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Summary of Contents for 7M-GE

Page 1: ...TOYOb4 REPAIR MANUAL ...

Page 2: ...SYSTEM m SYSTEM m SVSTEM m SYSTEM m 0 1996 TOYOTA MOTOR CORPORATION All rights reserved This book may not be re produced or copied in whole or in part with out the written permission of Toyota Motor Corporation ...

Page 3: ...9 HOW TO USE THIS MANUAL IN 2 I IDENTIFICATION INFORMATION IN 4 m GENERAL REPAIR INSTRUCTIONS z a IN 4 PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER l IN 6 ABBREVIATIONS USED IN THIS MANUAL IN 7 ...

Page 4: ... these precautions before starting any repair task TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the cause The repair for each possible cause is referenced in the remedy COI umn to quickly lead you to the solution REPAIR PROCEDURES Most repair operations begin with an overview illustration lt identifies the components and shows how the patiS f...

Page 5: ... the figure Torque 500 kg cm 36 ft lb 49 NW Specification This format provides the experienced technician with a FAST TRACK to the information needed The upper case task heading can be read at a glance and only when necessary the text below it provides detailed information Impor ant specifications and warnings always stand out in bold type REFERENCES References have been kept to a minimum However ...

Page 6: ...en the terminal nut and raise the cable straight up without twisting or prying it d Clean the battery terminal posts and cable terminals with a shop rag Do not scrape them with a file or other abrasive object e f Install the cable terminal to the battery post with the nut loose and tighten the nut after installation Do not use a hammer to tap the terminal onto the post Be sure the cover for the po...

Page 7: ...e of a lower rating 11 Care must be taken when jacking up and supporting the vehicle Be sure to lift and support the vehicle at the proper locations a If the vehicle is to be jacked up only at the front or rear end be sure to block the wheels in order to ensure safety b After the vehicle is jacked up be sure to support it on stands It is extremely dangerous to do any work on the vehicle raised on ...

Page 8: ... EM 1 I ENGINE MECHANICAL _ F e DESCRIPTION 1 111 E TROUBLESHOOTING n mamI I ENGINE TUNE UP COMPRESSION CHECK s e TIMING BELT EM 28 CYLINDER HEAD EM 37 CYLINDER BLOCK 1 1 1 EM 66 ...

Page 9: ...EM 2 ENGINE MECHANICAL Description DESCRl PTlON _ r 2 j The 7M GE and 7M GTE engines are an in line 6 cylinder 3 0 titer DOHC 24 valve engine i M G E MA _ 7M GE MS 7M GTE ...

Page 10: ...made in 2 pieces Pistons are made of highly temperature resis tant aluminum alloy and depressions are built into the piston head to prevent interference with valves Piston pins are the full floating type with the pins fastened to neither the piston boss nor the connecting rods Instead snap rings are fitted on both ends of the pins preventing the pins from falling out The No 1 compression ring is m...

Page 11: ...gh tension cord disconnected or broken Inspect cord IG 6 13 No fuel supply to injector Troubleshoot EFI system FI I 2 l No fuel in tank 0 Fuel pump not working l Fuel filter clogged 0 Fuel line clogged or leaking EFI system problems Repair as necessary ISC system problem Check ISC system FL 108 Spark plugs faulty Inspect plugs IG 7 Low compression Check compression EM 26 2 Rough idle stalls or Vac...

Page 12: ...Repair as necessary Spark plugs faulty Inspect plugs IG 7 Engine overheats Check cooling system co 4 Low compression Check compression EM 26 2 Engine diesels EFI system problems Repair as necessary runs after ignition switch is turned off Muffler explosion Deceleration fuel cut system always off Check EFI fuel cut system FI 128 after fire on deceleration only Muffler explosion Air cleaner clogged ...

Page 13: ...sion Tires improperly inflated Clutch slips Brakes drag Incorrect idle speed Incorrect ignition timing Vacuum leaks 0 PCV hoses 0 w EGR EGR valve 0 Intake manifold l Air intake chamber l Throttle body EFI system problems Remedy Repair as necessary Check PCV system Check rings Check valves Check seals Repair as necessary Check air cleaner Reset timing Repair as necessary Check ISC system Inspect pl...

Page 14: ...ally check that the air cleaner element is not excessively dirty damaged or oily b Clean the element with compr sed air First blow from back side thoroughly Then blow off the front side of the element INSPECTION OF BATTERY See page CH 3 INSPECTION OF HIGH TENSION CORDS See pages IG 6 13 INSPECTION OF SPARK PLUGS See pages 19 7 to 9 INSPECTION OF DRIVE BELT See page CH 41 ...

Page 15: ...rod c Disconnect the water by pass hoses from the throt tie body d Disconnect following hoses w EGR VSV hose for EGR l w TWC BVSV hose w EGR EGR vacuum modulator hoses 0 No 7 air hose e Disconnect the throttle position sensor connector f Remove the throttle body bracket s g Remove the air intake connector bracket mounting bolts c J I h Remove the four bolts two nuts air intake connect01 and gasket...

Page 16: ...IN and No 5 IN and No 3 EX and No 6 EX valves 4 Check that the valve lifters on the No 3 cylinder are loose 0 Measure only those valves indicated in the figure l Record the measurements which are out of specification They will be used later to determine the required replacement shims d Turn the crankshaft pulley 2 3 revolution and measure the clearance of No 2 IN and No 6 IN and No 2 EX and No 4 E...

Page 17: ... of shim new Intake N T A 0 20 mm 0 0079 in Exhaust N T A 0 25 mm 0 0098 in l Select a new shim with a thickness as close as possible to the calculated value NOTE Shims are available in 17 sizes in 0 050 mm 0 0020 in from 2 500 mm 0 0984 in 1 to 3 300 mm 0 1299 in cl Install a new adjusting shim l Place a new adjusting shim on the valve lifter l Using SST A press down the valve lifter and remove S...

Page 18: ... d Connect the throttle position sensor connector e Connect following hoses 0 No 7 air hose 0 w EGR 6 E6R vaixum modulator hoses BVSW hose l w EGR VSV hose for EGR 1 f Connect the water by pass hoses g ex MS RHD Connect the accelerator connecting rod s h Install the PCV pipe f 2 1 j r c ...

Page 19: ...ci 3 REMOVE INTAKE AIR CONNECTOR a Disconnect the air valve hose from the intake air con nector b Loosen the clamp and remove the two bolts c Remove the intake air connector 4 REMOVE IGNITION COVER a Remove the oil filler cap b Remove the five nuts and ignition coil cover c r 5 REMOVE IGNITION COIL WITH BRACKET a Disconnect the connector and ground strap b Remove the nut c Remove the No 1 and No 2...

Page 20: ...DER HEAD COVERS See pages EM 59 601 _ G j i rl 1 IN ALL lGNITION COIL WITH BRACKET _ la Install theNo and No 2 high tension cords to spark I l w _ i tall the withbracket and high tension cord Seepage c Install the No l and No 2 high tensioncords to igni tion coil and clamp _ 6 I d Install and torque the nut Torque 55 Kg cm 48 in lb 5 4 Nnrn NOTE Do not over tighten the nut e Connect the ground str...

Page 21: ... the air valve hose to intake air connector i r 14 INSTALL PCV PIPE WITH HOSES a install the PCV pipe with hoses to the throttle body and cylinder head covers I b Install and tighten the two bolts r F Connect the No 4 PCV hose to the PCV pipe d Connect the oxygen sensor wire to the two clam L 1 15 INSTALL ISC PIPE a Install the ISC pipe with the two bolts b Connect the hoses to the ISC pipe 1 s I ...

Page 22: ...Lrn Thickness 02 2 500 0 0984 20 04 2 550 0 1004 22 3 000 0 118i 06 2 600 0 1024 24 3 050 0 1201 08 2 650 0 1043 26 3 100 0 1220 10 2 700 0 1063 28 3 150 0 1240 12 2 750 0 1083 30 3 200 0 1260 1 Example A 2 800 mm shim is Installed and the measured clearance is 0 450 mm Replace the 2 800 mm shim with shim No 24 3 050 mm ...

Page 23: ... EXHAUST _ Lnstdod Shim Thlcknosr mm I 0 30 30 32 32 32132 4 34j34 34j _ Shim thickness mm in Exhaust valve clearance cold 0 20 0 30 mm 0 008 0 012 in Example A 2 800 mm shim is Installed and th measured clearance is 0 450 mm Replace the 2 800 mm shim with shim No 22 3 000 mm ...

Page 24: ...compatibility of your unit before using NOTE 7M GTE Connect the timing light pickup to t No 6 cylinder high tension cord CHECK IGNITION TIMING a Using a service wire short terminals T MA or TEI MS and El of the check connector CHEC K CCNNECTOR LOCATION See pages FI 111 b Check the idle speed Idle speed 7M GE w TWC 700 rpm w o TWC 800 rpm 7M GTE 800 rpm c Using a timing light check the ignition tim...

Page 25: ...ECHANICAL Engine Tune up 4 FURTHER CHECK IGNITION TIMING Check that the ignition timing advances Ignition timing 7M GE _ 10 13 BTDC idle 7M GTE More than 12 BTDC idle DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGJNE ...

Page 26: ... meter when adjusting the idle mix ture It is not necessary to adjust with the idle mix ture adjusting screw in most vehicles if they are in good condition If a CO meter is not available DO NOT ATTEMPT TO ADJUST WITH THE SCREW l If a CO meter is not available and it is absolutely necessary to adjust with the idle mixture adjusting screw or if the air flow meter is replaced use the alternative meth...

Page 27: ...k smoke from exhaust CAUSES 1 Faulty ignition 0 Incorrect timing 0 Fouled shorted or improperly gapped plugs 6 Open or crossed high tension cords 0 Cracked distributor cap 2 Incorrect valve clearance 3 Leaky EGR valve 4 Leaky intake and exhaust valves 5 Lea kv cvlinder 1 Vacuum leak 0 Vacuum hose 0 EGR valve 0 Intake manifold Air intake chamber 0 Throttle body l Cylinder head gasket 0 Brake booste...

Page 28: ...ioned for presetting Example Inscribed number depth c 83 8 3 mm 0 326 in Depths over 10 mm with a decimal point are abbreviated i Example Inscribed number depth 15 11 6 mm 0 463 in a Remove the rubber plug from the air flow meter b Measure the depth of the idle mixtura adjusting screw with vernier calipers cl Adjust the depth of idle mixture adjusting screw by turning the screw with SST SST 09243 ...

Page 29: ...d and calibrated 2 WARM UP ENGINE Allow the engine to reach normal operating temperature 3 CONNECT TACHOMETER TO ENGINE See page EM 17 w I FI16C 4 CHECK IDLE SPEED Idle speed 7M GE 700 rpm 7M GTE 800 rpm 5 CHECK OXYGEN SENSOR OPERATION a Using a service wire short terminals T and the check connector CHECK CONNECTOR LOCATION See page FI I 10 b Connect the positive I probe of a voltmeter to ter mina...

Page 30: ...TO TAIL PIPE AT a0 cm 1 3 ftt MEAS URE HC CO CONCENTRATION AT IDLE Wait t lest one minute before measuring to allow the concentration to stabilize Complete the measuring within three minutes Idle CO concentration 0 0 5 If the CO HC concentration do not conform to your regulations see the table in page EM 20 for possi ble cause I ...

Page 31: ...See page EM 171 3 CHECK IDLE SPEED M GE IIP DiTphragm I Ed M GTE C 7 2 i 1 1 7lVi GE i IM GTE rottle Valve leased alve 4 INSPECT AND ADJUST DP SETTING SPEED a Maintain the engine speed at 3 000 rpm b Pinch the vacuum hose between the DP and VTV i c Release the throttle valve d Check that the DP is set DP setting speed 2 000 rpm ...

Page 32: ... Release FM GTE Approx if not at specified speed adjust with the DP adjUitiri Screw 1 5 CHECK OPERATION OF VTV a f ye DP speed in the same ptocedure as above a b Release the pinched hose and check that the engine returns to idle speed in approx 1 second ...

Page 33: ...and gasket CHECK CYLINDER COMPRESSION PRESSURE a Insert a compression gauge into the spark plug hole b While cranking the engine with the starter motor measure the compression pressure NOTE Always use a fully charged battery to obtain an engine revolution of more than 250 rpm c Repeat steps Ia through Ib for each cylinder Compression pressure 11 0 kg cm2 156 psi 1 079 kPa or more Minimum pressure ...

Page 34: ...REMOVE NO 1 AIR CLEANER HOSE 5 REMOVE PCV PIPE 1 6 REMOVE IGNITION COIL See steps 4 5 on page EM 121 7 REMOVE SPARK PLUGS See page IO 121 _ 8 CHECK CYLlNDER COMPRESSION PRESSURE See step 7 on page EM 261 Compression pressure 10 0 kg cm2 142 psi 981 kPa or more Minimum pressure 9 0 kg cm2 128 psi 883 kPa Difference between each cylinder 1 O kg cm2 14 psi 98 kPa1 or less ...

Page 35: ...g Pulley I I ImIng oen I Crankshaft Pulley kg cm ft lb N ml Specified torque EM30f 31 REMOVAL OF TIMING BELT 1 REMOVE SPARK PLUGS 2 REMOVE WATER OUTLET Remove the two bolts water outlet and thermostat with gasket 3 with A C REMOVE A C BELT 4 REMOVE FAN AND ALTERNATOR DRIVE BELT 5 REMOVE PS BELT ...

