHANICAL Cyl...

Page 75: ...Completely remove the Plastigage 4 REMOVE PISTON AND CONNECTING ROD ASSEMBLIES a Using a ridge reamer remove the all carbon from the top of the cylinder b Cover the connecting rod bolts See page EM 72 c Push the piston connecting rod assembly and upper bearing through the top of the cylinder block HINT Keep the bearings connecting rod and cap together Arrange the piston and connecting rod assembli...

Page 76: ... c Lift out the crankshaft HINT Keep the upper main bearings and upper thrust wash ers together with the cylinder block d Clean each main journal and bearing e Check each main journal and bearing for pitting and scratches If the journal or bearing is damaged replace the bearings If necessary grind or replace the crankshaft f Place the crankshaft on the cylinder block g Lay a strip of Plastigage ac...

Page 77: ...ng cannot be de termined select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft then selecting the bearing with the same number as the total There are five sizes of standard bearings marked 1 2 3 4 and 5 accordingly Number marked Cylinder block 1 2 3 Crankshaft 0 1 2 0 1 2 0 1 2 Bearing 1 2 3 2 3 4 3 4 5 EXAMPLE Cylinder block 2 Crankshaft 1 Total ...

Page 78: ... block HINT Arrange the main bearings and thrust washers in cor rect order INSPECTION OF CYLINDER BLOCK 1 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gasket material from the top surfaces of the cylinder block 2 CLEAN CYLINDER BLOCK Using a soft brush and solvent thoroughly clean the cylinder block 3 INSPECT TOP SURFACES OF CYLINDER BLOCK FOR FLATNESS Using precision straight edge...

Page 79: ... cylinder gauge measure the cylinder bore diameter at positions A B and C in the thrust axial directions Standard diameter STD Mark 1 87 500 87 510 mm 3 4449 3 4453 in Mark 2 87 510 87 520 mm 3 4453 3 4457 in Mark 3 87 520 87 530 mm 3 4457 3 4461 in Maximum diameter STD 87 73 mm 3 4539 in O S 0 50 88 23 mm 3 4736 in If the diameter is greater than maximum rebore all the six cylinders or replace th...

Page 80: ...er remove the two compression rings b Remove the two side rails and oil ring expander by hand HINT Arrange the rings in correct order only 3 DISCONNECT CONNECTING ROD FROM PISTON Using SST press out the piston pin from the piston SST09221 25024 09221 00020 09221 00030 09221 00181 09221 00190 09221 00200 HINT The piston and pin are a matched set Arrange the pistons pins rings connecting rods and be...

Page 81: ...es to the piston pin center line 24 25 mm 0 9547 in from the piston head Piston diameter STD Mark 1 87 445 87 455 mm 3 4427 3 4431 in STD Mark 2 87 455 87 465 mm 3 4431 3 4435 in STD Mark 3 87 465 87 475 mm 3 4435 3 4439 in O S 0 50 87 945 87 975 mm 3 4624 3 4636 in b Measure the cylinder bore diameter in the thrust directions See step 5 on page EM 77 c Subtract the piston diameter measurement fro...

Page 82: ...ert the piston ring into the cylinder bore b Using a piston push the piston ring a little beyond the bottom of the ring travel 100 mm 3 94 in from the top of the cylinder block c Using a feeler gauge measure the ring end gap Standard ring end gap No 1 0 300 0 540 mm 0 0118 0 0213 in No 2 0 350 0 620 mm 0 0138 0 0244 in Oil Side rail 0 200 0 570 mm 0 0079 0 0224 in Maximum ring end gap No 1 1 14 mm...

Page 83: ...ll the cap nut to the connecting rod bolt Check that the cap nut can be turned easily by hand to the end of the thread b If the cap nut cannot be turned easily measure the outer diameter of the compressed thread with calipers Standard outer diameter 7 860 8 000 mm 0 3094 0 3150 in Minimum outer diameter 7 60 mm 0 2992 in HINT If the location of this area cannot be judged by visual inspection measu...

Page 84: ...er measure the piston diameter at right angles to the piston pin center line 24 25 mm 0 9547 in from the piston head b Calculate the amount each cylinder is to be rebored as follows Size to be rebored P C H P Piston diameter C Piston oil clearance 0 045 0 065 mm 0 0018 0 0026 in H Allowance for honing 0 02 mm 0 0008 in or less 3 BORE AND HONE CYLINDERS TO CALCULATED DIMENSIONS Maximum honing 0 02 ...

Page 85: ...m 2 5096 2 5100 in Crank pin diameter STD 47 987 48 000 mm 1 8892 1 8898 in U S 0 25 47 745 47 755 mm 1 8797 1 8801 in If the diameter is not as specified check the oil clearance See pages EM 71 to EM 75 b Check each main journal and crank pin for taper and out of round as shown Maximum taper and out of round 0 02 mm 0 0008 in If the taper or out of round is greater than maximum grind or replace t...

Page 86: ...surface is flush with the oil pump case edge SST 09309 37010 c Apply MP grease to the oil seal lip B If oil pump is installed to the cylinder block a Using a knife cut off the oil seal lip b Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crankshaft Tape the screwdriver tip c Apply MP grease to a new oil seal lip d Using SST and a hammer tap in the oil seal until its s...

Page 87: ...6010 c Apply MP grease to the oil seal lip B If rear oil seal retainer is installed to cylinder block a Using a knife cut off the oil seal lip b Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crankshaft Tape the screwdriver tip c Apply MP grease to a new oil seal lip d Using SST and a hammer tap in the oil seal until its surface is flush with the rear oil seal retaine...

Page 88: ...ST 09221 25024 09221 00020 09221 00030 09221 00181 09221 00190 09221 00200 d Check that the piston smoothly moves back and forth on the piston pin 2 INSTALL PISTON RINGS a Install the oil ring expander and two side rails by hand b Using a piston ring expander install the two compression rings with the code mark facing upward Code mark No 1 T or 1R No 2 T2 or 2R c Position the piston rings so that ...

Page 89: ...ngs come in widths of 20 mm 0 79 in and 22 mm 0 87 in Install the 22 mm 0 87 in bearings in the No 1 cylinder block journal position with the main bearing caps Install the 20 mm 0 79 in bearings in the other positions Upper bearings have an oil holes lower bearings do not a Align the bearing claw with the claw groove of the main bearing cap or cylinder block b Install the bearings in the cylinder ...

Page 90: ...it a Apply a light coat of engine oil on the threads and under the heads of the main bearing caps b Install and uniformly tighten the eight main bearing cap bolts in several passes in the sequence shown Torque 625 kg cm 45 ft lb 61 N m If any one of the main bearing cap bolts does not meet the torque specification replace the cap bolt c Mark the front of the main bearing cap bolt with paint d Reti...

Page 91: ...nnecting rod cap with the front mark facing forward B Install connecting rod cap nuts HINT The connecting rod cap nuts are tightened in two progressive steps steps b and d If any connecting rod bolt is broken or deformed replace them a Apply a light of engine oil on the threads and under the nuts of the connecting rod cap b Using SST install and alternately tighten the nuts of the connecting rod c...

Page 92: ...G material from the gasket surfaces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the retainer as shown in the figure Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening HINT Avoid applying an excessive amount to the su...

Page 93: ... material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the groove of the by pass pipe Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening HINT Avoid applying an excessive amount to the surface Parts must be assembled within 5 minutes of application Otherwise the material must be removed and reapplied ...

Page 94: ...late with the bolt Torque 75 kg cm 65 in lb 7 4 N m 12 M T INSTALL FLYWHEEL a Apply adhesive to two or three threads of the mount bolt end Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent b Install the flywheel on the crankshaft c Install and uniformly tighten the eight mount bolts in several passes in the sequence shown Torque 850 kg cm 61 ft lb 83 N m 13 A T INSTALL DRIVE PLATE See pro...

Page 95: ...switch c Keep the engine level and align RH and LH mounting with the body bracket d Attach the RH mounting insulator to the mounting bracket and body and temporarily install the four nuts and bolt e Temporarily install the No 2 mounting stay bolt A f Install the LH mounting bracket to the transaxle case with the three bolts Torque the bolts Torque 530 kg cm 38 ft lb 52 N m g Attach the LH mounting...

Page 96: ... ft lb 52 N m b Install the No 2 mounting stay with the bolt and nut Torque the bolt and nut Torque Bolt 670 kg cm 48 ft lb 66 N m Nut 530 kg cm 38 ft lb 52 N m 5 CONNECT LH ENGINE MOUNTING STAY M T Install the mounting stay with the bolt and two nuts Torque the bolt and nuts Torque Nut 530 kg cm 38 ft lb 52 N m Bolt 195 kg cm 14 ft lb 19 N m A T Install the mounting stay with the three nuts Torqu...

Page 97: ...Torque the bolts Torque 790 kg cm 57 ft lb 77 N m b Temporarily install the mounting insulator with the through bolt and a new nut 10 INSTALL ENGINE MOUNTING CENTER MEMBER a Install the engine mounting center member with the four bolts Torque the bolts Torque 400 kg cm 29 ft lb 39 N m b Install and torque the four bolts and two nuts holding the insulators front center and rear to the center member...

Page 98: ...que 2 120 kg cm 153 ft lb 207 N m 16 CONNECT ENGINE WIRE TO CABIN a Push in the engine wire through the cowl panel b Connect the following connectors 1 Three TCCS ECU connectors 2 Circuit opening relay connector 3 Cowl wire connector 4 Instrument panel wire connector c Install the glove compartment box d Install the under cover 17 CONNECT TRANSAXLE CONTROL CABLE S 18 CONNECT SPEEDOMETER CABLE 19 M...

Page 99: ...SSEMBLY a Install the air cleaner case with the three bolts b Install the air cleaner element c Connect the air cleaner hose and install the air cleaner cap and air flow meter assembly with the four clips d Connect the following connector and hoses 1 Air flow meter connector 2 ISC valve air hose 3 Vacuum pipe air hose 27 INSTALL CRUISE CONTROL ACTUATOR a Install the vacuum pump and bracket with th...

Page 100: ... UPPER BRACE Install the upper brace with the four nuts Torque 650 kg cm 47 ft lb 64 N m 36 INSTALL BATTERY Connect the grand strap 37 FILL WITH ENGINE COOLANT See page CO 5 38 FILL WITH ENGINE OIL See page LU 8 Capacity Drain and refill w Oil filter change 3 9 liters 4 1 US qts 3 4 Imp qts w o Oil filter change 3 7 liters 3 9 US qts 3 3 Imp qts Dry fill 4 6 liters 4 8 US qts 4 0 Imp qts 39 START ...

Page 101: ...le w Terminals TE1 and E1 connected 41 INSTALL ENGINE UNDER COVERS 42 INSTALL HOOD 43 PERFORM ROAD TEST Check for abnormal noise shock slippage correct shift points and smooth operation 44 RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS EM 99 ENGINE MECHANICAL Cylinder Block ...

Page 102: ...m 0 2350 0 2356 in Exhaust 5 965 5 980 mm 0 2348 0 2354 in Stem oil clearance STD Intake 0 025 0 060 mm 0 0010 0 0024 in Exhaust 0 030 0 065 mm 0 0012 0 0026 in Intake 0 08 mm 0 0031 in Exhaust 0 10 mm 0 0039 in Margin thickness STD 1 0 mm 0 039 in Limit 0 5 mm 0 020 in Valve spring Free length 42 6 mm 1 677 in g Installed tension at 33 8 mm 1 331 in 18 6 21 4 kg 41 0 47 2 lb 182 210 N Squareness ...

Page 103: ...0 045 0 065 mm 0 0018 0 0026 in Limit 0 085 mm 0 0033 in Piston ring groove clearance No 1 0 010 0 080 mm 0 0004 0 0031 in No 2 0 030 0 070 mm 0 0012 0 0028 in Piston ring end gap STD No 1 0 300 0 540 mm 0 0118 0 0213 in No 2 0 350 0 620 mm 0 0138 0 0244 in Oil 0 200 0 570 mm 0 0079 0 0224 in Limit No 1 1 12 mm 0 0441 in No 2 1 20 mm 0 0472 in Oil 1 15 mm 0 0453 in Connecting d Thrust clearance ST...

Page 104: ...ley X Crankshaft 2 500 181 245 Timing belt tensioner X Oil pump 270 20 26 Engine RH mounting bracket X Cylinder block 410 30 39 Cylinder head X Cylinder block 12 sided bolt 1st 350 25 34 2nd Turn 90 3rd Turn 90 Recessed head bolt 185 13 18 LH engine hanger X LH Cylinder head 380 27 37 Camshaft bearing cap X Cylinder head 160 12 16 Cylinder head cover X Cylinder head 60 52 in lb 5 9 No 3 timing bel...

Page 105: ...52 No 2 engine RH mounting stay X Engine RH mounting insulator 670 48 66 Engine LH mounting stay X Transaxle M T Bolt 195 14 19 Nut 530 38 52 A T 12 mm nut 210 15 21 14 mm nut 530 38 52 Engine LH mounting stay X Engine mounting insulator 530 38 52 Engine front mounting bracket X Engine mounting center member 740 54 73 Engine front mounting bracket X Transaxle 790 57 77 Engine front mounting insula...

Page 106: ...EFI SYSTEM FI 1 ...

Page 107: ...DESCRIPTION FI 2 EFI SYSTEM Description ...

Page 108: ...o 2 Electronic Spark Advance ESA The ECU is programmed with data for optimum ignition timing under any and all operating conditions Using data provided by sensors which monitor various engine functions rpm coolant temperature etc the microcomputer ECU triggers the spark at precisely the right instant See IG section 3 Idle Speed Control ISC The ECU is programmed with target idling speed values to r...

Page 109: ...e 09268 45012 PowerSteering Hose Nut 14 x 17 mm Wrench Set 09631 22020 Wiring A EFI Inspection 09842 30050 Wiring F EFI Inspection 09842 30070 Diagnosis Check Wiring 09843 18020 Fuel line flare nut RECOMMENDED TOOLS TOYOTA Electrical Tester 09082 00015 EngineAdjust Kit 09200 00010 Hose Plug Set 09258 00030 Plug for vacuum hose fuel hose etc FI 8 EFI SYSTEM Preparation ...

Page 110: ...EQUIPMENT Part Name Note Graduated cylinder Injector Ohmmeter Sound scope Injector Tachometer Torque wrench Voltmeter EFI SYSTEM Preparation FI 9 ...

Page 111: ...OPERATION System Circuit FI 4 EFI SYSTEM Operation System Circuit ...

Page 112: ...l is returned to the fuel tank through the return pipe When the engine is hot the fuel pressure is increased to control percola tion in the fuel system and improve restartability and idling stability The pulsation damper absorbs the slight fluctuations in fuel pressure caused by fuel injector from the injector The injectors operate on input of injection slights from the ECU and inject fuel into th...

Page 113: ...throttle valve opening is distributed from the air intake chamber to the manifold of each cylin der and is drawn into the combustion chamber At low temperature the ISC valve opens the air flows through the ISC valve as well as the throttle body into the air intake chamber During engine warming up even if the throttle valve is completely closed air flows to the air intake chamber thereby increasing...

Page 114: ...r temperature and atmospheric pressure etc and convert the information into an electrical signal which is sent to the ECU Based on these signals the ECU calculates the optimum ignition timing for the current conditions and operates the injectors The ECU not only controls the fuel injection timing but also the self diagnostic function which records the occurrence of a malfunction ignition timing co...

Page 115: ...ONS 1 CHECK CORRECT ENGINE TUNE UP See page EM 7 2 PRECAUTIONS WHEN CONNECTING GAUGE a Use the battery as the power source for the timing light tachometer etc b Connect the test probe of a tachometer to the terminal IG of the check connector 3 IN EVENT OF ENGINE MISFIRE FOLLOWING PRECAUTIONS SHOULD BE TAKEN a Check proper connection of battery terminals etc b Handle high tension cords carefully c ...

Page 116: ...ONS 1 CHECK CORRECT ENGINE TUNE UP See page EM 7 2 PRECAUTIONS WHEN CONNECTING GAUGE a Use the battery as the power source for the timing light tachometer etc b Connect the test probe of a tachometer to the terminal IG of the check connector 3 IN EVENT OF ENGINE MISFIRE FOLLOWING PRECAUTIONS SHOULD BE TAKEN a Check proper connection of battery terminals etc b Handle high tension cords carefully c ...

Page 117: ...UCTION SYSTEM 1 Separation of the engine oil dipstick oil filler cap PCV hose etc may cause the engine to run out of tune 2 Disconnection looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune ELECTRONIC CONTROL SYSTEM 1 Before removing EFI wiring connectors terminals etc first disconne...

Page 118: ...t the water proofing rubber if it is a water proof type connector b Insert the test probe into the connector from wiring side when checking the continuity amperage or voltage c Do not apply unnecessary force to the terminal d After checking install the water proofing rubber on the connector securely 10 Use SST for inspection or test of the injector cold start injector or its wiring connector SST 0...

Page 119: ...e Torque 300 kg cm 22 ft lb 29 N m Flare Nut Type a Apply a light coat of engine oil to the flare and tighten the flare nut by hand b Using SST tighten the flare nut to the specified torque SST 09631 22020 Torque 310 kg cm 22 ft lb 30 N m HINT Use a torque wrench with a fulcrum length of 30 cm 11 81 in 3 Observe the following precautions when removing and installing the injectors a Never reuse the...

Page 120: ...nition switch ON c When the fuel return hose is pinched the pressure within high pressure line will rise to approx 4 kg cm2 57 psi 392 kPa In this state check to see that there are no leaks from any part of the fuel system NOTICE Always pinch the hose Avoid bending as it may cause the hose to crack d Turn the ignition switch OFF e Remove the SST SST 09843 18020 FI 14 EFI SYSTEM InspectionPrecautio...

Page 121: ...FUEL SYSTEM Fuel Pump EFI SYSTEM Fuel System Fuel Pump FI 15 ...

Page 122: ...the fuel filter HINT At this time you will hear fuel return noise d Remove SST SST 09843 18020 e Turn the ignition switch OFF If there is no pressure check the following parts Fusible links Fuses EFI 15 A IGN 7 5 A EFI main relay Fuel pump ECU Wiring connections 2 CHECK FUEL PRESSURE a Check that the battery voltage is above 12 volts b Disconnect the cable from the negative terminal of the battery...

Page 123: ... bolt SST 09268 45012 Torque 200 kg cm 14 ft lb 20 N m g Wipe off any splattered gasoline h Using SST connect terminals B and FP of the check connector SST 09843 18020 i Reconnect the battery negative cable j Turn the ignition switch ON k Measure the fuel pressure Fuel pressure 2 7 3 1 kg cm2 38 44 psi 265 304 kPa If pressure is high replace the fuel pressure regulator If pressure is low check the...

Page 124: ... engine Check that the fuel pressure remains 1 5 kg cm2 21 psi 147 kPa or more for 5 minutes after the engine is turned off If pressure is not as specified check the fuel pump pressure regulator and or injector s After checking fuel pressure disconnect the battery negative cable and carefully remove the SST to prevent gasoline from splashing SST 09268 45012 t Install the cold start injector tube w...

Page 125: ...and the negative terminal cable is dis connected from the battery 2 REMOVE FUEL TANK See procedure FI 35 3 REMOVE FUEL PUMP BRACKET FROM FUEL TANK a Remove the bolt of the bracket b Remove the seven screws pull out the pump bracket INSPECTION OF FUEL PUMP 1 INSPECT FUEL PUMP RESISTANCE Using an ohmmeter measure the resistance between the ter minals Resistance 0 2 3 0 W If the resistance is not as ...

Page 126: ...ump from the bracket b Remove the rubber cushion from the fuel pump c Remove the two nuts and disconnect the wires from the fuel pump d Disconnect the fuel hose from the fuel pump 2 REMOVE FUEL PUMP FILTER FROM FUEL PUMP a Using a small screwdriver remove the clip b Pull out the pump filter INSTALLATION AND ASSEMBLY OF FUEL PUMP See page FI 19 1 INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the pu...

Page 127: ...en screws Torque 40 kg cm 35 in lb 3 9 N m b Install the bolt of the bracket 5 INSTALL FUEL TANK When installing the fuel tank refer to FI 35 for the installation position of the cushion and the tightening torque 6 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY EFI SYSTEM Fuel System Fuel Pump FI 21 ...

Page 128: ...ION Work must be started after approx 20 se conds or longer from the time the ignition switch is turned to the LOCK position and the negative termi nal cable is disconnected from the battery 2 DISCONNECT COLD START INJECTOR CONNECTOR 3 DISCONNECT COLD START INJECTOR TUBE a Put a suitable container or shop towel under the injector tube b Remove the union bolt and two gaskets and disconnect the inje...

Page 129: ...nnector SST 09843 18020 f Reconnect the battery negative cable g Turn the ignition switch ON NOTICE Do not start the engine h Connect the test probes of the SST wire to the battery and check that the fuel spray is as shown SST 09842 30050 NOTICE Perform this check within the shortest possible time 2 INSPECT LEAKAGE a In the condition above disconnect the test probes of SST wire from the battery an...

Page 130: ... 4 N m 2 CONNECT COLD START INJECTOR TUBE a Connect the injector tube to clamp b Connect the injector tube with new two gaskets and the union bolt Torque 200 kg cm 14 ft lb 20 N m 3 CONNECT COLD START INJECTOR CONNECTOR 4 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 5 CHECK FOR FUEL LEAKAGE See page FI 14 FI 24 EFI SYSTEM Fuel System Cold Injector ...

Page 131: ...CONNECT VACUUM SENSING HOSE 2 DISCONNECT FUEL RETURN HOSE a Put a suitable container or shop towel under the pressure regulator b Disconnect the return hose from the pressure regulator 3 REMOVE FUEL PRESSURE REGULATOR Loosen the lock nut and remove the pressure regulator EFI SYSTEM Fuel System Fuel Pressure Regulator FI 25 ...

Page 132: ...e regulator c Thrust the pressure regulator completely into the delivery pipe by hand d Turn the pressure regulator counterclockwise until the vacuum pipe faces in the direction indicated in the figure e Tighten the lock nut Torque 330 kg cm 24 ft lb 32 N m 2 CONNECT FUEL RETURN HOSE 3 CONNECT VACUUM SENSING HOSE 4 CHECK FOR FUEL LEAKAGE See page FI 14 FI 26 EFI SYSTEM Fuel System Fuel Pressure Re...

Page 133: ... you can check the injector transmission operation with your finger If no sound or an unusual sound is heard check the wiring connector injector or injection signal from ECU 2 INSPECT INJECTOR RESISTANCE a Disconnect the injector connector b Using an ohmmeter measure the resistance between the terminals Resistance Approx 13 8 W If the resistance is not as specified replace the injector c Reconnect...

Page 134: ...NER HOSE a Disconnect the air flow meter connector b Disconnect the air hoses c Loosen the air cleaner hose clamp bolt d Disconnect the air cleaner cap clips e Remove the air cleaner cap and air flow meter together with the air cleaner hose 6 DISCONNECT HOSES AND CONNECTORS a PCV hoses b Vacuum sensing hose c Water by pass hoses d Fuel pressure VSV hose e Emission control vacuum hoses f ISC connec...

Page 135: ...ir intake chamber stay from air intake chamber 14 REMOVE AIR INTAKE CHAMBER Remove the two bolts nuts air intake chamber and gasket 15 DISCONNECT CONNECTORS a Cold start injector connector b Water temperature sensor connector c Six injector connectors 16 DISCONNECT WIRE HARNESS CLAMPS FROM LH DELIVERY PIPE Disconnect the three wire harness clamp 17 DISCONNECT FUEL INLET AND TWO RETURN HOSES a Disc...