Page 36: ... on the camshaft timing pulleys and No 2 timing belt cover are aligned If not turn the crankshaft pulley one complete revolution 8 REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS NOTE If reusing the timingbelt draw a direction arrow on the in direction of engine revolution a Loosen the idler pulley bolt and shift it left as far as it will go with a screwdriver and wrench b Temporarily tighten the ...

Page 37: ...UTION Do nqt make use of the timing belt ten sion when removing and installing the pulley set bolts 10 REMOVE CRANKSHAFT PULLEY a Using SST to hold the crankshaft pulley loosen the pulley bolt SST MA 09213 70010 and 09330 00021 MS 09213 54014 and 09330 00021 b Remove SST pulley bolt cl Using SST remove the pulley SST 09213 31021 11 REMOVE PS AIR PIPE 12 REMOVE NO 1 TIMING BELT COVER with A C Remov...

Page 38: ...not bend twist or turn the belt inside out l Do not allow the belt to come into contact with oil water or steam l Do not utilize belt tension when installing or remov ing the set bolt of the camshaft timing pulley If there are defects as shotin in the figures Check the foljowing points and replace the timing belt if necessary a Premature parting l Check for proper installation l Check the timing b...

Page 39: ...guide and the alignment of each pulley e If there is noticeable wear on the belt teeth check the timing belt cover gasket for damage and check for foreign materials on the pulley teeth 2 INSPECT IDLER PULLEY Check the turning smoothness of the timing belt idler pulley If necessary repiace the idler pulley EM2909 3 INSPECT TENSION SPRING Check the free length of the spring Free length 66 mm 2 72 in...

Page 40: ...s far as it will go and temporarily tighten it NOTE Remove any oil or water on the idler pulley and keep it clean 4 TEMPORARILY INSTALL TIMING BELT CAUTION The engine should be cold NOTE If reusing the timing belt install it with the rota tion direction mark pointing in the same direction as before disassembly Install the timing belt on the crankshaft timing pulley oil pump drive pulley and idler ...

Page 41: ... timing pulley matchmark with the No 2 tim ing belt cover matchmark b Install the timing pulley c Install the pin into the middle hole NOTE l When replacing the camshaft or the camshaft timing pulley Align the center holes of the camshaft and timing pulleys as shown in the illustration and insert the straight pin l When reusing the camshaft or camshaft timing pulleys Check that the straight pin ho...

Page 42: ...amshaft timing pulley are aligned with those on the No 2 timing belt cover 11 CHECK TIMING BELT TENSION a Turn both the intake and exhaust camshaft pulleys inward at the same time to slacken the timing belt at position A Turning torque 200 kg cm 14 ft lb 20 N m b Measure the timing belt deflection as shown Belt deflection at 2 3 kg 4 4 6 6 lb 20 29 N Cold Used belt 5 7 mm 0 20 0 28 in New belt 4 6...

Page 43: ...374 in 1 Used belt A 15 17 mm 0 59 0 67 in 1 B 9 11 mm 0 35 0 43 in C MA 10 5 12 mm 0 413 0 47 in MS 10 13 mm 0 39 0 51 in Reference Using SST check the drive belt tension SST A 09216 00020 SST B 09216 00030 Drive belt tension New belt A 70 80 kg B 65 65 kg C 53 77 kg Used belt A 30 45 kg B 25 40 kg C 30 40 kg NOTE 0 New belt refers to a belt which has been used less than 5 minutes on a running en...

Page 44: ...ER HEAD COMPONENTS _ 7M GE No 2 Cylinder Cover No 3 Cylinder Cover Head PCV Pipe No 1 Cylinder Head Cover q Camshaft Bearing Water Outlet Housing No 2 Timing Belt Cover No 2 Engine Hanger II 1400 29 20 1 Air Intake Chamber Alternator Bracket ...

Page 45: ...ad Cover Heater Hose Clamp w No 3 Cylinder Head Cover Turbocharoer Oil Seal t Camshaft Bearing Cap No 2 Engine Hanger Exhaust Manifold Stary Water Outlet Housing No Belt Gasket Chamber with Connector kg cm ft lb N ml Specified torque Non reusable part Intake Manifold EM35 ...

Page 46: ...tart injector connector l Throttle position sensor connector l ISC valve connector c Disconnect following hoses aI l BVSV hose from throttle body l EGR hoses from throttle boby l Vacuum transmitting p ipe hose from intake cham ber 0 Pressure regulator hose I l VSV for fuel pressure up es 7M GE Diaphragm hose d Disconnect following hoses 0 7M GTE Auxiliary air pipe hose from vacuum transmitting pip...

Page 47: ...racket mounting bolts cj Remove the cold start injector tube k Remove the EGR vacuum modulator from bracket I Disconnect the engine wire from the clamps of intake chamber m Remove the two nuts five bolts vacuum transmitting pipes and intake chamber with connector and gasket t r 7M GTE Disconnect the cold start injector connector 7M GTE REMOVE IGNITION COIL WITH BRACKET See steps 5 and 6 on pages E...

Page 48: ...ctors l Three VSV connectors l Knock sensor connectors l Ground strap from intake manifold b Remove the engine wire from the each clamps 7 REMOVE PULSATION DAMPER VSV AND NO 1 FUEL PIPE 6 REMOVE NO 2 FUEL PIPE a Disconnect the fuel hose from the No 2 fuel pipe b Remove the union bolt No 2 fuel pipe and gaskets 9 7M GTE REMOVE AUXILIARY AIR PIPE 10 7M GE REMOVE HIGH TENSION CORDS AND DISTRIBUTOR 11...

Page 49: ...e the three bolts and exhaust manifold stay c Remove the seven nuts exhaust manifold and gasket 14 REMOVE WATER OUTLET HOUSING a b cd 7M GE Remove the union bolts union with No 4 water by pass hose and gaskets Disconnect the No 6 water by pass hose from the water by pass pipe Remove the bolt two nuts water outlet housing and gasket ...

Page 50: ...LINDER HEAD g _I a Using SST uniformly loosen and remove thecylinder head bolts in several passes in the sequence shown SST 09043 38100 CAUTION Head warpage or cracking could result from removing in incorrect order b Lift the cylinder head from the dowels on the cylinder block c Place the head on wooden blocks on a bench If the cylinder head is difficult to lift off pry with a screwdriver between ...

Page 51: ... the six insulators and three spacers from the cylinder head 4 REMOVE INTAKE MANIFOLD w EGR Remove the four nuts seven bolts EGR valve VSV intake manifold and gasket w o EGR Remove the four nuts seven bolts VSV intake manifold and gasket 5 REMOVE NO 2 ENGINE HANGER AND GROUND STRAP 6 REMOVE HEATER UNION 7 wl EGR REMOVE EGR COOLER 6 REMOVE BEARING CAPS AND CAMSHAFTS a Uniformly loosen and remove th...

Page 52: ...d retainers in order INSPECTION CLEANING AND REPAIR OF CYLl NDER HEAD COMPONENTS 1 CLEAN TOP OF ONS AND TOP OF CYLINDER BLOCk 1 a Turn the crankshaft and bring each piston to top dead center Using a gasket scraper remove all the carbon from the piston tops b Using a gasket scraper remove all gasket material from the top of the block Blow carbon and oil from the bolt holes WARNING Protect your eyes...

Page 53: ...face CLEAN VALVE GUIDE BUSHINGS Using a valve guide brush and solvent clean all the valve guide bushings CLEAN CYLINDER HEAD Using a soft brush and solvent thoroughly clean the head INSPECT CYLINDER HEAD FOR FLATINESS Using a precision straight edge and feeler gauge measure the surface contacting the cylinder block and manifold for warpage Maximum warpage 0 10 mm 0 0039 in 1 If warpage is greater ...

Page 54: ...he inside diameter of the valve guide Guide inside diameter 6 010 6 030 mm 0 2366 0 2374 in EM2586 EM2931 b Using a micrometer measure the diameter of the valve stem Stem diameter Intake 5 970 5 985 mm 0 2350 0 2356 in _ Exhaust 5 965 5 980 mm 0 2348 0 2354 in c Subtract the valve stem diameter measurement from the valve guide bushing inside diameter measure ment Standard stem oil clearance Intake...

Page 55: ...g by hitting it with a hammer CAUTION Be careful not to damage the lifter hole b Gradu ally heat the cylinder head to approx 194OF c Using SST and hammer drive out valve guide bush ing SST 09201 70010 d Using a caliper gauge measure the valve guide bore of the cylinder head e Select a new valve guide bushing If the valve guide bushing bore of the cylinder head is more than 11 027 mm 0 4341 in mach...

Page 56: ...valve guide bushing and new valve 11 INSPECT AND GRIND VALVES a Grind the valve only enough to remove pits and car bon b Check that the valve are ground to the correct valve face angle Valve face angle 44 5 c Check the valve head margin thickness Standard margin thickness 1 3 mm 0 051 in Minimum margin thickness 0 5 mm 0 020 in If the valve head margin thickness is less than minimum replace the va...

Page 57: ... to the valve face Install the valve Lightly press the valve against the seat Do not rotate the valve c Check the valve face and seat for the following 0 If blue appears 360 around the face the valve is concentric If not replace the valve 0 If blue appears 360 around the valve seat the guide and seat are concentric If not resurface the seat 0 Check that the seat contact is on the middle of the val...

Page 58: ...ength 41 64 mm 1 6394 in If the free length is not within specification replace the valve spring c Using a spring tester measure the tension of the valve spring at the specified installed length Installed tension 16 0 kg 35 lb 157 N at 35 0 mm 1 378 in If the installed tension is not as specified replace the valve spring 14 INSPECT CAMSHAFT AND BEARING CAPS a Place the camshaft on V blocks and usi...

Page 59: ...er Standard diameter No 1 28 949 28 986 mm I 0810 1 0616 in 1 No 2 No 7 26 888 26 976 mm 1 0686 1 1 0620 in If the journal diameter is less than specified replace the camshaft 16 INSPECT CAMSHAFT OIL CLEARANCE a Clean the bearing caps and camshaft journal b Place the camshaft in the cylinder head 4 Lay a strip of plastigage across each journal d Place the bearing caps with the top of the number on...

Page 60: ...17 INSPECT VALVE LIFTER OIL CLEARANCE a Using a micrometer measure the diameter of the valve lifter Valve lifter diameter 27 975 27 885 mm 1 1014 1 1018 in b Using a dial indicator measure the inside diameter of the cylinder head bore Lifter bore diameter 28 000 28 021 mm 1 1024 1 1032 in 4 Subtract the valve lifter measuremeht from the cylinder head bore Standard oil clearance 0 015 0 048 mm 0 00...

Page 61: ... Check that air flows from pipe B to A b Checkthat air does not flow from pipe A to B c Apply 500 mmHg I 9 69 in Hg 66 7 kPa of vacuum to pipe B and check that there is no change in vacuum after one minute If there is a change replace the vacuum tank 3 CHECK VACUUM CIRCUIT CONTINUITY IN THE VSV BY BLOWING Alti INTO PIPE a Connect the VSV terminals to the battery terminals as illustrated b Blow int...

Page 62: ...r head valve guide bushing Make sure the valves are installed in the cor rect order b Using SST install new oil seals on the valve guide bushings SST 09201 41020 c Install spring seats springs and spring retainers d Using SST compress the valve retainers and place two keepers around the valve stem SST 09202 70010 e Tap the stem lightly to assure proper fit 2 INSTALL VALVE LIFTERS WITH SHIMS Make s...

Page 63: ...E drive gear e Apply seal packing to the areas indicated in the figure Seal packing Part No 06826 00080 or equivalent NOTE Install the No 1 bearing cap immediately after applying the seal packing f Place bearing caps on each journal with the front marks pointing toward the front g Tighten each bearing cap bolt a little at a time and in the sequence shown in the figure h Using SST drive in a new ca...

Page 64: ...ght bolts Torque 140 kg cm IO ft lb 14 Nmrn w o EGR INSTALL EGR HOLE PLATE Install a new gasket and EGR hole plate with the two bolts 5 INSTALL HEATER UNION a Install a new gasket union another gasket and union bolt to the cylinder head b Torque the union bolt Torque 600 kg cm 43 ft lb 59 N m 6 INSTALL NO 2 ENGINE HANGER AND GROUND STRAP Torque 400 kg cm 29 ft lb 39 N m 7 INSTALL INTAKE MANIFOLD a...

Page 65: ...ead b Install the black rings on the upper portion of each of the three spacers Then install the spacers on the delivery pipe mounting holes of the cylinder head c Place the injectors together with delivery pipe on the cylinder head d Make sure that the injectors rotate smoothly e Install the three thinner spacers and bolts Torque the bolts Torque 180 kg cm 13 ft lb 18 N m 9 INSTALL ALTERNATOR BRA...

Page 66: ...se to the union Id Apply a light coat of the engine oil on the threads and under the cylinder head bolts e Using SST install and uniformity tighten the fourteen cylinder head bolts in several passes and in the sequence shown SST 09043 38 100 Torque 800 kg cm E8 ft lb 78 N m 2 3 4 INSTALL CAMSHAFT TIMING PULLEYS AND TIMING BELT See steps 8 to 12 and 14 on pages EM 34 to 36 INSTALL SPARK PLUGS See p...