Page 136: ... delivery pipes d Remove the six insulators and four spacers from the intake manifold INSPECTION OF INJECTORS 1 INSPECT INJECTOR INJECTION CAUTION Keep clear of sparks during the test a Disconnect the fuel hose from the fuel filter outlet b Connect SST union and hose to the fuel filter outlet with two new gaskets and the union bolt SST 09268 41045 90405 09015 HINT Use the vehicle s fuel filter c R...

Page 137: ...ine k Connect SST wire to the injector and battery for 15 seconds and measure the injection volume with a graduated cylinder Test each injector two or three times SST 09842 30070 Volume 45 55 cc 2 7 3 4 cu in per 15 sec Difference between each injector 5 cc 0 3 cu in or less If the injection volume is not as specified replace the injector 2 INSPECT LEAKAGE a In the condition above disconnect the t...

Page 138: ...tion on the intake manifold e Place the three injectors together with the RH delivery pipe and No 1 fuel pipe in position on the intake manifold f Place the three injectors together with the LH delivery pipe in position on the intake manifold g Check that the injectors rotate smoothly HINT If injectors do not rotate smoothly the probable cause is incorrect installation of O rings Replace the O rin...

Page 139: ...AIR INTAKE CHAMBER Install a new gasket and the air intake chamber with the two bolts and nuts Torque 440 kg cm 32 ft lb 43 N m 7 CONNECT EGR PIPE Torque 800 kg cm 58 ft lb 78 N m 8 CONNECT WIRE HARNESS CLAMP Connect the wire harness clamp with the nut 9 INSTALL NO 1 ENGINE HANGER AND AIR INTAKE CHAMBER STAY a Connect the air intake chamber stay with the two bolts Torque 380 kg cm 27 ft lb 37 N m ...

Page 140: ...SV hose h Emission control vacuum hoses 15 INSTALL AIR CLEANER CAP AIR FLOW METER AND AIR CLEANER HOSE a Connect the air cleaner hose and install the air cleaner cap and air flow meter with the four clips b Tighten the air cleaner hose clamp bolt c Connect the air hoses d Connect the air flow meter connector 16 CONNECT ACCELERATOR CABLE AND BRACKET TO THROTTLE BODY AND AIR INTAKE CHAMBER 17 A T CO...

Page 141: ...Fuel Tank and Lines COMPONENTS EFI SYSTEM Fuel System Fuel Tank and Lines FI 35 ...

Page 142: ...nections for deformation b Check the fuel tank vapor vent system hoses and connections for looseness sharp bends or damage c Check the fuel tank for deformation cracks fuel leakage or tank band looseness d Check the filler neck for damage or fuel leakage e Hose and tube connections are as shown in the illustration If a problem is found repair or replace the parts as necessary FI 36 EFI SYSTEM Fuel...

Page 143: ... 2 000 3 000 900 1 300 400 700 20 4 0 32 20 68 40 104 60 140 FC E1 Infinity If the resistance is not as specified replace the air flow meter c Reconnect the air flow meter connector REMOVAL OF AIR FLOW METER 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY Caution Work must be started after approx 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the neg...

Page 144: ...ty Fully closed FC E1 Zero Other than closed VS E2 200 600 Fully closed VS E2 20 1 000 Fully open HINT Resistance between terminals E2 and VS will change in a wave pattern as the measuring plate slowly opens If the resistance is not as specified replace the air flow meter INSTALLATION OF AIR FLOW METER 1 INSTALL AIR FLOW METER TO AIR CLEANER CAP a Install the air flow meter with the gasket lock pl...

Page 145: ...uum with your finger Port name At idling Other than idling P No vacuum Vacuum E No vacuum Vacuum R No vacuum Vacuum 2 INSPECT THROTTLE POSITION SENSOR a Disconnect the sensor connector b Insert a feeler gauge between the throttle stop screw and stop lever c Using an ohmmeter measure the resistance between each terminal EFI SYSTEM Air Induction System Throttle Body FI 39 ...

Page 146: ...rmal operating tempera ture B Check idle speed Idle speed 800 50 rpm C Remove cap filter and separator from DP D Check and adjust DP setting speed a Maintain the engine at 2 500 rpm b Plug the VTV hole with your finger c Release the throttle valve d Check that the DP is set DP setting speed 2 000 rpm w Cooling fan OFF If not as specified adjust with the DP adjusting screw E Reinstall DP separator ...

Page 147: ...s disconnected from the battery 2 DRAIN ENGINE COOLANT See page CO 5 3 A T DISCONNECT THROTTLE CABLE FROM THROTTLE LINKAGE 4 DISCONNECT ACCELERATOR CABLE FROM THROTTLE LINKAGE 5 REMOVE AIR CLEANER CAP AIR FLOW METER AND AIR CLEANER HOSE See step 5 or page FI 28 6 DISCONNECT THROTTLE POSITION SENSOR CONNECTOR 7 REMOVE THROTTLE BODY a Disconnect the following hoses PCV hose Water by pass hoses Emiss...

Page 148: ...N SENSOR See step 2 on pages FI 39 and 40 4 IF NECESSARY ADJUST THROTTLE POSITION SENSOR a Loosen the two set screws of the sensor b Insert a 0 50 mm 0 020 in feeler gauge between the throttle stop screw and stop lever c Connect the test probe of an ohmmeter to the terminals IDL and E2 of the sensor d Gradually turn the sensor clockwise until the ohmmeter deflects and secure it with the two set sc...

Page 149: ...13 N m c Connect the following hoses PCV hose Water by pass hoses Emission control vacuum hoses 2 CONNECT THROTTLE POSITION SENSOR CONNECTOR 3 INSTALL AIR CLEANER CAP AIR FLOW METER AND AIR CLEANER HOSE See step 15 or page FI 34 4 CONNECT ACCELERATOR CABLE AND ADJUST IT 5 A T CONNECT THROTTLE CABLE AND ADJUST IT 6 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 7 FILL WITH ENGINE COOLANT See page CO...

Page 150: ...S4 Resistance B1 S1 or S3 10 30 W B2 S2 or S4 10 30 W If resistance is not as specified replace the ISC valve c Reconnect the ISC valve connector REMOVAL OF ISC VALVE 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION Work must be started after approx 20 se conds or longer from the time the ignition switch is turned to the LOCK position and the negative termi nal cable is disconnected fr...

Page 151: ... battery voltage to terminals B1 and B2 and while repeatedly grounding S4 S3 S2 S1 S4 in sequence check that the valve moves toward the open position If operation is not as specified replace the ISC valve INSTALLATION OF ISC VALVE 1 INSTALL ISC VALVE a Install a new gasket and the ISC valve with the two bolts Torque 130 kg cm 9 ft lb 13 N m b Connect the wire harness clamp with the nut 2 CONNECT T...

Page 152: ...ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts FI 46 EFI SYSTEM Electronic Control System Location of Electronic Control Parts ...

Page 153: ... there is no continuity between terminals 2 and 4 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals 1 and 3 b Using an ohmmeter check that there is continuity between terminals 2 and 4 If operation is not as specified replace the relay EFI SYSTEM Electronic Control System EFI Main Relay FI 47 ...

Page 154: ... between terminals B and FP If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals STA and E1 b Using an ohmmeter check that there is continuity between terminals B and FP c Apply battery voltage across terminals B and FC d Check that there is continuity between terminals B and FP If operation is not as specified replace the relay FI ...

Page 155: ...START INJECTOR TIME SWITCH Using an ohmmeter measure the resistance between each terminal Resistance STA STJ 25 45 W below 15 C 59 F 65 85 W above 30 C 86 F STA Ground 25 85 W If the resistance is not as specified replace the switch EFI SYSTEM Electronic Control System Cold Start Injector Time Switch FI 49 ...

Page 156: ... INSPECT RESISTANCE OF WATER TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the ter minals Resistance Refer to the chart If the resistance is not as specified replace the sensor FI 50 EFI SYSTEM Electronic Control System Water TemperatureSensor ...

Page 157: ... SENSOR Using an ohmmeter measure the resistance between the ter minals Resistance 69 40 88 50 kW at 50 C 112 F 11 89 14 37 kW at 100 C 212 F 2 79 3 59 kW at 150 C 302 F If the resistance is not as specified replace the sensor EFI SYSTEM Electronic Control System EGR Gas Temperature Sensor CALIF only FI 51 ...

Page 158: ...ESSURE VSV A Inspect VSV for open circuit Using an ohmmeter check that there is continuity between terminals Resistance Cold 33 39 W If there is no continuity replace the VSV B Inspect VSV for ground Using an ohmmeter check that there is no continuity be tween each terminal and body If there is continuity replace the VSV FI 52 EFI SYSTEM Electronic Control System Fuel Pressure Control System ...

Page 159: ...air flows from ports E to G b Apply battery voltage across the terminals c Check that air flows from port E to filter If operation is not as specified replace the VSV EFI SYSTEM Electronic Control System Fuel Pressure Control System FI 53 ...

Page 160: ...he oxygen sensor with the engine at 2 500 rpm for approx 90 seconds And maintain engine at 2 500 rpm Check the number of times the voltmeter needle fluctuates in 10 seconds Disconnect terminals TE1 and E1 of the check connector And maintain engine speed at 2 500 rpm Measure voltage between terminals VF1 and E1 Read and record diagnostic codes See page TR 9 or TR 10 Repair the relevant diagnostic c...

Page 161: ...nector and connect resistor with a resistance of 4 8 W or another coded water temp sensor Connect terminals TE1 and E1 of the check connector Warm up the oxygen sensor with the engine at 2 500 rpm for approx 90 seconds And maintain engine speed at 2 500 rpm Measure voltage between terminals VF1 and E1 Replace the oxygen sensor Repair Over lean CONTINUED FROM PAGE FI 54 Malfunction code s Ex code N...

Page 162: ...T Drive for 5 minutes or more between 80 km h 50 mph and 100 km h in 4th or 5th gear A T Drive for 5 minutes or more between 80 km h 50 mph and 100 km h 62 mph in D range d Following the conditions in step c press fully on the accelerator pedal for 2 seconds or more HINT Do not exceed 100 km h 62 mph or diagnostic code will be cancelled e Stop the vehicle and turn the ignition switch to OFF f Carr...

Page 163: ...T Drive for 5 minutes or more between 80 km h 50 mph and 100 km h in 4th or 5th gear A T Drive for 5 minutes or more between 80 km h 50 mph and 100 km h 62 mph in D range d Following the conditions in step c press fully on the accelerator pedal for 2 seconds or more HINT Do not exceed 100 km h 62 mph or diagnostic code will be cancelled e Stop the vehicle and turn the ignition switch to OFF f Carr...

Page 164: ...H ISC1 ISC VALVE No 1 Coil A C A C COMPRESSOR IGT IGNITER 1OD1 CRUISE CONTROL ECU ISC2 ISC VALVE No 2 Coil SP1 No 1 SPEED SENSOR Meter Side 1S1 ECT SOLENOID 1OD2 O D MAIN SWITCH ISC3 ISC VALVE No 3 Coil 1SP2 No 2 SPEED SENSOR A T Side 1S2 ECT SOLENOID ISC4 ISC VALVE No 4 Coil 1DG TDCL 1SL ECT SOLENOID IGF IGNITER 2CHK SUB OXYGEN SENSOR G2 DISTRIBUTOR W CHECK ENGINE WARNING LIGHT G1 DISTRIBUTOR 1N ...

Page 165: ... attention to sections A and B in the il lustration which can be easily broken c Reconnect the connectors to the ECU 2 INSPECT VOLTAGE OF ECU Check the voltage between each terminal of the wiring con nectors Turn the ignition switch ON Measure the voltage at each terminal HINT Perform all voltage measurements with the connectors connected erify that the battery voltage is 11 V or more when the ign...

Page 166: ...0 C 68 F 1 3 THA E2 THW E2 IG SW ON Coolant temp 80 C 176 F 0 1 1 0 STA E1 Cranking 6 14 IGT E1 Cranking idling 0 7 1 0 ISC1 ISC2 ISC3 ISC4 E1 IG SW ON 9 14 W E1 No trouble CHECK engine warning light off and engine running 10 14 1A C E1 Air conditioning ON 8 14 1ACT E1 Heater blower SW ON 4 6 T1 IG SW ON Check connector TE1 E1 not connected 4 6 T1 T2 E1 IG SW ON Check connector TE1 E1 connected 0 ...

Page 167: ...istance W IDL E2 Throttle valve open Infinity IDL E2 Throttle valve fully closed 2 300 or less VTA E2 Throttle valve fully open 3 500 10 300 VTA E2 Throttle valve fully closed 300 6 300 VC E2 200 400 VS E2 Measuring plate fully closed 200 600 VS E2 Measuring plate fully open 20 1 200 THA E2 Intake air temp 20 C 68 F 2 000 3 000 THW E2 Coolant temp 80 C 176 F 200 400 G1 G1 G2 G 140 180 G G NE 140 1...

Page 168: ...r from the throttle position sensor b Connect terminals IDL and E2 of the wiring connector c Gradually raise the engine rpm and check that there is fluctuation between the fuel cut and fuel return points HINT The vehicle should be stopped Measure with the A C OFF Fuel cut rpm 1 800 rpm Fuel return rpm 1 200 rpm EFI SYSTEM Electronic Control System Fuel Cut RPM FI 61 ...

Page 169: ...0 4 0 7 kW Throttle position Clearance between stop screw and lever Between terminals Resistance sensor 0 mm 0 in VTA E2 0 3 6 3 kW 0 30 mm 0 012 in IDL E2 2 3 kW or less 0 70 mm 0 028 in IDL E2 Infinity Throttle valve fully open VTA E2 3 5 10 3 kW VC E2 4 25 8 25 kW ISC valve Resistance B1 S1 or S3 10 30 W B2 S2 or S4 10 30 W Cold start i j i Resistance STA STJ below 15 C 59 F 25 45 W injector ti...

Page 170: ...0 2 0 5 VS E2 Idling 1 6 4 1 3 000 rpm 1 0 2 0 EO1 EO2 No 10 No 20 No 30 IG SW ON 10 14 THA E2 IG SW ON Intake air temp 20 C 68 F 1 3 THW E2 Coolant temp 80 C 176 F 0 1 1 0 STA E1 Cranking 6 14 IGT E1 Cranking or idling 0 7 1 0 ISC1 ISC2 ISC3 ISC4 E1 IG SW ON 9 14 W E1 No trouble CHECK engine warning light off and engine running 10 14 1A C E1 Air conditioning ON 10 14 1 ACT E1 Heater blower SW ON ...

Page 171: ...2 30 Fuel pump X Fuel tank 40 35 in lb 3 9 Fuel inlet pipe x Fuel tank 20 17 in lb 2 0 Fuel tank band x Body 400 29 39 Cold start injector x Air intake chamber 55 48 in lb 5 4 Cold start injector tube x Cold start injector 200 14 20 Cold start injector tube X Delivery pipe 200 14 20 Fuel pressure regulator x Delivery pipe 330 24 32 Delivery pipe X Intake manifold 130 9 13 No 2 fuel pipe x Delivery...

Page 172: ...EXHAUST SYSTEM EXHAUST SYSTEM REPAIR INSTRUCTIONS EX 1 ...

Page 173: ...EXHAUST PIPES AND HEAT INSULATORS COMPONENTS EX 2 EXHAUST SYSTEM Exhaust Pipes and Heat Insulators ...

Page 174: ...EMISSION CONTROL SYSTEMS EC 1 ...

Page 175: ...e way catalyst Electronic fuel injection PCV EVAP EGR TWC EFI Reduces blow by gas HC Reduces evaporative HC Reduces NOx Reduces HC CO and NOx Regulates all engine conditions for reduction of exhaust emissions Remark For inspection and repair of the EFI system refer to EFI section of this manual EC 2 EMISSION CONTROL SYSTEMS System Purpose ...

Page 176: ...COMPONENT LAYOUT AND SCHEMATIC DRAWING EMISSION CONTROL SYSTEMS Component Layout and Schematic Drawing EC 3 ...

Page 177: ...LATION PCV SYSTEM To reduce HC emission crankcase blow by gas HC is routed through the PCV valve to the air intake chamber for combustion in the cylinders EC 4 EMISSION CONTROL SYSTEMS Positive Crankcase Ventilation PCV System ...

Page 178: ...s inside the valve are harmful 4 BLOW AIR FROM AIR INTAKE CHAMBER SIDE Check that air passes through with difficulty If the PCV valve fails either of the checks replace it 5 REMOVE CLEAN HOSE FROM PCV VALVE 6 REINSTALL PCV VALVE INSPECTION OF PCV HOSE AND CONNECTIONS VISUALLY INSPECT HOSE AND CONNECTIONS Check for cracks leaks or damage EMISSION CONTROL SYSTEMS Positive Crankcase Ventilation PCV S...

Page 179: ... F OPEN Positioned above port P OPEN HC from canister is led into air intake chamber High pressure in tank OPEN CLOSED CLOSED HC from tank is absorbed into the canister High vacuum in tank CLOSED OPEN OPEN Air is led into the fuel tank INSPECTION OF FUEL VAPOR LINES FUEL TANK AND TANK CAP 1 VISUALLY INSPECT LINES AND CONNECTIONS Look for loose connections sharp bends or damage 2 VISUALLY INSPECT F...

Page 180: ... attempt to wash the canister No activated carbon should come out 6 REINSTALL DUST COVER TO CHARCOAL CANISTER 7 REINSTALL CHARCOAL CANISTER INSPECTION OF BVSV CHECK BVSV BY BLOWING AIR INTO PIPE a Drain the coolant from the radiator into a suitable container b Remove the BVSV from the water by pass outlet c Cool the BVSV to below 35_C 95_F with cool water d Blow air into a pipe and check that the ...

Page 181: ...ot recirculated Above 54_C OPEN Positioned between 1 LOW Pressure constantly alter OPENS passage to atmosphere CLOSED Not recirculated 129_F OPEN port E and port R 2 HIGH y nating between low and high CLOSES passage to atmosphere OPEN Recirculated Positioned above port R 3 HIGH CLOSES passage to atmosphere OPEN Recirculated increase When the throttle valve is positioned above port R the EGR vacuum...

Page 182: ...INE a The coolant temperature should be below 40 _C 104_F b Check that the vacuum gauge indicates zero at 2 500 rpm 5 CHECK BVSV AND EGR VACUUM MODULATOR WITH HOT ENGINE a Warm up the engine b Check that the vacuum gauge indicates low vacuum at 2 500 rpm c Disconnect the vacuum hose from the R port of the EGR vacuum modulator and connect the R port directly to the intake manifold with another hose...

Page 183: ...f Reconnect the vacuum hoses to the proper locations INSPECTION OF EGR VALVE 1 REMOVE EGR VALVE Check for sticking and heavy carbon deposits If a problem is found replace the valve 2 REINSTALL EGR VALVE Install a new gasket INSPECTION OF BVSV CHECK BVSV BY BLOWING AIR INTO PIPE a Drain the coolant from the radiator into a suitable container b Remove the BVSV from the water by pass outlet c Cool th...

Page 184: ...x CO2 H2O N2 OXIDIZATION AND REDUCTION OXIDIZATION AND REDUCTION INSPECTION OF EXHAUST PIPE ASSEMBLY 1 CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE 2 CHECK CLAMPS FOR WEAKNESS CRACKS OR DAMAGE INSPECTION OF CATALYTIC CONVERTER CHECK FOR DENTS OR DAMAGE If any part of protector is damaged or dented to the extent that it contacts the converter repair or replace it EMISSION CONTROL SYSTEMS Three Way Cat...

Page 185: ...ck up the vehicle b Check that the converter is cool c Remove the four bolts and nuts holding the pipes to the converter d Remove the converter and two gaskets 2 REINSTALL CONVERTER a Place new two gaskets on the front and rear pipes b Install the converter with the bolts and nuts Torque the bolts and nuts Torque 440 kg cm 32 ft lb 43 N m EC 12 EMISSION CONTROL SYSTEMS Three Way Catalyst TWC Syste...

Page 186: ...COOLING SYSTEM CO 1 ...

Page 187: ...TION This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a by pass valve mounted on the inlet side OPERATION CO 2 COOLING SYSTEM Description Operation ...

Page 188: ...TION This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a by pass valve mounted on the inlet side OPERATION CO 2 COOLING SYSTEM Description Operation ...

Page 189: ...the coolant expands The pressurization prevents the coolant from boiling even when the coolant temperature exceeds 100 C 212 F A relief valve pressurization valve and a vacuum valve negative pressure valve are built into the radiator cap The relief valve opens and lets steam escape through the overflow pipe when the pressure generated inside the cooling system exceeds the limit coolant temperature...

Page 190: ... Radiator cap tester Torque wrench LUBRICANT Item Capacity Classification Item Liters US qts lmp Qts Classification Engine Coolant M T A T 9 5 9 4 10 0 9 9 8 4 8 3 Ethylene glycol base SSM SPECIAL SERVICE MATERIALS Part Name Part No Use etc Seal packing 1282B Three bond 1282B or equivalent 08826 00100 Water pump CO 4 COOLING SYSTEM Preparation ...

Page 191: ... Engine drain plugs are at the front center and rear right of engine block c Close the drain cocks Torque Engine drain cock 300 kg cm 22 ft lb 29 N m d To release the air loosen the union bolt of the water outlet five revolutions e Slowly fill the system with coolant HINT Use a good brand of ethylene glycol base coolant mixed according to the manufacturer s directions We recommended more than 50 e...

Page 192: ...al cable is disconnected from the battery 2 DRAIN ENGINE COOLANT See page CO 5 3 DISCONNECT RADIATOR LOWER HOSE FROM WATER INLET PIPE 4 DISCONNECT TIMING BELT FROM WATER PUMP PULLEY See pages EM 15 to 18 5 REMOVE WATER INLET PIPE a Remove the bolt holding the water inlet pipe to the alternator belt adjusting bar b Remove the water inlet pipe and O ring 6 REMOVE WATER INLET AND THERMOSTAT See steps...

Page 193: ...terial from the gasket surfaces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the water pump groove Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening HINT Avoid applying an excessive amount to the surface Parts must b...

Page 194: ...pipe to the water inlet d Install the bolt holding the water inlet pipe to the alternator belt adjusting bar Torque 200 kg cm 14 ft lb 20 N m 4 INSTALL TIMING BELT See pages EM 24 to 28 5 CONNECT RADIATOR LOWER HOSE 6 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 7 FILL WITH ENGINE COOLANT See page CO 5 CO 8 COOLING SYSTEM Water Pump ...

Page 195: ...three nuts and water inlet from the water pump 6 REMOVE THERMOSTAT AND GASKET INSPECTION OF THERMOSTAT INSPECT THERMOSTAT HINT The thermostat is numbered with the valve opening temperature a Immerse the thermostat in water and gradually heat the water b Check the valve opening temperature Valve opening temperature 80 84 C 176 183 F If the valve opening temperature is not as specified replace the t...

Page 196: ...mostat in the water pump 2 INSTALL WATER INLET Install the water inlet with the three nuts Torque 200 kg cm 14 ft lb 20 N m 3 CONNECT WATER TEMPERATURE SENSOR CONNECTOR 4 INSTALL WATER INLET PIPE See steps 3 and 5 on page CO 8 5 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 6 FILL WITH ENGINE COOLANT See page CO 5 7 START ENGINE AND CHECK FOR LEAKS CO 10 COOLING SYSTEM Thermostat ...