Page 67: ...all the heater hose clamp e 7M GTE Install the accelerator link 5 INSTALL WATER OUTLET HOUSING EM302 a Install a new gasket and water outlet housing with the bolt and two nuts b Connect the No 6 water by pass hose cl 7M GE Install a new gasket union another gasket and union bolt to the water outlet housing Front 6 INSTALL EXHAUST MANIFOLD a Face a new exhaust gasket so the protrusion is facing the...

Page 68: ...t lb 39 N m c 7M GTE Install the exhaust manifold stay with the three bolts d TM GTE install the heat insulators with the five bolts 7 7M GTE INSTALL TURBOCHARGER See steps 4 to 8 and 10 to 12 on pages TC 15 to 17 8 7M GE INSTALL OIL DIPSTICK 9 7M GE INSTALL DISTRIBUTOR AND HIGH TENSION CORDS See page 10 22 ...

Page 69: ... Connect the No 1 fuel pipe to the fuel support MA or fuel filter MS 13 INSTALL ENGINE WIRE a Install the engine wire to the each clamps b Connect following wires 0 Three VSV connectors 0 Knock sensor connector 0 Ground strap to intake manifold l Injector connectors l Distributor connector l Cold start injector time switch connector 0 Water temp sender gauge connector l Water temp sensor connector...

Page 70: ...e to the clamps of the intake chamber e install new gaskets and cold start injector tube Torque To delivery pipe 300 kg cm 22 f lb 29 N m io cold start injector f w EG 180 kg cm I 3 ft lb I8 N m Install the EGR vacuum modulator to the bracket g 7M GE Install the air intake connector bracket mounting bolts h 7M GE Install the throttle body bracket s i 7M GTE Install the ISC pipe and connect the hos...

Page 71: ...ses to throttle body and vacuum transmit ting pipe 0 Vacuum transmitting pipe hose to intake chamber I 0 BVSV hose to throttle body r r Connect following wires 0 ISC valve connector 0 Throttle position sensor connector 0 M GE Cold start injector connector 01 Install the PCV pipe 16 IM GTE INSTALL CAM POSITION SENSOR See steps 1 2 on page 10 26 17 7M GTE INSTALL PS RESERVOIR TANK Install the PS res...

Page 72: ...Block 7 CYLINDER BLOCK COMPONENTS EM 6 Piston Piston Snap Ring Connecting Rod Bushing Connecting Rod Bearing Gasket t Connecting Rod Cap I Oi Seal Rear Oil Seal Retainer W Oil Nozzle 7M GTE I 260 18 261 I Crr k aft Thrust Oil Pump ...

Page 73: ...der block and the water by pass pipe and hose with gasket __ r 6 REMOVE GROUND STRAP FROlV Y l tiER BLOkK 7 7M GE REMOVE VACUUM CONTROL VALVE SET 8 REMOVE FUEL RETURN PIPE SUPPORT Remove the two nuts fuel pipe support and insulator 9 REMOVE ENGINE MOUNTING BRACKETS 10 IM GE REMOVE OIL FILTER See page LU 6 7M GTE REMOVE OIL FILTER BRACKET See step 1 on page LU 18 11 12 13 7M GE w C l cooler REMOVE ...

Page 74: ... rear oil seal retainer and gasket 18 CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator measure the thrust clearance while moving the rod back and forth Standard thrust clearance 0 160 0 296 mm 0 0063 0 0117 in Maximum thrust clearance 0 3 mm 0 012 in If clearance is greater than maximum replace the connect ing rod assembly If necessary replace the crankshaft 19 REMOVE CONNECTING ROD CA...

Page 75: ...the lower bearing inserted with the con necting rod cap d Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage e Clean the crank pin and bearing f Check the crank pin and bearing for pitting and scratches If the crank pin or bearing are damaged replace the bear ings If necessary grind or replace the crankshaft g Lay a strip of Plastigage across the crank ...

Page 76: ...ng the same number If the number of the bearing can not be determined select a bearing fromthe table below according to the numbers imprinted on the connecting rod cap and crankshaft There are five sizes of standard bear ings marked I 3 4 and 5 Number marked Rod cap lI1 2111213 21313 1 Crankshaft l0l1I01211101211121 Bearing I l 212 3 313 4 415 Example Rod cap Z Crankshaft 1 Bearing 3 Refererjce mm...

Page 77: ...the piston and connecting rod assemblies in order 21 CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator measure the thrust clearance while prying the crankshaft back and forth with a screwdriver Standard thrust clearance 0 05 0 25 mm 0 0020 0 0098 in Maximum thrust clearance 0 30 mm 0 0118 in If the clearance is greater than maximum replace the thrust washers as a set Thrust washer thickness...

Page 78: ...ng for pitting and scratches If the jounial or bearing is damaged replace the bearings If necessary grind or replace the crankshaft f Place the crankshaft on the cylinder block Cg Lay a strip of Plastigage across each journal h Install the main bearing caps See step 5 on page EM 891 Torque 1 040 kg n 75 ft lb 102 N m NOTE Do not turn the crankshaft i Remove the main bearing caps i Measure the Plas...

Page 79: ...ter Journal Bore Diameter Wall Thickness I I 0 60 007 60 012 2 3625 2 3627 I 1 64 024 64 030 60 001 60 006 1 988 1 991 2 5206 2 5209 2 3622 2 3624 0 0783 0 0784 f I 2 I 2 5209 64 031 84 036 2 5211 2 3620 59 994 60 000 2 3822 0 0784 1 992 0 0785 1 994 3 64 037 64 042 1 995 1 997 2 5211 2 5213 0 0785 0 0786 4 1 998 2 000 0 0787 0 0787 t I I I 5 I 2 001 2 003 0 0788 0 0789 u s 64 022 64 046 59 730 59...

Page 80: ...warpage Maximum warpage 0 05 mm 0 0020 in warpage is greater than maximum replace the cylinder block 4 INSPECT CYLINDERS FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches If deep scratches are present rebore all six cylinders If necessary replace the cylinder block 5 INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge measure the cylinder bore diameter at positions A B an...

Page 81: ...FIT BETWEEN PlSTdN AND PIN Try to move the piston back and forth on the piston pin If any movement is felt replace the piston and pin as a set 2 REMOVE PISTON RINGS a Using a piston ring expander remove the compres sion rings b Remove the two side rails and oil ring expander by hand NOTE Arrange the rings in correct order 3 DISCONNECT CONNECTING ROD FROM PISTON a Using needle nose pliers remove th...

Page 82: ... remove the connecting rod NOTE 0 The piston and pin are a matched set l Arrange the pistons pins rings connecting rods and bearings in correct order INSPEi TION OF PliiTON AND CbNNECTING riOD EMBLIES 1 C EATv PISTONS a Using a gasket scraper remove the carbon from the piston top b Using a groove cleaning tool or broken ring clean the ring grooves ...

Page 83: ...der bore diameter measurement Standard oil clearance 7M GE 0 08 0 10 mm 0 0031 0 0039 in 7M GTE 0 07 0 09 mm 0 0026 0 0035 in Maximum oil clearance 0 13 mm 0 0051 in If the oil clearance is greater than maximum replace the piston rebore all six cylinders and replace all six pistons If necessary replace the cylinder block INSPECT CLEARANCE BETWEEN WALL OF RING GROOVE AND NEW PISTON RING Using a thi...

Page 84: ...445 in Oil Side rail 7M GE w o TWC and 7M GTE 1 04 mm 0 0409 in 7M GE w TWC 1 00 mm 0 0394 in If the gap is greater than maximum replace the piston ring lf the gap is greater than maximum even with a new piston ring rebore the cylinder and use an O S piston ring 5 CHECK PISTON PIN FIT At 14OOF you should be able to push the pin into the piston with your thumb If the pin can be installed at a lower...

Page 85: ...diameter 22 005 22 017 mm IO 8663 0 8668 in l Using a micrometer measure the piston pin diameter Piston pin diameter 21 996 22 009 mm 0 8660 0 8665 in l Subtract the piston pin diameter measurement from the bushing inside diameter measurement Standard oil clearance 0 005 0 011 mm 0 0002 0 0004 in Maximum oil clearance 0 02 mm 0 0008 in If the oil clearance is greater than maximum replace the bushi...

Page 86: ...ing SST and a press press in the bushing SST 09222 30010 d Using a pin hole grinder hone the bushing to obtain the specified clearance between the bushing and piston pin e Check the piston pin fit at normal room temperature Coat the piston pin with engine oil and push it into the connecting rod with your thumb ...

Page 87: ... AMOUNT TO BORE CYLINDER a Using a micrometer measure the piston diameter at a right angle to the piston pin hole center line 22 mm 0 87 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 clearance 7M GE 0 08 0 10 mm 0 0020 0 0028 in 1 7M GTE 0 07 0 09 mm 0 0028 0 0035 in H Allowance for honing 0 02 mm 0 0008...

Page 88: ...59 994 60 012 mm 2 3620 2 3627 in 1 U S 0 25 59 730 59 740 mm 2 3516 2 3520 in I Crank pin diameter STD size 51 976 52 000 mm 2 0463 2 0472 in U S 0 25 51 725 51 735 mm 2 0364 2 0368 in If the diameter is not within specification check the oil clearance If necessary grind or replace the crankshaft b Check each main journal and crank pin for taper and out of round as shown Maximum taper and out of ...

Page 89: ...meter Front 41 OOO 41 025 mm il 6142 1 6152 in Rear 33 000 33 025 mm 1 2992 1 3002 in c Subtract the journal diameter measurement from the bearing inside diameter measurement Standard oil clearance 0 025 0 066 mm 0 0010 0 0026 in Maximum oil clearance 0 08 mm 0 0031 in If the clearance is greater than maximum replace the bearing If necessary replace the drive shaft IF NECESSARY REPLACE OIL PUMP DR...

Page 90: ...13 mm 0 0024 0 0051 in Maximum thrust clearance 0 30 mm 0 0118 in If clearance is greater than maximum replace the thrust plate and or collar 4 IF NECESSARY REPt ACE THRUST PLATE AND COLLAR a Using SST remove the thrust plate and collar SST 09950 20017 b Install the thrust plate and collar in the direction as shown c Using a press install the thrust plate and collar 5 IF NECESSARY REPLACE OIL PUMP...

Page 91: ...the front of block REPLACEMENT OF OIL SEALS NOTE There are two methods A and B of oil seal rep lacement 1 REPLACE CRANKSHAFT FRONT OIL SEAL A If the timing case is removed from the cylinder block a Using a screwdriver and hammer tap out the oil seal b Using SST and a hammer tap in a new oil seal SST 09214 60010 and 09506 35010 cl Apply MP grease to the oil seal lip B If the timing case is installe...

Page 92: ...oil seal b Using SST and a hammer tap in a new oil seal SST 09223 41020 cl Apply MP grease to the oil seal lip 8 If the rear oil seal retainer is installed to the cylinder block a Using a knife cut off the lip of the oil seal as shown b Using a screwdriver pry out the oil seal CAUTION Be careful not to damage the crankshaft Tape the screwdriver tip c Check the oil seal lip contact surface of the c...

Page 93: ...14 41ClO C c Apply MP grease to the oil seal lip A If the timing belt case is installed to the cylinder block a Using a knife cut off the lip of the oil seal as shown b Using a screwdriver pry out the oil seal CAUTION Be careful not to damage the crankshaft Tape the screwdriver tip c Check the oil seal lip contact surface of the pump drive shaft for cracks or damage d Apply MP grease to a new oil ...

Page 94: ...f the piston pin hole b Gradually heat the piston to approx c Coat the piston pin with engine oil IdI Align the front marks of the piston and the connect ing rod and push in the piston pin with your thumb e Install a new snap ring on the other side of the pin hole 2 INSTALL q TON RINGS a Install the oil ring expander and two side rails by hand b Using a piston ring expander install the two com pre...

Page 95: ...ing rod or connecting rod cap b Install the bearing in the rod and rod cap CAUTION Install the bearings with the oil hole in the connecting rod ASFEMBLY OF CYLINDER BLOCK See page EM 651 NOTE l Thoroughly clean all parts to be assembled l Before installing the parts apply new engine oil to all sliding and rotating surfaces l Replace all gaskets O rings and oil seals with new parts 1 7M GTE INSTALL...

Page 96: ...th the oil grooves facing outward PLACE ANKSHAFT ON CYLINDER BLOCK INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS NOTE Each bearing cap has a number and front mark a Install the thrust washers on the No 4 bearing cap with the grooves facing outward b Install the bearing caps in numbered order with arrows facing forward c Install and uniformly tighten the fourteen cap bolts in several passes in...

Page 97: ...M482 7 INSTALL CONNECTING ROD CAPS a Match the numbered cap with the numbered con necting rod b Install the cap with the protrusion facing forward c Install and alternately tighten the cap nuts in several passes Torque 650 kg cm 47 ft lb 64 N m d Check that the crankshaft turns smoothly e Check the connecting rod thrust clearance See step 18 on page EM 671 6 JNSTALL OIL PUMP ASSEMBLY a Clean the o...

Page 98: ... RETAINER Install a new gasket and rear oil seal retainer with the five bolts Torque 130 kg cm 9 ft lb 13 N m 11 INSTALL TIMING BELT CASE WITH WATER PUMP a Position new gaskets on the cylinder block b Apply sealant to two or three threads of the 10 mm bolt end Sealant Part No 08833 00070 THREE BOND 1324 or equivalent c Install the timing belt case with the seven bolts and three nuts 12 INSTALL OIL...