Page 197: ...eed 1 push 3 seconds or more NOTICE Push the pump at a constant speed If air is not coming from the relief valve replace the radiator cap b Pump the tester several times and measure the relief valve opening pressure Pump speed 1st time 1 push 1 second or less 2nd time or more Any speed Standard opening pressure 0 75 1 05 kg cm2 10 7 14 9 psi 74 103 kPa Minimum opening pressure 0 6 kg cm2 8 5 psi 5...

Page 198: ...sition and the negative termi nal cable is disconnected from the battery 2 DRAIN ENGINE COOLANT See page CO 5 3 REMOVE BATTERY 4 REMOVE IGNITION COIL IGNITER AND BRACKET ASSEMBLY See step 8 on page EM 63 5 DISCONNECT RADIATOR RESERVOIR HOSE 6 REMOVE ENGINE UNDER COVER 7 DISCONNECT RADIATOR HOSES 8 DISCONNECT COOLING FAN CONNECTORS 9 A T DISCONNECT OIL COOLER HOSES CO 12 COOLING SYSTEM Radiator ...

Page 199: ...cushion A of the supports are not depressed 3 A T CONNECT OIL COOLER HOSES 4 CONNECT COOLING FAN CONNECTORS 5 CONNECT RADIATOR HOSES 6 INSTALL ENGINE UNDER COVER 7 CONNECT RADIATOR RESERVOIR HOSE 8 INSTALL IGNITION COIL IGNITER AND BRACKET ASSEMBLY See step 34 on page EM 98 9 INSTALL BATTERY Connect the grand strap 10 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 11 FILL WITH ENGINE COOLANT See pa...

Page 200: ...ELECTRIC COOLING FANS SYSTEM CIRCUIT LOCATION OF ELECTRIC COOLING FAN COMPONENTS CO 14 COOLING SYSTEM Electric Cooling Fans ...

Page 201: ...d water temperature sensor 3 CONNECT WATER TEMPERATURE SENSOR CONNECTOR High Temperature 85 90 C 185 194 F 4 START ENGINE a Raise coolant temperature to 85 90_C 185 194_F b Check that the cooling fan rotates at low speed If not replace the water temperature sensor High Temperature Above 90 C 194 F 5 START ENGINE a Raise coolant temperature to above 90_C 194_F b Check that the cooling fan rotates a...

Page 202: ...6 F Approx 1 18 kW at 90 C 194 F Approx 1 03 kW at 95 C 203 F If resistance is not as specified replace the sensor 3 INSPECT ENGINE MAIN RELAY See page CH 17 4 INSPECT NO 1 COOLING FAN RELAY FAN NO 1 A Inspect relay continuity a Using an ohmmeter check that there is continuity between terminals 1 and 2 b Check that there is continuity between terminals 3 and 4 If continuity is not as specified rep...

Page 203: ...oltage across terminal 2 and 6 b Using an ohmmeter check that there is no continuity between terminals 1 and 3 b Check that there is continuity between terminals 1 and 4 If operation is not as specified replace the relay 6 INSPECT NO 3 COOLING FAN RELAY A C FAN NO 3 See procedure EFI Main Relay on page FI 47 7 INSPECT COOLING FANS a Connect battery and ammeter to the cooling fan connector b Check ...

Page 204: ...4 9 psi 74 103 kPa 0 6 kg cm2 8 5 psi 59 kPa Thermostat Valve opening temperature Valve lift at 95 C 203 F 80 84 C 8 5 mm 0 35 in or more 176 183 F TORQUE SPECIFICATIONS Part tightened kg cm ft lb N m Cylinder block X Drain plug 300 22 29 Water pump X Cylinder block 200 14 20 Water inlet X Water pump 200 14 20 Water inlet pipe X Alternator belt adjusting bar 200 14 20 CO 18 COOLING SYSTEM ServiceS...

Page 205: ...LUBRICATION SYSTEM LUBRICATION SYSTEM Description Operation LU 1 ...

Page 206: ...EAR CAMSHAFT GEAR VALVE LIFTERS STEMS VALVE LIFTERS STEMS CAMS CAMS PISTONS CONNECTING ROD CRANKSHAFT CAMSHAFT JOURNALS CAMSHAFT JOURNALS CYLINDER HEAD FOR LEFT BANK CYLINDER HEAD FOR RIGHT BANK MAIN OIL HOLE RELIEF VALVE RELIEF VALVE OIL FILTER OIL PUMP OIL STRAINER OIL PAN LU 2 LUBRICATION SYSTEM Description Operation ...

Page 207: ...EAR CAMSHAFT GEAR VALVE LIFTERS STEMS VALVE LIFTERS STEMS CAMS CAMS PISTONS CONNECTING ROD CRANKSHAFT CAMSHAFT JOURNALS CAMSHAFT JOURNALS CYLINDER HEAD FOR LEFT BANK CYLINDER HEAD FOR RIGHT BANK MAIN OIL HOLE RELIEF VALVE RELIEF VALVE OIL FILTER OIL PUMP OIL STRAINER OIL PAN LU 2 LUBRICATION SYSTEM Description Operation ...

Page 208: ...is drawn in when the space is wide and is discharged when the space in narrow OIL PRESSURE REGULATOR At high engine speeds the engine oil supplied by the oil pump exceeds the capacity of the engine to utilize it For that reason the oil pressure regulator works to prevent an oversupply of oil During normal oil supply a coil spring and valve keep the bypass closed but when too much oil is being fed ...

Page 209: ...ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ API grade SG multigrade Recommended ÑÑÑÑÑÑÑÑÑÑÑ Engine oil Dry fill ÑÑÑÑÑÑ 4 6 ÑÑÑÑÑ 4 8 ÑÑÑÑÑ 4 0 ÑÑÑÑÑÑÑÑÑÑÑÑÑ API grade SG multigrade Recommended viscosity is as follows with SAE 5W 30 ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ Dry fill Drain and refill ÑÑÑÑÑÑ ÑÑÑÑÑÑ 4 6 ÑÑÑÑÑ ÑÑÑÑÑ 4 8 ÑÑÑÑÑ ÑÑÑÑÑ 4 0 ÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ viscosity is as follows with SAE 5W 30 being the perferred eng...

Page 210: ...ow check for the leakage and add oil up to F mark 3 REMOVE OIL PRESSURE SWITCH 4 INSTALL OIL PRESSURE GAUGE 5 WARM UP ENGINE Allow the engine to warm up to normal operating tempera ture 6 CHECK OIL PRESSURE Oil pressure At idling 0 3 kg cm2 4 3 psi 29 kPa or more At 3 000 rpm 3 0 5 5 kg cm2 43 78 psi 294 539 kPa 7 REINSTALL OIL PRESSURE SWITCH Apply adhesive to two or three threads Adhesive Part N...

Page 211: ...ed with soap and water or use waterless hand cleaner to remove any used engine oil Do not use gasoline thinners or solvents In order to preserve the environment used oil and used oil filters must be disposed only at designated disposal sites 1 DRAIN ENGINE OIL a Remove the oil filler cap b Remove the oil drain plug and drain the oil into a container 2 REPLACE OIL FILTER a Using SST remove the oil ...

Page 212: ...age LU 5 Capacity Drain and refill w Oil filter change 3 9 liters 4 1 US qts 3 4 Imp qts w o Oil filter change 3 7 liters 3 9 US qts 3 3 Imp qts Dry fill 4 6 liters 4 8 US qts 4 0 Imp qts c Install the oil filler cap 4 START ENGINE AND CHECK FOR LEAKS 5 RECHECK ENGINE OIL LEVEL See page LU 5 LUBRICATION SYSTEM Replacement of Engine Oil and Oil Filter LU 7 ...

Page 213: ...s turned to the LOCK position and the negative termi nal cable is disconnected from the battery 2 REMOVE HOOD 3 REMOVE ENGINE UNDER COVERS 4 DRAIN ENGINE OIL See page LU 6 5 REMOVE SUSPENSION LOWER CROSSMEMBER See step 27 on page EM 65 6 DISCONNECT FRONT EXHAUST PIPE See step 28 on page EM 66 7 REMOVE ENGINE MOUNTING CENTER MEMBER See step 32 on page EM 66 8 REMOVE FRONT ENGINE MOUNTING INSULATOR ...

Page 214: ...0 NOTICE Be careful not to damage the flanges of the oil pan and baffle plate 11 REMOVE OIL PAN BAFFLE PLATE Insert the blade of SST between the cylinder block and baffle plate cut off applied sealer and remove the baffle plate SST 09032 00100 NOTICE Do not use SST for the oil pump body side and rear oil seal retainer Be careful not to damage the baffle plate flange 12 REMOVE OIL STRAINER Remove t...

Page 215: ...ATOR See page CH 8 16 REMOVE A C COMPRESSOR WITHOUT DISCONNECTING HOSES See step 29 on page EM 66 17 REMOVE A C COMPRESSOR BRACKET 18 REMOVE PS BELT ADJUSTING BAR 19 REMOVE OIL PUMP a Remove the nine bolts b Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap c Remove the O ring LU 10 LUBRICATION SYSTEM Oil Pump ...

Page 216: ...VE RELIEF VALVE a Using snap ring pliers remove the snap ring b Remove the retainer spring and relief valve 2 REMOVE DRIVE AND DRIVEN ROTORS Remove the eight screws pump body cover the drive and driven rotors LUBRICATION SYSTEM Oil Pump LU 11 ...

Page 217: ...place the oil pump assembly B Inspect rotor side clearance Using a feeler gauge and precision straight edge measure the clearance between the rotors and precision straight edge Standard side clearance 0 030 0 090 mm 0 0012 0 0035 in Maximum side clearance 0 15 mm 0 0059 in If the side clearance is greater than maximum replace the ro tors as a set If necessary replace the oil pump assembly C Inspec...

Page 218: ...en rotors into pump body with the marks facing the pump body cover side b Install the pump body cover with the eight screws 2 INSTALL RELIEF VALVE a Insert the relief valve spring and retainer into the pump body hole b Using snap ring pliers install the snap ring LUBRICATION SYSTEM Oil Pump LU 13 ...

Page 219: ...ean both sealing surfaces b Apply seal packing to the oil pump as shown in the figure Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening HINT Avoid applying an excessive amount to the surface Parts must be assembled within 5 minutes of application Otherwise the material must be removed and reapplied Immediately remove nozzle from the ...

Page 220: ...STALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and two nuts Torque 70 kg cm 61 in lb 6 9 N m 9 INSTALL OIL PAN BAFFLE PLATE a Remove any old packing FIPG material and be careful not to drop any oil on the contact surfaces of the baffle plate and cylinder block Using a razor blade and gasket scraper remove all the old packing FIPG material from the gasket surfaces Thorou...

Page 221: ... and cylinder block Using a razor blade and gasket scraper remove all the old packing FIPG material from the gasket surfaces and sealing grooves Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces NOTICE Do not use a solvent which will affect the painted surfaces b Apply seal packing to the oil pan as shown in the figure Seal pac...

Page 222: ...INSULATOR See step 7 on page EM 95 13 INSTALL ENGINE MOUNTING CENTER MEMBER See step 10 on page EM 95 14 CONNECT FRONT EXHAUST PIPE See step 14 on page EM 96 15 INSTALL SUSPENSION LOWER CROSSMEMBER See step 15 on page EM 96 16 INSTALL ENGINE UNDER COVERS 17 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 18 FILL WITH ENGINE OIL See page LU 7 19 START ENGINE AND CHECK FOR LEAKS 20 RECHECK ENGINE OIL ...

Page 223: ...SERVICE SPECIFICATIONS SPECIFICATIONS TORQUE SPECIFICATIONS LU 18 LUBRICATION SYSTEM ServiceSpecifications ...

Page 224: ...IGNITION SYSTEM IG 1 ...

Page 225: ... Ī of the check connector 3 As some tachometers are not compatible with this ignition system we recommend that you confirm the compatibility of your unit before use 4 NEVER allow the tachometer test probe to touch the ground as this could damage the igniter and or ignition coil 5 Do not disconnect the battery when the engine is running 6 Check that the igniter is properly grounded to the body IG 2...

Page 226: ...ir fuel mix ture IGNITER The igniter temporarily interrupts the primary cur rent with the ignition signal IGT signal from the ECU and generates sparks at the spark plug Also as a fail safe measure when ignition occurs an igni tion confirmation signal IGF signal is sent to the ECU IGNITION COIL The ignition coil uses a closed core coil with the primary coil wrapped around the core and the sec ondar...

Page 227: ...TION To maintain the most appropriate ignition timing the ECU sends a control signal so that the igniter sends current to the ignition coil and the spark plugs produce a spark IG 4 IGNITION SYSTEM Operation ...

Page 228: ...iring RECOMMENDED TOOLS 09082 00015 TOYOTA Electrical Tester 09200 00010 Engine Adjust Kit EQUIPMENT Part Name Note Timing light Ignition timing Tachometer Megger Insulation resistance meter Ohmmeter Spark plug cleaner 16 mm plug wrench IGNITION SYSTEM Preparation IG 5 ...

Page 229: ... the distribuitor housing Check wiring between ECU and distributor only then try another ECU SPARK TEST CHECK CONNECTION OF IGNITION COIL IGNITER AND DISTRIBUTOR CONNECTORS CHECK RESISTANCE OF HIGH TENSION CORDS See page IG 7 Maximum resistance 25 kW per cord CHECK RESISTANCE OF SIGNAL GENERATOR PICKUP COIL See page IG 9 Resistance 205 255W TRY ANOTHER IGNITER CHECK POWER SUPPLY TO IGNITION COIL 1...

Page 230: ...ICE Never use a wire brush for cleaning Never attempt to adjust the electrode gap on used spark plug Spark plug should be replaced every 100 000 km 60 000 miles 1 INSPECT ELECTRODE Using a megger insulation resistance measure the insula tion resistance Standard insulation resistance More than 10 MW If less than 10 MW proceed to step 2 HINT If a megger is not available the following simple meth od ...

Page 231: ...maximum replace the spark plug Correct electrode gap of new spark plug 1 1 mm 0 043 in If adjusting the gap of a new spark plug bend only the base of the ground electrode Do not touch the tip 5 CLEAN SPARK PLUGS If the electrode has traces of wet carbon allow it to dry and then clean with a spark plug cleaner Air pressure Below 6 kg cm2 85 psi 588 kPa Duration 20 seconds or less HINT If there are ...

Page 232: ...the ignition coil INSPECTION OF DISTRIBUTOR 1 INSPECT AIR GAPS Using a thickness gauge measure the gap between the sig nal rotor and pickup coil projection Air gap 0 2 0 4 mm 0 008 0 016 in If the air gap is not as specified replace the distributor hous ing 2 INSPECT SIGNAL GENERATOR PICKUP COIL RESISTANCE Using an ohmmeter measure the resistance between the ter minals G1 pickup coil resistance G1...

Page 233: ...air hoses c Loosen the air cleaner hose clamp bolt d Disconnect the air cleaner cap clips e Remove the air cleaner cap and air flow meter together with air cleaner hose 3 DISCONNECT HIGH TENSION CORDS FROM DISTRIBUTOR CAP 4 DISCONNECT DISTRIBUTOR CONNECTOR 5 REMOVE DISTRIBUTOR Remove the two hold down bolts and pull out the distributor Remove the O ring IG 10 IGNITION SYSTEM Distributor ...

Page 234: ...UTOR a Install a new O ring to the housing b Apply a light coat of engine oil on the O ring c Align the cutout marks of the coupling and housing d Insert the distributor aligning the line of the housing with the cutout of the distributor attachment bearing cap e Lightly tighten the two hold down bolts 3 CONNECT HIGH TENSION CORDS TO DISTRIBUTOR CAP a Ex Center Cord First insert the grommet part on...

Page 235: ... pulling the holder d Center Cord Insert the grommet and holder together e Connect the high tension cords as shown in the illustration 4 CONNECT DISTRIBUTOR CONNECTOR 5 INSTALL AIR CLEANER CAP AIR FLOW METER AND AIR CLEANER HOSE a Connect the air cleaner hose and install the air cleaner cap and air flow meter with the four clips b Tighten the air cleaner hose clamp bolt c Connect the air hoses d C...

Page 236: ...before use 9 ADJUST IGNITION TIMING a Check the idle speed Idle speed 700 50 rpm b Using SST connect terminals TE1 and E1 of the check connector SST 09843 18020 c Using a timing light check the ignition timing Ignition timing 10 BTDC idle Transmission in N range d Loosen the two hold down bolts and adjust by turning the distributor e Tighten the hold down bolts and recheck the ignition timing Torq...

Page 237: ...SERVICE SPECIFICATIONS IG 14 IGNITION SYSTEM ServiceSpecifications ...

Page 238: ...ENGINE TROUBLESHOOTING TR 1 ...

Page 239: ...o normal In order to determine this the problem symptoms should be confirmed in 3 and the diagnostic code should be rechecked in 5 Accordingly if troubleshooting is begun based on the malfunction code only in the diagnostic code check in 2 it could result in a misdiagnosis leading to troubleshooting of normally operating circuits and making it more difficult to locate the cause of the problem 3 PR...

Page 240: ...r the ECU 11 REPAIRS After the cause of the problem is located perform repairs by following the inspection and replacement procedures in this manual 12 CONFIRMATION TEST After completing repairs confirm not only that the problem is eliminated but also perform diagnostic code check etc again to make sure the entire engine control system is operating correctly ENGINE TROUBLESHOOTING How to Proceed w...

Page 241: ...nositc Code Chart P TR 18 Circuit Inspection P TR 26 Basic Inspection P TR 19 Matrix Chart of Problem Symptoms P TR 23 Identification of Problem Adjustment or Repair Confirmation Test END Components Inspection Problem Symptom Confirmation Normal Code Problem Symptom Does Not Exist Problem Symptom Exist Malfunction Code TR 4 ENGINE TROUBLESHOOTING How to Proceed with Troubleshooting ...

Page 242: ...t Ohm Meter and check the applicable circuit using a volt ohm meter Determine if the malfunction is in the sensor actuator wire harness connector or the ECU If the malfunctioning circuit cannot be detected using the checker proceed to Basic Inspection and perform troubleshooting If a malfunction code is displayed in the diagnostic code check use the checker to inspect the circuit indi cated by the...

Page 243: ...P TR 9 P TR 18 P TR 23 P TR 26 P TR 19 P TR 14 P TR 7 P TR 9 TR 13 TR 6 ENGINE TROUBLESHOOTING How to Proceed with Troubleshooting ...

Page 244: ...eration j Racing without load j Deceleration j Engine does not start j Engine does not crank j No initial combustion j No complete combustion j Difficult to start j Engine cranks slowly j Others mptoms j Poor Idling j Incorrect first idle j Rough idling j Others j Idling rpm is abnormal j High j Low rpm Problem Sym j Poor Driveability j Hesitation j Surging j Others j Back fire j Knocking j Muffle...

Page 245: ...es items indicated by code No as shown in TR 11 A CHECK engine warning light on the instrument panel in forms the driver that a malfunction has been detected The light goes off automatically when the malfunction has been repaired But the diagnostic code s remains stored in the ECU memory except for code Nos 16 51 and 53 The ECU stores the code s until it is cleared by removing the EFI fuse with th...

Page 246: ...tic codes proceed as follows 1 Initial conditions a Battery voltage 11 V or more b Throttle valve fully closed c Transmission in neutral position d Accessories switches turned OFF 2 Turn ignition switch ON Do not start the engine 3 Using SST connect terminals TE1 and E1 of the TDCL or check connector SST 09843 18020 4 Read the diagnostic code as indicated by the number of flashes of the CHECK engi...

Page 247: ...wo or more codes there will be a 2 5 second pause between each After all the codes have been output there will be a 4 5 second pause and they will all be repeated as long as the terminals TE1 and E1 of the TDCL or check connector are connected HINT In the event of 2 or more trouble codes indication will begin from the smaller numbered code and continue in order to the larger 5 After the diagnostic...

Page 248: ...or more THW D Open or short in water temp sensor circuit D Water temp sensor D ECU O 24 Intake Air Temp Sensor Signal ON 3 Open or short in intake air temp sensor circuit for 0 5 sec or more THA D Open or short in intake air temp sensor circuit D Intake air temp sensor D ECU O 25 Air fuel Ratio Lean Malfunc tion ON 1 Oxygen sensor ouput is less than 0 45 V for at least 90 sec when oxygen sen sor i...

Page 249: ...between 1 600 rpm 5 200 rpm signal from knock sensor is not input to ECU for 6 revolution KNK D Open or short in knock sensor circuit D Knock sensor looseness etc D ECU O 53 Knock Control Signal ON Engine speed is between 650 rpm and 5 200 rpm and engine control computer for knock control mal function is detected D ECU X 71 EGR System Malfuncti on ON With engine warmed up and EGR operation possibl...

Page 250: ...r repair of the trouble areas the diagnostic code retained in the ECU memory must be cancelled out by removing the EFI fuse 20A for 10 seconds or more depending on ambient temperature the lower the temperature the longer the fuse must be left out with the ignition switch OFF HINT Cancellation can also be done by removing the battery negative terminal but in this case other memory systems clock rad...

Page 251: ... much as possible follow ing the customer problem analysis check sheet See page TR 7 and try to reproduce the intermittent problem The problem simulation methods described below are the effective ways for this nature of problem to produce the problem conditions by applying vibration heat and humidity 1 VIBRATION METHOD When vibration seems to be the major cause CONNECTORS Slightly shake the connec...

Page 252: ... object Check to see if the malfunction will occur NOTICE D Do not heat to more than 605C 1405F Temperature limit that the component can be touched with a hand D Do not apply heat directly to part in the ECU 3 WATER SPRINKLING METHOD When the malfunction seems to occur on a rainy day or in a high humidity condition Sprinkle water onto the vehicle and check to see if the malfunction will occur NOTI...

Page 253: ...ms to occur when electrical load is excessive Turn on all electrical loads including the heater blower head lamps rear window defogger etc and check to see if the malfunction will occur TR 16 ENGINE TROUBLESHOOTING SymtomSimulation ...

Page 254: ...NJECTOR No 2 and 3 VF CHECK CONNECTOR 1SP2 No 2 speed sensor a t SIDE E1 ECU GROUND T2 CHECK CONNECTOR STJ COLD START INJECTOR 1PWR PATTERN SELECT SWITCH 1DG CHECK CONNECTOR T1 CHECK CONNECTOR FPU FUEL PRESSURE VSV OX1 OXYGEN SENSOR 2CHK SUB OXYGEN SENSOR ACT A C AMPLIFIER KNK KNOCK CONTROL SENSOR HT OXYGEN SENSOR HEATER 2OX2 SUB OXYGEN SENSOR W CHECK ENGINE WARNING LIGHT 1BK BRAKE SWITCH 1N SHIFT...

Page 255: ...r Heater Signal TR 36 22 Water Temp Sensor Signal TR 40 24 Intake Air Temp Sensor Signal TR 42 25 Air fuel Ratio Lean Malfunction TR 44 26 Air fuel Ratio Rich Malfunction TR 44 27 Sub oxygen Sensor Signal California Only TR 52 31 Air Flow Meter Signal TR 59 32 Air Flow Meter Signal TR 59 41 Throttle Position Sensor Signal TR 63 42 Vehicle Speed Sensor Signal TR 67 43 Starter Signal TR 69 52 Knock ...

Page 256: ...y Therefore use of this check is essential in engine troubleshoot ing Is Battery voltage 11 V or more when engine is stopped Change or replace battery Does engine crank Go to Matrix Chart of Problem Symptoms See page TR 21 Does engine start Go to step 8 Check air filter Replace air cleaner element Remove air filter Visually check if the air cleaner element is not exces sively damaged or oily If ne...