Page 99: ...19 INSTALL GROUND STRAP TO BLOCK 20 lN STALL WATER BY PASS PIPE a Install a new gasket and water by pass pipe to the timing belt case with the two nuts Torque 140 kg cm IO ft b 14 N m b Install the water by pass pipe tqthe cylinder block with the three bolts Torque 130 kg cm 9 ft lb 13 N m 21 INSTALL CYLINDER HEAD See steps 1 and 4 to 18 on pages EM 59 to 64 22 INSTALL TIMING BELT See step 1 to 8 ...

Page 100: ...TC 1 TURBOCHARGER SYSTEM _ DESCRIPTION Page PRECAUTIONS x 2 TROUBLEiHOOTlNG TC 4 _ a L f g I TURBOCHARGER T ib y I ...

Page 101: ...ited per unit of time Therefore to increase engine output the most effective method is to send a greater amount of air fuel mixture into the cylinder than usual engine output can be increased by increasing the average combustion pressure with out increasing the engine speed Superchargers are either turbocharger type using exhaust gas to turn the turbine or supercharger type using the engine cranks...

Page 102: ... engine output is caused If the turbocharged air pressure exceeds the prescribed air pressure the flow of exhaust gas bypasses the turbine controlling turbine wheel revolutions and turbocharge air pressure This by pass valve which controls the quantity of exhaust gas flowing to the turbine is called the waste gate valve When the supercharged air pressure exceeds the prescribed pressure the actuato...

Page 103: ...t be replac first check for thd use of the defect in referent the foilowing ite and replace parts if necessary l Engine oil level and quality c _ I c Conditions under which the turbocharger MI used c Oil lines leading to the turbocharger PRECAUTIO NS 5 use caution when removing and reinstalling the bocharger assembly Do not drop it or bang it anything or grasp it by easily deformed parts the actua...

Page 104: ...ecification begin diagnosis from item 2 2 RESTRICTED INTAKE AIR SYSTEM Check intake air system and repair or replace 1 parts as necessary See page TC 7 J 3 LEAK IN INTAKE AIR Check intake air system and repair or replace parts as necessary See page TC 7 4 RESTRICTED EXHAUST SYSTEM Check exhaust system and repair or replace parts as necessary See page TC 7 Check exhaust system and repair or replace...

Page 105: ...OCHARGER c 3 OPERATION Refer to 6 of SUFFICIENT ACCELERATION LACK QF POW R OF FUEL CONSUMPTION x J fy EXCESSIVE OIL COhlSUMPTION OR WHITE EXHAUST i Possible Cause L FAULTY TURBOCHARGER OIL SEAL I Chedk le ir a t sti iri l Remove the turbine from the turbocharger and check for excessive carbon depdsjts on the we _ ll I _ __ a turbine wheel sl ar o depqsits would indicate a faultyturbocharger Check ...

Page 106: ...arger out let and exhaust pipe 0 Deformed components Repair or replace 6 Foreign material in passages Remove j EM3521 l Leakage from components Repair or replace 0 Cracks in components Check and replace 3 WPECT OPERATION OF ACTUATOR AND WASTE GATE VAiVE a Remove the No 4 air cleaner pipe with No 1 and No 2 air cleaner hoses b Disconnect the air hoses cl Disconnect the air flow meter connector 1 d ...

Page 107: ...essure when the engine speed is over 2 500 rpm Standard pressure 0 39 0 53 kg cm2 6 8 7 8 psi 38 82 kPa c A T models From a stationary state accelerate the vehicle in I range with the throttle valve fully open Measure the turbochargining pressure when the engine speed is over 3 500 rpm Standard p ressure 0 34 0 42 kg em2 4 8 8 0 psi 33 41 kpa If the pressure is less than that specified check the i...

Page 108: ...M iurbqcharger TC 8 COMPONENTS No 1 Turbo Water Hose I No 1 Turbo Water Pipe I No 2 Turbocharger Stay s z I Turbo Heat insulator Turbine dutlet Elba Turbocharger Stay kg cm ft lb N rn l Specified torque Non reusable part ...

Page 109: ... CLEANER HOSE WITH AIR FLOW METER AND AIR CLEANER CAP a Disconnect the three air hoses and PCV hose b Disconnect the air flow meter connector cl Disconnect the PS idle up air hose I d Loosen the clamps and remove the bolt 1 EM3528 5 e Remove the No 7 air cleaner hose with air flow mete and air cleaner cap i j REMOVE TURBO HEAT INSULATOR a Disconnect the oxygen sensor connector b Remove the three n...

Page 110: ...ounting bolt c Remove the No 1 air cleaner with No 6 air cleaner hose _ DiSCONNECT FRONT EXHAUST a Remove the three nuts i b Remove the front exhaust pipe clamp _ G c disconnect the front exhaust pipe from the ex haush manifold I d Remove the gasket I I 9 OIL PIPE MOUNTING NUTS p 10 REMOVE TURBO OIL PIPE MOlJNJ NG y N ON BOLT EM3535 EM35361 I _ _ ...

Page 111: ...STAY 6 12 REMOVE NO 2 TURBOCHARGER STAY 13 DjSCONNECT NO 1 TURBO WATER HOSE FROM WATER OUTliT HOUSING 14 DISCONNECT UNION PIPE 1 Remove the union bolt and gaskets i 15 EMOVE TURBOCHARGER Remove t h four nuts turbocharger and gasket EM3665 ...

Page 112: ...iURBOGHA _ t ll LL a Remove the two nuts turbo d l pipe and gasket 1 i _ r _ 36 REMOVE TURBINE OUTLET Remove the four nuts turbine outlet elbow and gasket I _ 5 I c _ _ _ ...

Page 113: ...eck the axial play Standard clearance 0 13 mm O OOBl in or less If not within specification replace the turbocharger assembly i v EM32761 INSTALLATION OF TURBOCHARGER See page TC 9 CAUTION After replacing the turbocharger assemb ly pour approx 20 cc 1 2 cu in of new oil into the oil inlet and turn the impeller wheel by hand to splash oil on the bearing 1 INSTALL TURBINE OUTLET ELBOW install a new ...

Page 114: ... oil return hole of the cylinder block c Install the turbocharger through the turbocharger stud bolts and turbo oil pipe stud bolts d Temporarily install the four nuts holding the exhaust manifold and turbocharger e Temporarily install the turbo oil pipe flange nuts f rk Trily install the union bolt with two new g Torque the turbocharger mounting nuts Torque 450 kg cm 33 f lb 44 N m h Torque the t...

Page 115: ...TLET HOUSING 7 INSTALL NO 2 TURBOCHARGER STAY 8 INSTALL TURBOCHARGER STAY Torque To turbocharger 810 kg cm 59 ft lb 70 N m To engine mounting bracket 680 kg cm 43 ft lb 68 N m 9 CONNECT FRONT EXHAUST PIPE a Install a new gasket to the front exhaust pipe b Connect the front exhaust pipe to the exhaus manifold with three new nuts Torque 630 kg cm 46 ft lb 62 Nem ...

Page 116: ...amps 11 i INSTALL OIL DIPSTICK GUIDE a lnstall a new O ring to the oil dipstick guide lb insert the oil dipstick guide to the No 2 oil dipstick guide c Connect the oil dipstick guide to the turbocharger with the bolt d Install the oil dipstick 12 INSTALL TURBO HEAT INSULATOR a Install the turbo heat insulator and plate washer with the three nuts b Connect oxygen sensor connector 13 INSTALL NO 7 AI...

Page 117: ... air hose d Connect the air flow meter connector e Conn t thk PCV hose and three air hoses 14 INSTALL NO 4 AIR CLEANER PIPE WITH NO 1 AND NO 2 HOSES 15 FILL WITH COOLANT See page CO 5 16 CX hXi CABLE TO NEGATIVE TERMINAL OF 17 START ENGINE AND CHECK FOR LEAKS ...

Page 118: ...Air Flow Meter 7M GE FI 96 Air Flow Meter 7M GTE FI 98 Throttle Body FI 102 Idle Speed Control ISC Valve FI 108 ELECTRONIC CONTROL SYSTEM FI 110 Location of Electronic Control Parts FI 110 l EFI Main Relay Fl 112 Circuit Opening Relay FI 113 Solenoid Resistor Fl 114 Cold Start Injector Time Switch FI 115 Water Temperature Sensor FI 116 Fuel Pump Relay and Resistor FI 117 High Temperature Line Pres...

Page 119: ...el Pump Relay I Warning 1 I I 7 I ECU P 1 L VSV FPU Electronic Load di Check C tnector A C Compressc I Szeed Sensor IIIII IIlI Igniter w coil l it Start lnjector Time Switch Water Te p Sensor TWC Neutral Start Switch A T ...

Page 120: ...Pump Relay CHECK 1 f 1 llll II ENGINE Warning Light ECU I iIll llllllllllll Electronic Load Air Temp Sensor Check Connector 1 1 1 1 1 1 1 1 1 1 1 uator Igniter A C Compressor 1 wTwy 1 To Charcoal Canister Neutral Start Switch A T ...

Page 121: ...EFI SYSTEM STystem Description SYSTEM DESCRIPTION 5 Others I I I I I 5 a J I ...

Page 122: ...EFI SYSTEM System Description FI 5 FM GTE SYSTEM DESCRIPTION _ 1 ...

Page 123: ...speed Acceleration deceleration etc These signals are utilized by the ECU to determine the injection duration necessary for an optimum air fuel ratio 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 func tions rpm A C signal coolant temperature etc the microc...

Page 124: ...Connect the tachometer test probe to the terminal IGO of check connector CHECK CONNECTOR LOCATION See pages FI 110 111 b Use the battery as the power source for the timing light tachometer etc 3 IN EVENT OF ENGINE MISFIRE FOLLOWING PRECAUTIONS SHOULD BE TAKEN a Insure proper connection of battery terminals etc b Handle high tension cords carefully c After repair work insure that the ignition coil ...

Page 125: ...nstalled in the rear of the vehicle 2 Keep the antenna feeder as far away as possible from the ECU wires at least 20 cm 7 87 in and especially do not wind them together 3 Insure that the feeder and antenna are properly adjusted 4 Do not equip your vehicle with a powerful mobile radio system Do not open the cover or the case of the ECU unless absolutely necessary If the IC terminals are touched the...

Page 126: ...ing troubleshooting as there are numerous transistor circuits and even slight terminal con tact can cause further troubles 5 6 Do not open the ECU cover When inspecting during rainy weather take care to pre vent entry of water Also when washing the engine com partment prevent water from getting on the EFI parts and wiring connectors 7 Parts should be replaced as an assembly 8 Care is required when...

Page 127: ...pressure line a large amount of gasoline will spill out so observe the following procedure a Put a container under the connection b Slowly loosen the connection c Disconnect the connection d Plug the connection with a rubber plug When connecting the flare nut or union bolt on the high pressure pipe union observe the following procedure Union bolt type a Always use a new gasket b Hand tighten the u...

Page 128: ...ead as shown in the figure NOTE Install the spacer with the black ring side facing upward Check that there are no fuel leaks after performing any maintenance on the fuel system a With engine stopped turn the ignition switch ON b Short circuit the fuel pump check terminal B and FP of the check connector with the service wire CHECK CONNECTOR LOCATION See pages FI 110 111 c When the fuel return hose ...

Page 129: ...Vacuum leaks f Emission control system 0 PCV system 0 EGR system w EGR g Others l Ignition timing ESA system 0 Idle speed ISC system r 2 The most frequent cause of problems is simply a bad don tact in wiring connectors Always make sure that connec tions are secure When inspecting the connector pay particular attention to the following points a Check to see that the terminals are not bent b Check t...

Page 130: ...See pages FL34 57 TROUBLESHOOTING PROCEDURES SYMPTOM DIFFICULT TO START OR NO START EbIJiiIf l WILL NO CRANK OR CRANK SLOWLY w CHECK ELECTRIC SOURCE BAD 1 Battery 1 Connection 2 Gravity Drive belt charging system 3 Voltage 2 Fusible links OK CHECK STARTING SYSTEM c BAD 1 Ignition switch 2 Starter relay MS 3 Starter 4 Neutral start switch A T 5 Wiring Connection ...

Page 131: ...ipped Type 1 1 mm 0 043 in 7M GTE 0 8 mm 0 031 In NOTE Check compression pressure and valve clearance if necessary OK CONTINUED ON PAGE FI 15 I BAD 1 Oil filler cap 2 Oil dipstick 3 Hose connections 4 PCV hose 5 w EGR EGR system EGR valve stays open 1 High tension cords 2 Distributor IM GE or cam position sensor 7M GTE 3 Ignition coil 4 Igniter NO BAD 1 Spark plugs 2 Compression pressure Limit 9 0...

Page 132: ... Check circuit opening relay See page FI 1 13 OK CHECK FUEL PUMP SWITCH IN AIR FLOW METER 7M GE Check continuity between terminals FP and El with measuring plate of air flow meter open L I BAD c Air flow meter See page FL96 IOK CHECK IGNITION TIMING 1 Short terminals T MA or TEl MS and El of the check connector 2 Check ignition timing STD BTDC Idle short circuited TIMA or 3 IOK NO Adjust ignition ...