Page 257: ... at normal operating tempera ture 3 Switch off all accessories 4 Switch off air conditioner 5 Connect tachometer test probe to terminal IG of check connector Check idle speed Idle speed 700 50 rpm Check ignition timing 1 Connect timing light to engine 2 Keep engine at idle 3 Using SST connect terminals TE1 and E1 of check connector SST 09843 18020 D NEVER allow tachometer test probe to touch groun...

Page 258: ...ng 10 BTDC at idle Transmission into N range Disconnect SST Check if the ignition timing advances using a timing light Ignition timing The timing mark moves in a range between 13 and 27 Transmission into N range Go to Matrix Chart of Problem Symptoms See page TR 21 FURTHER CHECK ENGINE TROUBLESHOOTING Basic Inspection TR 21 ...

Page 259: ...B and FP of check connector SST 09843 18020 Go to IGNITION SYSTEM See page IG 1 Check for spark Go to Matrix Chart of Problem Symptoms See page TR 21 Check if there is a pressure in hose from fuel filter by pinching hose by fingers At this time you will hear fuel return noise Fuel pressure can be felt TR 22 ENGINE TROUBLESHOOTING Basic Inspection ...

Page 260: ...umber in order given in the table below The circuits indicated by on the matrix chart can be inspected using the TCCS checker HINT Before proceeding with troubleshooting using this matrix chart of problem symptoms basic inspection on page TR 19 should be performed first TR 26 TR 29 TR 44 TR 40 TR 42 TR 52 TR 59 TR 63 TR 86 TR 69 TR 71 TR 81 TR 81 FI 15 FI 25 FI 35 FI 27 FI 22 FI 48 ENGINE TROUBLES...

Page 261: ...start in cold 4 11 3 Diffic Difficult to start in hot 3 4 11 2 g Incorrect first idle 4 5 dling High engine idle speed 4 11 r idl Low engine idle speed 2 6 3 Poor Rough idling 9 19 1 4 5 3 Po Misfire 11 1 3 5 2 ility Hesitation Poor acceleration 20 3 5 6 4 vabil Back fire 12 1 r driva Muffler explosion after fire 1 11 Poor Serging 5 2 3 Po Knocking 10 2 3 4 l Engine stall soon after starting 6 11 ...

Page 262: ... Pump Valve Stem Guide Bushing Oil Pump Connecting Rod Bearing Crankshaft Bearing Cylinder Head Piston Ring Flywheel or Drive Plate Radiator and Radiator Cap Thermostat Drive Belt Water Temp Sender Gauge Oil Plessure Switch Alternator Cylinder Block 2 9 10 11 5 7 8 6 3 4 9 11 10 1 2 1 2 10 13 14 15 20 11 7 2 1 7 16 17 2 2 7 5 9 6 8 3 6 4 5 11 13 12 2 7 5 6 10 11 3 4 13 12 1 2 3 3 2 5 4 6 2 3 4 5 1...

Page 263: ...nspection shown on matrix chart See page TR 23 CIRCUIT INSPECTION Diag Code 12 RPM Signal CIRCUIT DESCRIPTION The distributor in the Engine Control System contains three pick up coils G1 G2 and Ne The G1 G2 signals inform the ECU of the standard crankshaft angle The Ne signals inform the ECU of the crankshaft angle and the engine speed Code No Diagnosis Trouble Area 12 No NE or G signal is sent to...

Page 264: ... ECU wiring connectors from ECU Using an ohmmeter measure resistance between each terminal shown in table below Check resistance of pickup coils at ECU connector Replace ECU Using a thickness gauge measure the gap between signal rotor projection and pickup coil Air gap 0 2 mm 0 008 in or more Using an ohmmeter measure resistance between each terminal shown in table below However when diag code 12 ...

Page 265: ...s that a momentary interruption of the RPM signal from the distributor to the ECU has occurred but that it is returned to normal Note that although this problem may not necessarily appear at the time of inspection it cannot be ignored because this diagnostic code is output indicating that there is or was a malfunction in the RPM signal circuit this malfunction is usually a loose connector The dist...

Page 266: ...n it reaches the ignition timing the ECU turns TR1 off and outputs the IGT signal 0 This turns TR2 off interrupting the primary current flow and generating a high voltage in the secondary coil which causes the spark plug to spark Also by the counter electromotive force generated when the primary current is interrupted the ignitor sends an ignition confirmation signal IGF to the ECU The ECU stops f...

Page 267: ...harness or connector Repair or replace harness or connector between igniter and ignition coil or replace igniter Repair harness or connector between ignitor and ignition coil or replace ignitor Replace ignition coil Replace ignitor Check and repair harness or con nector between ECU and ignitor Repair or replace harness or connector When diag code 14 is not displayed proceed to next circuit inspect...

Page 268: ...DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS ENGINE TROUBLESHOOTING CircuitInspection TR 31 ...

Page 269: ...ure voltage between terminal IGF of ignitor connector and body ground Check voltage between terminal IGF of ECU connector and body ground 1 Disconnect ignitor connector 2 Turn ignition switch ON Repair or replace harness or connector Go to step 5 Check voltage between terminal IGF of ignitor connector and body ground Check harness and connector between ECU and ignitor Replace ECU INSPECTION PROCED...

Page 270: ...ect ignitor connector 2 Disconnect ignition coil connector 3 Turn ignition switch ON Check ignition coil Primary coil resistance cold 0 41 0 50 W Measure voltage between terminal B and E of ignition coil connector CHECK PRIMARY COIL RESISTANCE Voltage Battery voltage Measure voltage between terminal B of ignitor connector and body ground 1 Disconnect ignitor connector 2 Turn ignition switch ON How...

Page 271: ... connector and body ground when engine is cranked Check voltage between terminal IGT of ignitor connector and body ground Check voltage between terminal IGT of ECU connector and body ground 1 Connect ignition coil connector 2 Disconnect ignitor connector Replace ignitor Voltage Approx 1 0V Neither 0V nor 5V Measure voltage between terminal IGT of ECU con nector and body ground when engine is crank...

Page 272: ... output from ECU of ECT D ECU When the ECU stores diagnostic code 16 in memory torque control which performs smooth gear shift ing is prohibited DIAGNOSTIC CHART Are there any other codes besides code 16 being output Replace ECU Go to relevant Diag Code Chart ENGINE TROUBLESHOOTING CircuiitInspection TR 35 ...

Page 273: ...t gas is low current flows to the heater to heat the sensor for accurate detection Code No Diagnosis Trouble Area 1 Open or short in heater circuit of main oxygen sensor for 0 5 sec or more HT Open or short in heater circuit of main oxygen sensor Main oxygen sensor heater ECU 21 2 At normal driving speed below 60 mph and engine speed is above 1 500 rpm amplitude of oxygen sensor signal OX1 is redu...

Page 274: ...200 rpm when shifting Gradually depress the accelerator pedal and kept it Steady so that engine braking does not occur 4 Keep vehicle speed below 60 mph 5 Stop the vehicle then 10 sec or more after turning IG switch to OFF not Acc perform 1 2 3 4 again For M T Vehicle 1 Start engine and warm engine up 2 After engine is warmed up let it idle for 3 min 3 With the A C ON and vehicle speed approx 35 m...

Page 275: ...l HT ECU connector and body ground Check main oxygen sensor Check and repair harness and connector between ECU and EFI main relay Replace main oxygen sensor Replace ECU Replace main oxygen sensor Check voltage between terminal HT of ECU connector and body ground TR 38 ENGINE TROUBLESHOOTING CircuiitInspection ...

Page 276: ... of ECU con nector and body ground when engine is idling and racing at 4000 rpm Replace main oxygen sensor Measure resistance between terminals B and HT of main oxygen sensor connector Disconnect main oxygen sensor connector Measure voltage between terminal HT of ECU con nector and body ground 1 Connect main oxygen sensor connector 2 Disconnect ECU connector 3 Turn ignition switch ON Voltage Batte...

Page 277: ...t 80 C 176 F Code No Diagnosis Trouble Area 22 Open or short in water temp sensor circuit for 0 5 sec or more THW Open or short in water temp sensor circuit Water temp sensor ECU DIAGNOSTIC CHART Check water temp sensor Check voltage between terminals THW and E2 of ECU connector Check harness and connector between ECU and water temp sensor Replace ECU Replace water temp sensor Replace ECU Repair o...

Page 278: ... Replace ECU Measure voltage between terminals THW and E2 of ECU connector 1 Connect water temp sensor connector 2 Turn ignition switch ON Voltage Neither 0V nor 5V Repair or replace harness or connector Check harness and connector between ECU and water temp sensor Replace ECU When diag code 22 is not displayed proceed to next circuit inspection shown on matrix chart See page TR 21 ENGINE TROUBLES...

Page 279: ...he intake air temperature sensor is built in the air flow meter and senses the intake air temperature The resistance value of a thermistor built in sensor changes according to the intake air temperature The lower the intake air temperature the larger the resistance value becomes If diagnostic code 24 is recorded in memory the fair safe function operates and fixes the intake air temperature at a co...

Page 280: ...eplace ECU Measure voltage between terminals THA and E2 of ECU connector 1 Connect air flow meter connector 2 Turn ignition switch ON Voltage Neither 0V nor 5V Repair or replace harness or connector Check harness and connector between ECU and intake air temp sensor Replace ECU When diagnostic code 24 is not displayed proceed to next circuit inspection shown on matrix chart See page TR 21 ENGINE TR...

Page 281: ...ct caught in valve value or ada tive control value continues at the upper lean or lower rich limit for a t i i d f ti d ti t l Foreign object caught in valve ECU certain period of time or adaptive control value is not renewed for a certain period of ECU value is not renewed for a certain eriod of time Engine ground bolt loose Open in E1 circuit Sh t i i j t i it Short in injector circuit Fuel line...

Page 282: ...xygen Sensor 1 Start engine and warm engine up 2 After engine is warmed up let it idle for 3 min 3 Perform sudden racing to 4 000 rpm three times Rapidly depress the accelerator pedal then remove your foot from the pedal at 4 000 rpm 4 After performing the racing in perform racing at 2 000 rpm for 90 sec 5 Keep the IG switch at OFF not Acc for at least 10 sec then perform 1 2 3 4 again NOTICE If t...

Page 283: ...ector between ECU and main oxygen sensor ECU and check connector Repair or replace harness or connector Check each item found to be a possible cause of problem Repair or replace Does malfunction disappear when a known good main oxygen sensor is installed Replace main oxygen sensor Replace ECU TR 46 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 284: ...mes for every 10 seconds replace main oxygen sensor Check harness or connector between ECU and main oxygen sensor ECU and check connector Repair or replace harness or connector Check each item found to be a possible cause of problem Repair or replace Does malfunction disappear when a known good main oxygen sensor is installed Replace main oxygen sensor Replace ECU NG Voltage stays at 0 V Check eac...

Page 285: ...DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS TR 48 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 286: ...of check connector SST 09843 18020 2 Using an analog voltmeter connect positive prove to VF1 terminal and negative prove to E1 terminal of check connector and set it to 5 20 V range 3 Warm up oxygen sensor by running engine at 2 500 rpm for about 2 minutes 4 Then maintaining engine at 2 500 rpm count how many times needle of voltmeter fluctuates between 0 and 5 V Needle fluctuates a minimum of 8 t...

Page 287: ...6 are displayed go to step 3 When voltage stays at 5 V go to step 5 When needle fluctuates less than 8 times for every 10 seconds replace main oxygen sensor Check harness or connector between ECU and main oxygen sensor ECU and check connector Repair or replace harness or connector See page IG 1 FI 15 FI 49 FI 37 FI 37 EM 15 Check air leakage Check item Check installation of main oxygen sensor Chec...