Page 133: ...ilter 5 Fuel pressure regulator See page FI 84 6 Circuit opening relay See page FI 1 13 OK CHECK AIR FILTER I BAD Element Clean or replace OK CHECK IDLE SPEED STD 7M GE wl TWC 700 rpm 7M GE w o TWC 800 rpm 7M GTE 800 rpm t w BAD ISC system I 1 Wiring connection 21 ISC valve 3 ECU CHECK IGNITION TIMING I Short terminals TiMA or TEl MS and El of the check connector 2 Check ignition timing STD 10 BTD...

Page 134: ...UIT USING VOLT OHMMETER See pages FI 34 57 BAD 1 Wiring connection 2 Power to ECU I Fusible links 2 Fuses 3 EFI main relay 3 Air flow meter 4 Water temp sensor 5 Air temp sensor 6 Injection signal circuit I 1 Injector wiring SYMPTOM ENGINE SOMETIMES STALLS ICHECK DIAGNOSIS SYSTEM Check for output of diagnostic code I dSee page FI 26 INormal code ICHECK AIR FLOW Air flow meter See pages Fl 96 98 I ...

Page 135: ...0 rpm OK BAD SC system 1 Wiring connection 2 ISC valve 3 ECU CHECK IGNITION TIMING 1 Short terminals T MA or TEI MS and El of the check connector 2 Check ignition timing STD IO BTDC Idling w short circuited T MA ITEl MS1 El NO F Adjust ignition timing See page EM l 7 i OK 7 I CHECK SPARK PLUGS Plug gap 7M GE Converitional Tipped Type 0 8 mm 0 031 in 7M GE Platinum Tipped Type 1 1 mm 0 043 in 7M GT...

Page 136: ... Fuel pump See page FI 73 2 Fuel filter 3 Fuel pressure regulator See page FI 84 I I 1 c 4 OK ICHECK INJECTORS See page FI 86 8AD Injection condition I OK L 1 ZHECK EFI ELECTRONIC CIRCUIT USING VOLT OHMMETER See pages FL34 57 c BAD 1 Wiring connection 2 Power to ECU F t e links 3 EFI main relay 3 Air flow meter 4 Water temp sensor 5 Air temp sensor 6 Throttle position sensor 7 Injection signal cir...

Page 137: ...srtron sensor ECU 1 CHECK THROTTLE POSITION SENSOR t x Throttle body OK CHECK FUEL PRESSURE See page FI 74 7 BAD w Fuel pressure regulator High pressure OK CHECK COLD START INJECTOR ee page FI 80 BAD w Cold start injector Leakage CHECK INJECTORS See page FI 86 I Injectors Leakage Injection quality I OK CHECK EFI ELECTRONIC CIRCUIT USING VOLT OHMMETER See pages FI 34 57 BAD 1 Wiring connection 2 Po...

Page 138: ...iming See page EM 1 7 1 Cold start injector 2 Cold start injector time switch See page FI 115 CHECK FUEL PRESSURE See page FI 74 I I BAD 1 Fuel pump See page FI 73 2 Fuel filter 3 Fuel pressure regulator See page Fl 84 I HECK INJib I See page Injectors Clogged BAD l IOK CHECK Eii ELECTRONIC ClR lT USING VOLT OHMMETER See pages FI 34 57 4 BAD 1 Wiring connection 2 Power to ECU 1 Fusible links 2 Fus...

Page 139: ...old start injector 2 Cold start injector time switch See page FI 115 1 CHECK INJECTORS BAD injector Leakage I IOK CHECK SPARK PLUGS Plug gap 7M GE Conventional Tipped Type 0 8 mm 0 031 in 7M GE Platinum Tipped Type 1 1 mm 0 043 in 7M GTE 0 8 mm OiO31 in NOTE Check compression pressure and valve clearance if necessary OK CHECK EFI ELECTRONIC CIRCUIT USING VOLT OHMMETER See pages Fl 34 57 NO BAD 1 S...

Page 140: ...I code Diagnostic code s See pages FI 30 31 32 I I I I J 1Normal code CHECK IGNITION SPARK 7M GE See page IO 61 7M GTE See page 16 12 BAD I IOK CHECK IGNITION TIMING 1 Short terminals T MA1 or TEl MS and El of the check connector 2 Check ignition timing i STD 10 BTDC Idling I short circuited TiMA or I IOK CHECK FUEL PRESSURE See page Fl 74 1 High tension cords 2 Distributor 7M GE or cam position s...

Page 141: ...ssary r L BAD 1 HECK EFI ilNG VOLT OHMMETER _ See pages FI 34 57 Y 1 Spark plugs 2 Compression pressure Limit 9 0 kg cm2 128 psi 883 kPa at 250 rpm 3 Valve clearance Cold STD IN 0 15 0 25 m 0 06 O OlO in EX 0 20 0 30 mti 0 008 0 012 in 1 c BAD 1 Wiring connection 2 Power to ECU I Fusible links 2 Fuses 3 EFI main relay 3 Air flow meter 4 Water temp sensor 5 Air temp sensor 6 Throttle position senso...

Page 142: ...nel flashes By analyzing various signals as shown in the later table See page FI 32 the Electronic Control Unit ECU detects system malfunctions which are related to the various operating parameter sensors or to the actuator The ECU stores the failure until the diagnosis system is cleared by removing the EFI fuse with the ignition switch off In the ECU a test mode function has been added to the fun...

Page 143: ...s on However once the ignition switch is turned to OFF the ECU erases all of the malfunctions in the memory The diagnostic mode normal or test and the output of the CHECK ENGINE warning light can be selected by the TEl TE2 and El terminal connections on the check connector as shown in the later CHECK ENGINE WARNING LIGHT CHECK 1 The CHECK ENGINE warning light will come on when the ignitiorqw ch is...

Page 144: ...alternately blink on and off for 0 25 second intervals b Malfunction Code Indication i l The light will blink the number of times equal to the malfunction code indication with pauses as follows 1 Between the first digit and se d digit 1 5 seconds 2 Between code and code 2 5 se onds 3 Before repeating all malfunction codes 4 5 seconds 0 The diagnostic code series will be repeated as long as the CHE...

Page 145: ... the conditions of the malfunction described by the user 5 Using a service wire short terminals TEl and El of the check connector NOTE l The test mode will not start if terminals TE2 and El are con nected after the ignition switch is turned on or terminals TE2 and El are connected after terminals TEI and El are con nected l 0 The starter signal and vehicle speed signal will be diagnosed by the ECU...

Page 146: ...ture trouble l If it is necessary to work on engine components requir ing removal of the battery terminal a check must first be made to see if a diagnostic code has been recorded After cancellation road test the vehicle to check that a normal code is now read on the CHECK ENGINE warning light If the same diagnostic code is still indicated it means that the trouble area has not been repaired thorou...

Page 147: ...d E2 when idle contacts are ctosed 7M GTE Open or Short circuit in air flow meter signal IM GE Open circuit in E2 or short circuit between VC and VS IM GTE Open or short circuit in HAC sensor signal Turbocharger Pressure 3 Turbocharger pressure is abnormal B Ignition and ignition coil circuit 8 Igniter and ignition coil 0 ECU I 5 1 gnition Signal l l 2 Fl 48 I 1 1 Fll608 nn n FIl609 FI 44 d r FI 4...

Page 148: ...i 52 Knock control in ECU faulty Knock Control signal in ECU No IDL signal NSW signal or A C signal to ECU with check terminals El and T shorted Switch Signal 1 WI TWC vehicles only 2 7M GTE only 3 Abnormalities in the air flow meter may also be detected DIAGNOSTIC CODES MS Number of Check engine System blinks m Normal fl1604 nn ECU B Diagnosis This appears when none of the other codes are identif...

Page 149: ...sensor signal 0 Throttle position sensor ECU Fl1614 No SPD signal for 5 seconds when engine speed 0 Vehicle speed sensor 42 nnnruvl is below except when racing the engine fl16151 I No STA sianal to ECU until 0 Ignition switch circuit 43 i m Starter Signal n i pee ct ng on switch FI 6 FM FM Fl1616 0 Knock sensor circuit 52 I JjJJMJjn Eyn Sensor n op circuit in knock gk sensor 53 I F11616 w6 9 Knock...

Page 150: ... ECU and ignition switch SAD Repair or replace Does CHECK ENGINE warning light go off when the engine is started YES System Normal NO Check wiring between ECU and CHECK ENGINE warning light 1 OK Is there diagnostic code output when check connector terminals T MA or TEl MS and El are short circuited t Check wiring between ECU terminal T and check NO connector terminal T MA or TEl MS and ECU termina...

Page 151: ...e lies in either a short or open circuit in a component out side the computer or a short circuit within the computer Jefore beginning inspection it is best to first make 3 simple check of the fuses fusible links and the ondition of the connectors If engine trouble occurs even though proper operating voltage is detected in the computer con nectar then it can be assumed that the ECU is faulty and sh...

Page 152: ... Terminal Name T CHECK CONNECTOR G2 DISTRIBUTOR VTA THROTTLE POSITION SENSOR NE DISTRIBUTOR IDL THROTTLE POSITION SENSOR IGT IGNITER IGF IGNITER THW WATER TEMP SENSOR Symbol Terminal Name L3 ECT COMPUTER EGR vsv EGR A C A C MAGNET SWITCH SPD SPEEDOMETER W WARNING LIGHT FPR FUEL PUMP RELAY DFG DEFOGGER RELAY THA AIR TEMP SENSOR ECT ECT COMPUTER vs AIR FLOW METER KNK KNOCK SENSOR LP HEADLIGHT RELAY ...

Page 153: ...ROUND KNKl KNOCK SENSOR t HAC 1 tl NSW NEUTRAL START SWITCH A T THW WATER TEMP S N C CLUTCH SWITCH M T KNK2 KNOCK SENSOR 1 vc THROTTLE AIR FLOW I LTITUDE COMPENSATION xNSOR ENSOR 1 FC 1 CIRCUITOPENING RELAY I IGdB IGNITER ox OXYGEN SENSOR KS AIR FLOW METER ISC 1 ISC MOTOR NO 1 COIL E2 SENSOR GROUND BATT BATTERY r ISC 3 ISC MOTOR NO 3 COIL vsv VSV FPU B EFI MAIN RELAY ISC 2 ISC MOTOR NO 2 COIL Ll E...

Page 154: ... fully closed 4 5 3 Measuring plate fully open 0 02 0 08 FI 44 VS E2 Idling 2 4 3 000 rpm 0 3 1 0 No 10 EOI 5 No 20 Ignition S W ON 9 14 FI 47 No 30 E02 6 THA E2 Ignition S W ON Intake air temperature 1 3 FI 48 7 THW E2 Ignition S W ON Coolant temperature II 0 1 1 O FI 49 8 STA El Cranking 6 14 FI 50 9 IGF IGT El Idling 0 7 1 0 FI 5 1 11 ISCI I 4 El Ignition S W ON 9 14 Fl 53 12 W El No trouble CH...

Page 155: ...ition S W CN 9 14 Fl 47 No 30 E02 6 THA E2 Ignition S W ON Intake air temperature 1 3 FI 48 7 THW E2 Ignition S W ON Coolant temperature 0 1 1 O FI 49 8 STA El Cranking 6 14 FI 50 9 IGF IGT El Idling 0 7 1 0 FI 5 1 10 IGdA IGdB El Idling 1 3 FI 52 11 I Cl 7 9 14 FI 53 ISC4 El Ignition S W ON 12 W El No trouble CHECK ENGINE warning light off and engine running 8 14 FI 54 13 A C El 14 HAC E2 Air con...

Page 156: ... No voltage lgnitlon switch ON lo 14v Fusible Link Battery ECU Fusible Link Bl B M REL IG S W El 0 BATT El There is no voltage between ECU terminals BATT and El I ECU BATT Voltmeter J V ECU BATT I n 1 0 Check that there is voltage between ECU terminal BATT and body ground NO OK 0 Check wiring between ECU terminal El and body ground I I I I Replace I OK I I I I I ICheck wiring between ECU terminal ...

Page 157: ...eck wiring between ECU terminal El and body ground OK Try another ECU Check fuse fusible links and BAD Repair or replace M REL El 0 There is no voltage between ECU terminals M REL and El IG S W ON 1 0 Check that there is voltage between ECU terminal M REL and body ground IG S W ON NO OK Check wiring between ECU terminal El and body ground OK Try another ECU I Replace or repair Check EFI main relay...

Page 158: ...e between ECU terminal B Bl 1 and body ground IO S w ON I I NO OK Check wiring between ECU terminal El and body ground OK BAD Try another ECU I Replace or repair 1 I I ICheck fuse fusible links and wiring BAD harness H Repair or replace I I I I I I 1OK I I I 1 Check EFI main relay See page FI 1 12 OK BAD Replace IRefer to M REL El trouble section I ...

Page 159: ... IDL VTA VC El 4 5v I Voltmeter R102 FlO31 l IDL E2 0 There is no voltage between ECU terminals IDL and E2 IO S W ON Throttle valve open c I 0 Check that there is voltage between ECU terminal B Bl and body ground IO S W ON c h 1 1OK 1 1 Check wiring between ECU terminal El and body ground 1 t Refer to No 1 See page FI 41 I BAD 7 Replace or repair 1 b OK 1 I Check throttle position sensor 1 BAD 1 I...