Page 288: ...istics deviation Check intake air temp sensor characteristics deviation Check each item found to be a possible cause of problem Check each item found to be a possible cause of problem Repair or replace Replace ECU Repair or replace Does malfunction disappear when a known good main oxygen sensor is installed ENGINE TROUBLESHOOTING CircuitInspection TR 51 ...

Page 289: ... the diag code is erased the malfunction is reproduced and the diag code is recorded again b To check that the malfunction is cleared once the repair is completed confirm that diag code is no longer detected Malfunction Open or Short in Sub Oxygen Sensor For A T Vehicle 1 Start engine and warm engine up 2 After engine is warmed up let it idle for 3 min 3 With the A C ON and the transmission in D r...

Page 290: ...the driving in stop the vehicle 5 Within 1 min of stopping the vehicle shift into 2nd gear and gradually accelerate for 5 sec while gradually increasing the engine speed from 1 500 rpm up to 3 500 rpm Then without releasing the accelerator pedal at all accelerate with throttle wide open for 2 sec NOTICE If the conditions in this test are not strictly abserved detection of the malfunction will not ...

Page 291: ...d GND of sub oxygen sensor connector Check voltage between terminals CHK and GND of sub oxygen sensor connector Check voltage between terminal CHK of sub oxygen sensor connector and body ground Check voltage between terminal CHK of ECU connector and body ground Replace ECU Check air leakage Check voltage between terminals OX2 and E2 of ECU connector Check harness or connector between ECU sub oxyge...

Page 292: ...DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS ENGINE TROUBLESHOOTING CircuitInspection TR 55 ...

Page 293: ...nector Check continuity between terminals CHK and GND of sub oxygen sensor connector Repair Check continuity between terminals CHK and GND of sub oxygen sensor connector Continuity Replace sub oxygen sensor Measure voltage between terminals CHK and GND of sub oxygen sensor connector Voltage 12V Measure voltage between terminal CHK of sub oxygen sensor connector and body ground Voltage 12V INSPECTI...

Page 294: ...continue racing at 4 000 rpm to approx 3 minutes Measure voltage between terminals OX2 and E2 of ECU connector when engine is suddenly raced to full throttle Voltage should be 0 5 V or higher at least once Check air leakage Check voltage between terminals OX2 and E2 of ECU connector Replace ECU No air leaking into air intake system between air flow meter and cylinder head Loose or missing engine o...

Page 295: ... harness or connector Check harness or connector between ECU sub oxygen sensor and body ground Repair fuel system Check fuel system See page FI 15 Replace sub oxygen sensor TR 58 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 296: ...eplace air flow meter Check for an open circuit between ECU and air flow meter Replace ECU Go to step 7 Diag Code 31 or 32 Air Flow Meter Signal CIRCUIT DESCRIPTION The air flow meter is located directly behind the air cleaner and detects the intake air volume It con verts the intake air readings into a voltage signal by means of a potentiometer Intake air volume signal is used to calculate the ba...

Page 297: ... DIAGRAM AND ECU CONNECTORS Check VS circuit for short circuit between ECU and air flow meter Repair or replace harness or connector Replace ECU DIAGNOSTIC CHART TR 60 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 298: ...plate from closed to open position with a screwdriver or similar object Check change in voltage between terminals Vs and E2 of ECU connector while slowly pushing air flow meter measuring plate from closed to open position with a screwdriver or similar object Voltage changes smoothly from about 5V when closed to about 0V when open i e does not suddenly jump up to 5V or down to 0V Check voltage betw...

Page 299: ... E2 of air flow meter connector Voltage 5V Repair or replace harness or connector Replace air flow meter Measure voltage between terminals Vc and E2 of ECU connector Voltage 5V Check voltage between terminals VC and E2 of ECU connector CheckVC circuit for shortcircuitbetweenECUandairflowmeter Replace ECU Replace ECU CheckVScircuitforshortcircuitbetweenECUandairflowmeter Repair or replace harness o...

Page 300: ...rottle position sensor cir cuit 41 IDL contact is ON and VTA output exceeds 1 45 V Throttle position sensor ECU HINT When the connector for the throttle position sensor is disconnected diagnostic code 41 is not output Diagnostic code 41 is output only when there is an open or short in the VTA signal circuit of the throttle position sensor DIAGNOSTIC CHART Check voltage between terminals VC and E2 ...

Page 301: ...DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS TR 64 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 302: ...pening throttle valve from closed to open position Voltage changes smoothly from 0 1V when closed to about 5V when open i e does not suddenly jump up to 5V or down to 0 1V Check throttle position sensor When diag code 41 is not displayed proceed to next circuit inspection shown on matrix chart See page TR 23 Turn ignition switch LOCK Measure resistance between each terminal shown below 1 Connect t...

Page 303: ...onnector between ECU and throttle position sensor Replace ECU Check for an open circuit between ECU and throttle position sensor Check for short circuit between ECU and throttle position sensor Check voltage between terminals VC and E2 of ECU connector Repair or replace harness or connector Measure voltage between terminals Vc and E2 of ECU connector Voltage 5V TR 66 ENGINE TROUBLESHOOTING Circuit...

Page 304: ...t 8 seconds during high load driving with engine speed between 2 500 rpm and 4 500 rpm Open or short in vehicle speed sensor circuit Vehicle speed sensor ECU DIAGNOSTIC CHART Check continuity between terminal SP1 of ECU connector and body ground Check No 1 speed sensor Repair or replace No 1 speed sensor Replace ECU Check harness and connector between ECU and speed sensor in speedometer WIRING DIA...

Page 305: ...in speedometer Check continuity between terminal SP1 of ECU connector and body ground Check continuity between terminal SP1 of ECU connector and body ground while turning wheel slowly by hand Resistance changes from RW to RW Repair or replace No 1 speed sensor Replace ECU Check No 1 speed sensor TR 68 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 306: ...er start injection control Code No Diagnosis Trouble Area 43 No STA signal to ECU until engine speed reaches 800 rpm with vehicle not moving Open or short in starter signal circuit Open or short in IG switch circuit ECU DIAGNOSTIC CHART Check starter operation Check starter circuit Check voltage between terminals STA and E1 of ECU connector Check harness and connector between ECU and terminal STA ...

Page 307: ... voltage between terminals STA and E1 of ECU circuit Replace ECU Check starter circuit Check starter operation Measure voltage between terminals STA and E1 of ECU connector Voltage 6 V or more When diag code 43 is not displayed proceed to next circuit inspection shown on matrix chart See page TR 23 TR 70 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 308: ...se of the driving patten a After the diag code is erased the malfunction is reproduced and the diag code is recorded again b To check that the malfunction is cleared once the repair is completed confirm that diag code is no longer detected Malfunction Open or Short in Knock Sensor À Start engine and warm engine up Á After engine is warmed up let it idle for 3 min  With the A C ON perform sudden r...

Page 309: ...of ECU connector and body ground Check for short circuit between ECU and knock sensor Check for open circuit between ECU and knock sensor Does malfunction disappear when a known good knock sensor is installed Replace ECU Replace knock sensor Repair or replace harness and connector Replace knock sensor WIRING DIAGRAM AND ECU CONNECTORS TR 72 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 310: ...d boy ground Open Go to step 3 Check continuity between terminal KNK of ECU connector and body ground Check for open circuit between ECU and knock sensor Repair or replace harness or connector Does malfunction disappear when a known good knock sensor is installed When diag code 52 is not displayed proceed to next circuit inspection shown on matrix chart See page TR 21 Replace ECU Replace knock sen...

Page 311: ...knocking occurs ignition timing is retarded to reduce it Code No Diagnosis Trouble Area 53 Engine speed is between 650 rpm and 5 200 rpm and engine control computer for knock control Malfunction is detected D ECU DIAGNOSTIC CHART Are there any other output codes besides code 53 being output Replace ECU Go to relevant Diag Code Chart TR 74 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 312: ... passage D ECU See page TR 13 DIAGNOSIS CODE DETECTION DRIVING PATTERN Purpose of the driving patten a After the diag code is erased the malfunction is reproduced and the diag code is recorded again b To check that the malfunction is cleared once the repair is completed confirm that diag code is no longer detected Malfunction Open in EGR Gas Temp Sensor Loose EGR or BVSV Vacuum Hose Valve Stuck Cl...

Page 313: ... 45 70 mph in 4th gear with air conditioner ON Keep the accelerator pedal position constant Turn the IG switch to OFF not Acc when you finish driving then 30 min later to cool the engine perform Á Â again NOTICE If the conditions in this test are not strictly observed detection of the malfunction will not be possible TR 76 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 314: ...G of EGR gas temp sensor connector and body ground Check voltage between terminals THG and E2 of ECU connector Check for short circuit between ECU and EGR gas temp sensor Repair EGR system Repair or replace EGR gas temp sensor connector Check for open circuit between ECU and EGR gas temp sensor Check harness and connector between terminal E2 of ECU con nector and EGR gas temp sensor Replace ECU Re...

Page 315: ...DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS TR 78 ENGINE TROUBLESHOOTING CircuitInspection ...

Page 316: ...r Replace ECU Replace EGR gas temp sensor Repair or replace EGR gas temp sensor connector Measure voltage between terminals THG and E2 of EGR gas temp sensor connector on harness side Voltage 5 V Remove EGR gas temp sensor Measure resistance between terminals of EGR gas temp sensor connector Check voltage between terminals THG and E2 of EGR gas temp sensor connector ENGINE TROUBLESHOOTING CircuitI...

Page 317: ...GR gas temp sensor Measure voltage between terminal THG of EGR gas temp sensor connector and body ground Voltage 5V Check harness and connector between terminal E2 of ECU connector and EGR gas temp sensor Check voltage between terminal THG of EGR gas temp sensor connector and body ground Check for short circuit between ECU and EGR gas temp sensor Replace ECU Repair or replace harness or connector ...

Page 318: ...le condition Code No Diagnosis Trouble Area 51 Displayed when A C is ON IDL contact OFF or shift position in R D 2 or 1 renges with the check terminals E1 and TE1 connected A C switch circuit Throttle position sensor IDL circuit Neutral start switch circuit Accelerator pedal cable ECU DIAGNOSTIC CHART Is code 51 being output Go to relevant switch signal circuit inspection Check operation of starte...

Page 319: ...ody ground Replace ECU Check voltage between terminals IDL and E2 of throttle position sensor connector Check throttle position sensor Replace ECU Check voltage between terminal IDL of throttle position sensor connector and body ground Check voltage between terminals IDL and E2 of ECU connector Check for short circuit between ECU and throttle position sensor Repair or replace harness or connector ...

Page 320: ...DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS ENGINE TROUBLESHOOTING CircuitInspection TR 83 ...

Page 321: ...l Check neutral start switch See page AT 155 Turn ignition switch ON Measure voltage between terminal NSW of ECU connector and body ground Check harness or connector between ECU and neutral start switch Check voltage between terminal NSW of ECU connector and body ground Check operation of starter Replace neutral start switch Check starter circuit Go to step 3 Replace ECU When diag code 51 is not d...

Page 322: ...arness and connector between ECU and A C amplifier Check voltage between terminal A C of ECU connector and body ground Check operation of A C system Repair A C system Replace ECU When diag code 51 is not displayed proceed to next circuit inspection shown on matrix chart See page TR 23 ENGINE TROUBLESHOOTING CircuitInspection TR 85 ...

Page 323: ... and stop lever Measure voltage between terminals IDL and E2 of throttle position sensor connector When diag code 51 is not displayed proceed to next circuit inspection shown on matrix chart See page TR 21 Check voltage between terminal IDL of throttle position sensor connector and body ground Measure voltage between terminal IDL of throttle position sensor connector and body ground Voltage 5 V Ch...

Page 324: ...ss or connector Check for short circuit between ECU and throttle position sensor Connect throttle position sensor connector Measure voltage between terminals IDL and E2 of ECU connector Check for open circuit between ECU and throttle position sensor ENGINE TROUBLESHOOTING CircuitInspection TR 87 ...

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