Page 160: ...CD Check throttle position sensor See page FI 102 BAD OK I IRepair or replace I 1 Check wiring between ECU and throttle nosition sensor I I I I I 1OK 1 BAD 1 1 I I T I ITry another ECU 1 i or replace 1 VTA E2 There is no specified voltage at ECU terminals VTA and E2 IG S W ON 1 0 Check that there is voltage between ECU terminal VC and E2 IO S W ON 1OK t 1 7 I I ICheck wiring between ECU and BAD th...

Page 161: ...v ECU Air flow meter Voltmeter E3lL Voltmeter Air Flow Meter j 0 There is no voltage between ECU terminals VC or VS and E2 IIG s w ON i 1 0 Check that there is voltage between ECU terminal B Bl and body ground IG S W ON OK NO Refer to No 1 See page FI 41 I t 1 Check wiring between ECU terminal El and body ground I 1 IOK 0 Check air flow meter See page FI 96 1Repair or replace Check wiring between ...

Page 162: ...ir Flow Meter _ Ivc ECU z31 VC KS r El FFA7m F1257i Oh KS Body ground I0There is no voltage between ECU terminals KS and body ground IO S W ON I0Check that there is voltage between and body ground IG S W ON OK i 0 Check wiring between ECU terminal El and body ground OK BAD L ICheck air flow meter See page FL981 I IRepair or replace I Check wiring between ECU and air BAD Try another ECU Repair or r...

Page 163: ...low Meter vc Body ground alThere is no voltage between ECU terminals VC and body ground 10 S W ON 0 Check that there is voltage between ECU terminal B Bl and body ground IO S W ON Check wiring between ECU terminal El and body ground Check wiring between ECU and air Try another ECU ...

Page 164: ...CU terminal No 10 No 20 and or No 30 and EOl or E02 IO S W ON 1 0 Check that there is specified voltage between resistor terminal B and body ground STD voltaae 9 14 V 1NO 1 Check fuse fusible links BAD and ignition switch Repair or replace I i 1OK I I I 1 Check wiring between resistor and battery BAD Repair or replace Check that there is specified voltage between resistor terminal No IO No 20 or N...

Page 165: ...U CB i B11 l HA 0 There is no voltage between ECU terminals THA and E2 IG S W ON 1 Fl1636 M GTE Ohmmeter Air Flow Meter I 1 THA Check that there is voltage between ECU terminal B Bl and body ground IO S W ON I OK NO Refer to No 1 See page FI 4 I Check wiring between ECU terminal El and body ground OK t I I I 0 Check air temp sensor See pages FI 96 98 L 1 Repair or replace I I BAD OK Replace air fl...

Page 166: ...l Jf Voltmeter n F1031 1 0 There is no voltage between ECU terminals THW and E2 IO S W ON 1 i CD Check that there is voltage between ECU terminal B Bl and body ground IG S W ON 1 OK NO Refer to No 1 See page FI 41 Check wiring between ECU terminal El and body ground OK 1 0 Check water temp sensor See page FI 1 161 I I Try another ECU OK Check wiring between ECU and water temp sensor OK BAD Repair ...

Page 167: ...ge between ECU terminals STA and El II0 S W START Check starter OK Check wiring between ECU terminal STA operation and ignition switch terminal STI L BAD OK I BAD I 1 I 1 Repair or replace I I 1 I I0 Check wiring between ECU terminal El and body around I Check fusible links battery wiring ignition switch and neutral start switch BAD e Repair or replace OK I 0 Check that there is voltage at STA 50 ...

Page 168: ...o voltage between ECU terminals IGT and El Idling I I 0 Check that there is voltage between ECU terminal IGT and body ground Idling INO IOK 1 0 Check wiring between ECU BAD Repair or terminal El and body ground replace ICheck fusible links and ignition switch Repair or replace I 1 I I I 1OK Check distributor or cam position BAD sensor See pages IG 11 18 Repair or replace I 1OK Check wiring between...

Page 169: ...There is no voltage between ECU terminals IGdA or IGdB and El Idlinal 0 Check that there is voltage between ECU terminal IGdA or IGdB and body ground Idling I I NO 1 9 0 Check wiring between ECU BAD Repair or L terminal El and body ground replace OK Try another ECU Check fusible links and ignition BAD switch Repair or replace c I I 1 I r 1 Check cam position sensor See page IG 18 I Repair or repla...

Page 170: ...M2 30A I ECU ISCI ISC2 ISC3 ISC4 B Bl M REL 01 doltmeter I Bl V PI Y I Fk n12 Fl16431 0 There is no voltage between ECU terminals ISCl ISC4 and El IG S W ON1 0 check that there is voltage between ECU terminal B Bl and body ground UG S W ON OK 1 Check wiring between ECU terminal El and body ground 1 I OK 0 Check ISC valve See page FI I 08 1 Repair or replace IReplace ISC I I Check wiring between EC...

Page 171: ...Wahiing Light Combination Mete W El FlO7 Joltmeter ELv _ Fl1251 1 Voltmeter FH25C 0 There is no voltage between ECU terminals W and El Idlin I0Check that there is voltage between ECU terminal W and I hod Q 0 Check wiring between ECU terminal El and body Check GAUGE fuse 7 5A and CHECK ENGINE warning light I I IRepair or replace I 1 Check wiring between ECU terminal BAD W and fuse Repair or replace...

Page 172: ...e between ECU terminals A C and El Air conditioning ON I i I0 Check that there is voltage between ECU terminal A C and 1 bodl y ground I NO OK 0 Check wiring between ECU terminal El and body ground BAD terminal A C and Check that there is voltage between BAD amplifier terminal and body ground c Repair or replace I c 1OK Check wiring between amplifier and BAD ECU or compressor Repair or replace ...

Page 173: ...er ECU 1HAC bE2 2 000 0 Alitude m 1 000 FI1995Fil99 _ _ I _ _ itage between ECU terminal HAC and E2 Check that there is voltage between ECU tdrminal VC and body ground IG S W ON _ Refer to No 2 See page FI 43 Voltmeter EL 1 v _ E2 VC b FI199 Check wiring between ECU terminal El and body ground BAD 0 Check HAC sensor See page FI 121 Repair or replace 4 BAD OK Replace HAC Check wiring between ECU an...

Page 174: ...ing inspection it is best to first make a simple check of the fuses fusible links and the The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit in a component out side the computer or a short circuit within the computer If engine trouble occurs even though proper operating voltage is detected in the computer con nector then it...

Page 175: ... DISTRIBUTOR ACPS A C PRESSURE SWITCH co2 POWER GROUND El COMPUTER GROUND SPD SPEEDOMETER o 10 INJECTOR No 1 and 4 VF CHECK CONNECTOR ECT ECT COMPUTER o 30 INJECTOR No 3 and 5 GO DISTRIBUTOR ACR A C COMPRESSOR o 20 INJECTOR No 2 and 6 TE2 CHECK CONNECTOR Ll ECT COMPUTER ELS DEFOGGER SWITCH HEADLIGHT SWITCH TEl CHECK CONNECTOR L2 ECT COMPUTER FPU VSV FPU KNK KNOCK SENSOR FPR FUEL PUMP RELAY ACV VSV...

Page 176: ...S W ON Throttle valve fully closed 0 1 1 0 Throttle valve fully open 4 5 4 6 Ignition S W ON Measuring plate fully closed 4 5 Measuring plate fully open 0 02 0 08 Idling 2 4 3 000 rpm 0 3 1 o Ignition S W ON 9 14 FI 66 Ignition S W ON Intake air temperature 1 3 Ignition S W ON Coolant temperature 0 1 1 0 Cranking 6 14 Idling 0 7 1 0 Ignition S W ON 9 14 No trouble CHECK ENGINE warning light off an...

Page 177: ...N IO 14v B B1 El No voltage Ignition switch ON 10 14 v Battery BATT Bl B M REL IG S W El z ECU Fl275 I Fl275 ECU w I Fl275 BATT El There is no voltage between ECU terminals BATT and El I I I0 Check that there is voltage between ECU terminal BATT and body ground I NO OK 0 Check wiring between ECU terminal El and body ground BAD Replace 1OK Check wiring between ECU terminal BAD and battery w Repair ...

Page 178: ... Check wiring between ECU terminal El and body ground I I I Check fuse fusible link and ignition switch BAD Repair or replace l M REL El 0 There is no voltage between ECU terminals M REL and El IG S W ON 1 3 Check that there is voltage between ECU terminal M REL and body ground IG S W ON NO OK wiring between ECU terminal El and body ground OK BAD Try another ECU 1 Replace or repair F I I I BAD c R...

Page 179: ...nals B Bl and El IG S W ON I t I I0Check that there is voltage between ECU terminal B Bl and body ground IG S W ON I NO OK Check wiring between ECU terminal El and body ground Try another ECU I 1 Replace or repair Check fuse fusible link and wiring BAD harness Repair or replace I 1OK Check EFI main relay See page FI 1 12 BAD w Replace IOK El trouble I ...

Page 180: ...here is no voltage between ECU terminals IDL and E2 IO S W ON Throttle valve open I 1 0 Check that there is voltage between ECU terminal B Bl and body ground IO S W ON NO OK 1 I ICheck wiring between ECU terminal El and body I 1ground OK Try another ECU 1 BAD I Repair or replace I i t Refer to No 1 BAD See page FI 62 p Replace or repair t OK t I Check throttle position sensor BAD BAD OK Replace or...

Page 181: ... page FL102 See page FL62 k IOK 1 Repair or replace Check wiring between ECU and throttle position sensor OK t I 1 BAD 1 Rwe ix3 orreplace Try another ECU l VTA E2 I I 0 There is no specified voltage at ECU terminals VTA and E2 IG S W ON I 0 Check that there is voltage between ECU terminal VCC and E2 IO S W ON I 1 I OK I Check thrc1 BAD 4 Repair or replace 1 I 1OK I 1 4 Check wiring between ECU an...

Page 182: ... 3 1 0 v 0 E2 r wt I I Air Flow Meter Air Flow Meter I I ECU Air Flow Meter I FIl28 I I I ECU El Fl126 0 There is no voltage between ECU terminals VCC or VS and E2 IG S W ON 1 0 Check that there is voltage between ECU terminal B I and body ground IG S W ON c OK NO 7 Refer to No 1 See page FI 62 7 Check wiring between ECU terminal El and body ground OK BAD 0 Check air flow meter See page FI 96 Repa...

Page 183: ...tween ECU terminal No IO No 20 and or No 30 and EOl or E02 IG S W ON J 0 Check that there is specified voltage between resistor terminal B and body ground STD voltage 9 14 V Check wiring between resistor and battery BAD t Repair or replace I Check that there is specified voltage between resistor terminal No 10 No 20 or No 30 and body ground STD voltage 9 14 V I e i Check resistance of magnetrc co1...

Page 184: ...is no voltage between ECU terminals THA and E2 IG S W ON I 0 Check that there is voltage between ECU terminal B Bl 1 and body ground IG S W ON OK NO Refer to No 1 See page FI 62 1 Check wiring between ECU terminal El and body ground OK 0 Check air temp sensor See page FI 96 Repair or replace c BAD OK Replace air frow Check wiring between ECU and air meter temp sensor OK BAD Try another ECU I 1Repa...

Page 185: ...nals THW and E2 I 0 There is no voltage between ECU IG S W ON I 0 Check that there is voltage between ECU terminal B 61 and body ground IG S W ON 1 OK NO I I 8 1 IRefer to No 1 See page FL62 I I I I Check wiring between ECU terminal El and body ground I BAD Check water temp sensor Repair or replace BAD Replace water temp sensor OK Check wiring between ECU and water I temp sensor OK BAD Try another...

Page 186: ...terminals STA and El IO S W START I Check starter OK operation BAD Check ring between ECU terminal STA and ignition switch terminal STI OK BAD Repair or replace t 0 Check wiring between ECU terminal El and body ground v OK Try another ECU BAD Repair or replace Check fusible links battery wiring ignition switch and neutral start BAD c Repair or replace switch I OK 0 Check that there is voltage at S...

Page 187: ...voltage between ECU terminals IGT and El Idling 0 Check that there is voltage between ECU terminal IGT and body ground Idling I NO OK 0 Check wiring between ECU BAD Repair or terminal El and body ground replace I OK 1Try another ECU I Check fusible link and ignition switch BAD BAD Repair or replace I I I I OK I T 1 I I Check wiring between ECU and battery I BAD c Repair or replace BAD Repair or re...

Page 188: ...291 B 81 M REL 0 There is no voltage between ECU terminals ISCl ISC4 and El 10 S W ON 1 Check that there is voltage between ECU terminal B Bl and bod TYn 10 S W ON Re e t o I See page FI 62 1 I Check wiring between ECU terminal El and body ground I OK I v I 1 f 8 Check ISV valve See page FI 108 I IRepair or replace I I I I I I 1 Check wiring between ECU and EFl piii j I I I I I 1 1Try another ECU ...

Page 189: ...2772 ECU __ There is no voltage between ECU terminals W and El p i I fldling 1 CD Check that there is voltage between ECU terminal W and bodv around 1 _ I NO OK 0 Check wiring between ECU terminal El and body ground OK BAD Try another ECU I Repair or replace F1277 d F12755 Check GAUGE fuse 7 5A and CHECK ENGINE warning light r OK BAD Repair or replace t Fuse blows again Check wiring between ECU te...

Page 190: ...Fusible Link Ignition Switch 1 G S W 3ATT tB1 I B B WREL FPR FM CT El 1 AM2 30A 1 AM2 IG2 IGN MA Fusible Link Fuse Q p I EFI Main Relay fc4 r MAIN I MS EFi 15A Ignition Fusible Link Switch 1 El I m AM1 ST1 AM1 40A MA MS Check Connector Circuit usible ink IAIN 2 0 IF L Air Flow Meter MA Battery1 T ALT A w M T 1 MA 7M GTE 1OOA MS 1OOA FlO491 Fl14 ...

Page 191: ...re is pressure in the fuel return hose NOTE At this time you will hear fuel pressure noise d Remove the service wire el Turn the ignition switch OFF If there is no pressure check the following parts i Fusible links 0 Fuse 0 EFI main relay 0 Fuel pump 0 Wiring connections 2 INSPECT FUEL PRESSURE a Check that battery voltage is above 11 bolts b Disconnect the cable from the negative terminal of the ...

Page 192: ...r tube and remove the bohand two gaskets from the cold start injector 0 Remove the union bolt fuel tube and two gaskets 0 Remove the two bolts and disconnect the cold start injector with gasket 0 Disconnect the cold start injector connector l Install the gasket and cold start injector with the bolts Torque 55 kg cm 48 in lb 5 4 N m d Install SST pressure gauge to the delivery pipe with new gaskets...

Page 193: ...e following parts 0 Fuel hoses and connection 0 Fuel pump l Fuel filter 0 Pressure regulator j Remove the service wire from the check connector k Start the engine I Disconnect the vacuum sensing hose from the pressure regulator and plug hose end m Measure the fuel pressure at idling Fuel pressure 2 3 2 8 kg cm2 33 40 psi 226 275 kPa r r Reconnect the vacuum sensing hose to the pressure regulator 1...

Page 194: ...m splashing SST 09268 45012 r Install cold start injector tube 7M GE l Reconnect the cold start injector tube with new gaskets and union bolt to the delivery pipe Torque 300 kg cm 22 ft lb 29 Nsm 0 Connect the wiring connector to the cold start injector 7M GTE 0 Remove the two bolts and cold start injector with gasket 0 Connect the cold start injector connector l Install the cold start injector tu...

Page 195: ...NK WARNING Do not smoke or work near an open flame when working on the fuel pump 3 4 REMOVE FUEL TANK REMOVE FUEL PUMP BRACKET FROM FUEL TANK a Remove the screws b Pull out the fuel pump bracket REMOVE FUEL PUMP FROM FUEL PUMP BRACKET a Remove the two nuts and disconnect the wires from the fuel pump b Pull off the lower side of the fuel pump from the bracket c Remove the fuel pump from the fuel ho...

Page 196: ...ALL FUEL PUMP BRACKET Install a new gasket and the pump bracket with the screws Torque 35 kg cm 30 in lb 3 4 N m 4 INSTALL FUEL TANK a Apply a thin coat of oil to the flare and tighten the flare nut b Then using SST tighten the nut to the specified tor que SST 09631 22020 Torque 310 kg cm 22 ft lb 30 N m NOTE Use a torque wrench with a fulcrum length 30 cm 1 1 181 in CAUTION l Tighten the fuel tan...

Page 197: ... the cold start injector connector REMOVAL OF COLD START INJECTOR 1 2 3 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 7M GE DISCONNECT COLD START INJECTOR CONNECTOR REMOVE COLD START INJECTOR TUBE IM GE a Place a suitable container or shop towel under the cold start injector tube b Slowly loosen the two union bolts of the cold start injector tube and remove the bolts four gaskets and injector...

Page 198: ... OF COLD START INJECTOR 1 7M GTE INSPECT RESISTANCE OF COLD START INJECTOR Using an ohmmeter check the resistance of the injector Resistance 2 4 fi If the resistance is not as specified replace the cold start injector 2 INSPECT INJECTION OF COLD START INJECTOR WARNING Keep clear of sparks during the test a Install SST two unions to the injector and delivery pipe with new gaskets and the union bolt...

Page 199: ... 10 111 h Connect the test probes of the SST wire to the bat tery and check that the fuel spray is as shown SST 09842 30050 CAUTION 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 and check fuel leakage from the injector SST 09842 30050 Fuel drop One drop or less per minute b Disconnect the batt...

Page 200: ...stall a new gasket and the the cold start injector with the two bolts Torque 55 kg cm 148 in lb 5 4 N m INSTALL COLD START INJECTOR TUBE Using new gaskets connect the cold start injector tube to the delivery pipe and cold start injector Install the union bolts Torque Delivery pipe side 300 kg cm 22 ft lb 29 N m Cold start injector side 180 kg cm 13 ft lb 18 N m 17M GE CONNECT COLD START INJECTOR C...

Page 201: ...UEL PRESSURE See page FI 74 REMOVAL OF PRESSURE REGULATOR 1 DISCONNECT PCV HOSE 2 DISCONNECT VACUUM SENSING HOSE 3 DISCONNECT NO 2 FUEL PIPE 4 Place a suitable container or shop towel under the pressure regulator b Remove the union bolt and two gaskets cl Remove the clamp bolt of the No 2 fuel pipe 4 REMOVE PRESSURE REGULATOR Loosen the lock nut and remove the pressure regulator ...

Page 202: ...mpletely into the delivery pipe by hand c Turn the pressure regulator counterclockwise until the outlet faces in the directi on indicated in the figure d Torque the lock nut Torque 250 kg cm 18 ft lb 25 N m 2 CONNECT NO 2 FUEL PIPE a Using new gaskets connect the No 2 fuel pipe to the pressure regulator Install the union bolt Torque 250 kg cm 18 ft lb 25 N mI b Install the clamp bolt 3 CONNECT VAC...

Page 203: ...have no sound scope you can check the injec tor transmission operation with your finger If no sound or an unusual sound is heard check the wiring connector injector resistor or injection signal from the ECU INSPECT RESISTANCE OF INJECTOR a Disconnect the injector connector b Using an ohmmeter measure the resistance of both terminals Resistance 7M GE 1 8 3 4 n 7M GTE 2 0 3 8 Q If the resistance is ...

Page 204: ... body 0 Vacuum sensing hose from pressure regulator 0 Throttle position sensor connector 0 ISC valve connector 0 IM GE Cold start injector connector REMOVE AIR INTAKE CONNECTOR 7M GE a Disconnect the air cleaner hose from the throttle body b Remove the throttle body and air intake connector brackets c Remove the four bolts and two nuts intake connec tor and gasket 7M GTE See steps 1 to 3 on page E...

Page 205: ... two gaskets b Remove the union bolts and two gaskets from the fuel pipe support MA or fuel filter MS cl Remove the clamp bolt No 1 fuel pipe and VSV w EGR 11 REMOVE NO 2 FUEL PIPE a Remove the union bolt and two gaskets from the pressure regulator b Pisconnect the fuel hose from the No 2 fuel pipe cl Remove the clamp bolt and No 2 fuel pipe I2 REMOVE PRESSURE REGULATOR a Loosen the look nut b Rem...

Page 206: ...ove the delivery pipe with injectors CAUTION Be careful not to drop the injectors when removing the delivery pipe b Remove the six insulators and three spacers from the cylinder head 14 REMOVE INJECTORS a Pull out the injectors from the delivery pipe b Remove the O ring from the injector ...

Page 207: ...om the fuel return pipe support MA or fuel filter MS b Connect SST hose to the fuel pipe support MA or fuel filter MS outlet with SST union new gaskets and union bolt SST 0926841045 NOTE Use the fuel support MA or fuel filter MS c Remove the pressure regulator See page FI 84 d Connect the fuel return hose to the pressure regula tor with SST union new gasket and union bolt SST 09268 41045 e Connect...

Page 208: ...ION Se6 pages Fl 110 111 k Connect SST resistor wire to the injector and bat tery for 15 seconds and measure the injection volume with a graduated cylinder Test each injector two or three times SST 09842 30060 Volume 7M GE 65 60 cc 4 0 4 9 cu in per 15 sec 7M GTE 101 114 cc 6 2 7 0 cu in 1 per 15 sec Difference between each injector 9 cc 0 5 cu in 1 or less If the injection volume is not as specif...

Page 209: ...mmet to the injector Black Ring 2 INSTALL DELIVERY PIPE WITH INJECTORS a Install the six insulators into the injector hole of the cylinder head b Install the black rings on the upper portion of each of the three spacers Then install the spacers on the delivery pipe mounting hole of the cylinder head c Place the injectors together with the delivery pipe on the cylinder head d Check that the injecto...

Page 210: ...ted in the figure FI172 4 5 d Torque the lock nut Torque 250 kg cm 18 ft lb 25 N m INSTALL NO 2 FUEL PIPE a Install the No 2 fuel pipe and clamp bolt b Connect the fuel hose cl Install the union bolt and new two gaskets to pressure regulator Torque the union bolt Torque 250 kgicm 18 ft lb 25 N m INSTALL NO 1 FUEL PIPE a Install the No 1 fuel pipe VSV w EGR and clamp bolt b Install the union bolt a...

Page 211: ...cm 9 ft lb 13 Nmrn b Connect No 2 water by pass hose to the ISC valve 9 7M GTE INSTALL THROTTLE BODY See step 1 on page FI 106 _ 10 INSTALL AIR INTAKE CONNECTOR 7M GE a Install a new gasket and air intake connector with the four bolts and two nuts Torque 180 kg cm 13 ftdb 18 Nmrn b Install the air intake connector and throttle body brackets c Connect th a air cleaner hose to the throttle body 7M G...

Page 212: ...nnector 12 CONNECT FOLLOWING HOSES 0 Water hoses from throttle body 7M GE or water by pass pipe 7M GTE l Vacuum hoses from throttle body 0 ISC valve hoses from throttle body l Vacuum sensing hose from pressure regulator 13 REFILL CQOLANT See page CO 51 14 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY fy 15 CHECK FOR FUEL LEAKAGE See page Fl I 1I i ...

Page 213: ...C E1E2 VC E2 VS THA I ON VEHICLE INSPECTION INSPECT RESISTANCE OF AIR FLOW METER a Disconnect the air flow meter connector lb Using an ohmmeter measure the resistance between each terminal Terminals Resistance Temperature VS E2 20 600 SL VC E2 200 400 2 IO 20 Kfi 4 F 4 7KR THA E2 2 3KR 0 9 1 3 Kfi I 0 4 0 7 KR FC El Infinity If the resistance is not as specified replace the air flow meter cl Recon...

Page 214: ...each terminal by moving the measuring plate Terminals Resistance a Measuring plate opening FC El Infinity Zero Fully closed Other than closed position VS E2 20 600 20 1 200 Fully closed Fullv open L NOTE 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 M...

Page 215: ...STANCE OF AIR FLOW METER I a Disconqect the air floyiri tei connector b Using an ohmmeter tieasure the resis tance betweeit each fer i ai Terminals Res anc Temperature KS El CQR El KS 5 10 k0 VS El IO 15 kR El 4VC 5 10 kSZ 10 20 kR 20 4 F 4 7kn JHA E2 2 3kfi 68OF 0 9 1 3 k0 I 0 4 0 7 ka If the resistance is not as specified replace the air flow meter c Reconnect the air flow meter connector ...

Page 216: ...ANER PIPE WITH NO 1 AND NO 2 AIR CLEANER HOSES 2 REMOVE AIR FLOW METER WITH AIR CLEANER CAP a Disconyect the connector b Remove the three clamps and bolt c Loosen the clamp and remove the air flow meter with air cleaner cap h f 3 REMOVE AIR FLOW METER a Remove the two screws and bracket ...

Page 217: ...esh is neither deformed nor damaged If necessary replace the air flow meter INSTALLATION OF AIR FLOW METER 1 INSTALL AIR FLOW METER a Install the air cleaner cap No 1 air cleaner cover and lock plates to the air flow meter with the four nuts b Pry the lock plates on the nuts c Install the bracket with the two screws 2 INSTALL AIR FLOW METER WITH AIR CLEANER CAP a Install the air flow meter with ai...

Page 218: ... b Install the bolt and clamps EFI SYSTEM Air Induction System FI 101 k Connect the connector 3 INSTALL NO 4 AIR CLEANER PIPE WITH NO 1 AND NO 2 AIR CLEANER HOSES ...

Page 219: ...l9f F 1 ON VEHtCLE INSPECTION 1 INSPECT THROTTLE BODY a Check that the throttle linkage moves smoothly b Check the vacuum at each port 0 Start the engine 0 Check the vacuum with your finger Port Purge EGR R At idling No vacuum No vacuum No vacuum Other than idling Vacuum Vacuum No vacuum ...

Page 220: ...nd stop lever c Using an ohmmeter measure the resistance between each terminal d Reconnect the sensor connector REMOVAL OF THROTTLE BODY 7M GE 1 DRAIN COOLANT FRdM THROTTLE BODY 2 REMOVE ACCELERATOR CONNECTING ROD 3 DISCONNECT VACUUM HOSES 4 DISCONNECT NO 2 AND NO 3 WATER BY PASS HOSES 1 5 DISCONNECT THROTTLE POSITION SEI 7 REMOVE THROTTLE BODY BRACKET S 6 REMOVE THROTTLE BODY Remove the four bolt...

Page 221: ...s hoses from the ISC valve and water pipe b Remove the four bolts throttle body and gasket cl Remove the two water by pass hoses INSPECTION OF THROTTLE BODY 1 CLEAN THROTTLE BODY a Using a soft brush and carburetor cleaner clean the cast parts d Using compressed air clean all passages and aper tures CAUTION To prevent deterioration do not clean the throttle position sensor and dash pot 2 INSPECT T...

Page 222: ... GTE thickness gauge between the throttle stop screw and lever c Connect the test probe of an ohmmeter to terminals IDL and E dd Gradually turn the sensor clockwise until the ohm meter deflects and secure the sensor with the two screws e Recheck the continuity between terminals IDL and E2 I Clearance between I I lever and stop screw I Continuity IDL E2 I 7M GE 7M GTE I 0 40 mm I 0 50 mm 0 0157 in ...

Page 223: ... 13 Narn CONNECT THROTTLE BODY BRACKET CONNECT AIR CLEANER HOSE CONNECT THROTTLE POSITiON SENSOR CONNECTOR CONNECT VACUUM HOSES CONNECT WATER HOSES CONNECT ACCELERATOR CONNECTING ROD REFILL WITH COOLANT M GTE 1 INSTALL THROTTLE BOPY a Install the two water by pass hoses b Install a new gasket and throttle body with the four bolts c Connect the two water by pass hoses to the ISC valve and water pip...

Page 224: ... Induction System FI 107 2 CONNECT THROTTLE POSITION SENSOR CONNiXTOR 3 CONNECT VACUUM HOSES 4 INSTALL AiR INTAKE CONNECTOR See steps 13 to 15 on page EM 141 5 INSTALL ACCELERATOR CONNECTING ROD 6 REFILL WITH COOLANT ...

Page 225: ...FROM ISC VALVE Check that is a clicking sound immediately after stopping the engine REMOVAL OF ISC VALVE 1 DRAIN COOLANT 2 DISCONNECT ISC VALVE CONNECTOR 3 DISCONNECT TWO WATER BY PASS AND AIR HOSES FROM ISC VALVE 4 REMOVE ISC VALVE a Remove the two bolts b Remove ISC valve and gasket cd 7M GTE Remove the seal washer and check valve from the intake chamber ...

Page 226: ...ery voltage to terminals Bl and 82 and while repeatedly grounding S4 S3 S2 Sl S4 in sequence check that the valve moves toward the open position INSPECTION OF CHECK VALVE 7M GTE only INSPECT CHECK VALVE Inspect the check valve for damage and the diaphragm for cracks If necessary replace the check valve INSTALLATION OF ISC VALVE 1 INSTAiL ISC VALVE a TM GTE Install the check valve and the seal wash...

Page 227: ...lectronic Control System ELECTRONIC CONTROL SYSTEM _ Lkation of Electronic Control Parts A 7M GE Fuel Pump Solenoid olenoid Resistor VSV fo FPUK r l EFI Main Relay 7M GTE _ Cold Start Injector SV for EGR Solenoid Resistor ...

Page 228: ...HD RHO EFI Main Relay Fuel Pump Relay Check Cold Start lniector Water Tern Switch VSV for FPU id Resistor Check Cohor I Circuit Opening R l y Y Cold Start Injector Time Switch Water Tern Switch Resistor Fuel Pump Solenoid Resistor I4 yw VSV for FPU Solenoih Resistor Fl28 FIZ I19 I 120 ...

Page 229: ... 1 INSPECT RELAY CONTINUITY a Using an ohmmeter check that there is continuity between terminals 1 and 3 b Check that there is no continuity between terminals 2 and 4 3 BE0009 Continuity Battery 2 If continuity is not as specified replace the relay INSPECT RELAY OPERATION a Apply battery voltage across terminals 1 and 3 b Check that there is continuity between terminals 2 and 4 If operation is not...

Page 230: ...nd El b Check that there is continuity between terminals B and FC c Check that there is no continuity 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 El 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 ...

Page 231: ...W No 10 No 20 No 30 EOl E02 1 INSPECTION OF SOLENOID RESISTOR INSPECT RESISTANCE OF SOLENOID RESISTOR Using an ohmmeter measure the resistance between B and other terminals Resistance 3 n each If the resistance is not as specified replace the resistor No 20 Nci 30 l l257 ...

Page 232: ...b Using an ohmmeter measure the resistance between each terminal Resistance w TWC STA STJ 25 50 Cl below 60 85 Cl above 30 860 STA Ground 25 85 Q w o TWC STA STJ 20 40 n below 86OFI 40 60 i2 above STA Ground 20 80 I If the resistance is not as specified replace the switch 2 IF NECESSARY REPLACE COLD START INJECTlbN TIME SWITCH a Drain the coolant b Using SST replace the switch with a new gasket SS...

Page 233: ...0 100 120 4 32 68 104 140 1176 212 248 TEMPERATURE C IoF Fl0516FiO7C INSPECTION OF WATER TEMPERATURE SENSOR INSPECT RESISTANCE OF WATER TEMPERATURE SENSOR Using an ohmmeter measure the resistance between both terminals Resistance Refer to chart If the resistance is not as specified replace the water tem perature sensor ...

Page 234: ...ty a Using an ohmmeter check that there is continuity between terminals B and FP b Check that there is continuity between terminals B and FPR c Check that there is no continuity between terminals B and PR If continuity is not as specified replace the relay B Inspect Relay Operation la Apply battery voltage across terminals B and FPR b Using an ohmmeter check that there is continuity between termin...

Page 235: ...No continuity I 2 INSPECT FUEL PUMP RESISTOR inspect Resistance of Fuel Pump Resistor Using an ohmmeter mea e the resistance between both terminals Resistance Approx 0 7 a If the resistance is not as specified replace the fuel pump resistor ...

Page 236: ...INSPECT VSV A Inspect VSV for Open Circuit Using an ohmmeter check that there is continuity be tween terminals Resistance 30 60 n If there is no continuity replace the VSV 1 B Inspect VSV for Short Circuit Using an ohmmeter check that there is no continuity be tween each terminal and the body If there is continuity replace the VSV I J FllSll C Inspect VSV Operation a Apply battery voltage across t...

Page 237: ... 120 EFI SYSTEM Electronic Control System _ I I c Diyrinect the battery d Check that air flo ws froril the pipe E and pipe G If operation is not as specified replace the VSV ...

Page 238: ...o HAC on Sensor t Ai I o E2 El z al mnn I T J o _ Y r If I 1 INSPECTION OF HAC SENSOR P n199 zl INSPECT RESISTANCE OF HAC SENSOR a Remove the glove box b Using an ohmmeter measure the resistance between each terminal Terminals vc P VC E2 P E2 Resistance 700 860 42 2 2 3 3 n 2 9 4 2 Q I 1 If the resistance is not as specified replace the HAC sen sor ...

Page 239: ... 2 560 i pm i Check the number of times the voltmeter meedle fluctuates in 1Oseconds Zero again 1After replacing Ithe oxygen sensor i Less than 8 times t Warm up the oxygen sensor with the engine at I 2 500 rpm for approx 90 seconds And maintain engine at 2 500 rpm I c Check that the number of times the voltmeter needle fluctuates in 10 seconds 8 times or more Zero 8 times c Unshort terminals T an...

Page 240: ...ltage between terminals VF and El ov t 1 Disconnect the PCV hose 1 Measure voltage between terminals VF and El 1 t Replace the oxygen sensor Repair Over lean 5V Disconnect the water temp sensor connector and connect resistor with resistance of 4 8 kS1 or another coded water temp sensor 1 Short terminals T and El of the check connector I I Warm up the oxygen sensor with the engine at I 1 2 500 rpm ...

Page 241: ...ic Control System Ohmmeter 3 IM GTE INSPECT HEATERAESISiANCE OF OXYGEN SENSOR Using an ohmmeter measure the resistance between the terminals 2 and 3 R8SiStaflC8 3 0 3 6 n If the resistance is not as specified replace the sensor ...

Page 242: ...ted 0 Verify that the battery voltage is 11 V or more when the ignition switch is ON Voltage at ECU Wiring Connectors I I I Terminals STD Voltage t Condition I BATT El IG S W El 10 14 M REL El Ignition S W ON IDL E2 VC VCC E2 VIA E2 4 6 Throttle valve open 4 6 Ignition S W ON 0 1 1 0 Throttle valve fully closed 4 5 Throttle valve fully open 4 5 Measuring plate fully closed Ignition S W ON 0 02 0 0...

Page 243: ...I 29 53 in Hg 100 0 kPa W El g L I4 No trouble CHECK ENGINE warning light off and engine running 1 3A C El llC 1 14 Air conditioning ON T El 4A 6 Check connector T TE1 El not short Ignition S W ON 0 Check connector TfTEl El short 3NSW A T El 3N C Uvl TI El 0 Shift position P or N range Ignition S W ON IO 14 Ex P or N range 0 Clutch pedal not depressed Ignition S W ON IO 14 Clutch pedal depressed I...

Page 244: ...CU Wiring Connectors Terminals Condition I Resistance Ifi I IDL E2 VTA E2 VC WCC E2 Throttle valve open Throttle valve fully closed Throttle valve fully open Throttle valve fully closed cc Less than 2 300 3 500 10 300 300 6 300 200 400 VS E2 Measuring plate fully closed Measuring plate fully open 20 600 20 1 200 I 2KS E2 co I I I 2E2 KS 5 000 10 000 I I 2VC E2 10 000 15 000 I 2E2 VC I I 5 000 10 0...

Page 245: ...l operating temperature INSPECT FUEL CUT RPM a Disconnect the connector from the throttle position sensor b Short circuit terminals IDL and El on the wire con nector side c Gradually raise the engine rpm and check that there is fluctuation the fuel cut and fuel return points NOTE The vehicle should be stopped Fuel cut rpm 1 800 rpm Fuel return rpm 1 200 rpm ...

Page 246: ...engine utilizes a pressurized water forced circulation cooling system which includes a thermostat equip ped mounted on the outlet side 5 7M GE Throttle Body ISC Valve To Radiator RHD From Heater rM GTE To Heater From Heat ISC Valve To Radiator COGS COOF ...

Page 247: ... which coolant flows from the upper tank to the lower tank as well as cooling fins which radiate heat away from the coo lant in the tubes The air sucked through the radia tor by cooling fan as well as the wind generated by the travel passes through the radia tor cooling it Models with automatic transmission incrl le an automatic transmission fluid cooler built in le lower tank of the radiator RADI...

Page 248: ...s or head gasket leakage Thermostat faulty Ignition timing retarded Fluid coupling faulty Radiator hose plugged or rotted Water pump faulty Radiator plugged or cap faulty Cylinder head or block cracked or phwd Remedy Adjust or replace belt Clean radiator or condenser Repair as necessary Check thermostat Set timing Replace fluid coupling Replace hose Replace water pump Check radiator Repair as nece...

Page 249: ...ht rear of cylinder block cl Close the drain cocks d Fill system with coolant Use a good brand of ethylene glycol base coolant mixed according to directions Capacity MA w Heater or air conditioner M T 8 1 liters 8 5 US qts 7 1 Imp qts A T 8 0 liters 8 5 US qts 7 0 Imp qts w o Heater or air conditioner M T 7 5 liters 7 9 US qts 6 6 Imp qts A T 7 4 liters 7 8 US qts 6 5 Imp qts MS w Heater or air co...

Page 250: ...TOR DRIVE BELT FLUID COUPLING AND WATER PUMP PULLEY a Loosen the water pump pulley set nuts b Loosen the pivot bolt adjusting bolt and nut and remove the drive belt c Remove the four nuts fluid coupling and wate w w d Remove the fan from the fluid coupling 2 REMOVE PS AIR PIPE 3 REMOVE WATER PUMP Remove the eight bolts and two nuts and remove wate pump and gasket ...

Page 251: ...he fluid coupling is not damaged and that no silicon oil leaks If necessary replace the fluid coupling INSTALLATION OF WATER PUMP See page CO 6 1 INSTALL WATER PUMP install water pump on new gasket with the eight bolts and two nuts Torque 160 kg cm 13 ft lb 18 N mI 2 INSTALL PS AIR PIPE 3 INSTALL WATER PUMP PULLEY FLUID COUPLING AND ALTERNATOR DRIVE BELT al Install the water pump pulley and fluid ...

Page 252: ...k the valve opening temperature Valve opening temperature 86 187 If the valve opening temperature is not within specifica tion replace the thermostat c Check the vatve lift Valve lift 8 mm 0 31 in or more at If the valve lift is less than specification replace the ther mostat d Check that the valve spring is tight when the ther mostat is fully closed If necessary replace the thermostat INSTALLATIO...

Page 253: ...radiator cap tester pump tester until relief valve opens Check that valve opens between 0 75 kg cm2 10 7 psi 74 kPa and 1 05 kg cm2 14 9 psi 103 kPa Check that pressure gauge does not drop rapidly when pressure on cap is below 0 6 kg cm2 8 5 psi 59 kPa J If either check is not within limits replace cap 1 2 CHECK COOLING SYSTEM FOR LEAKS a Fill the radiator with coolant and attach a radiator cap te...

Page 254: ... Upper Tank Tank Plate 0 Rina IIIIIIIIIIIIIIIICore Lower Tank Non reusable part coo55 SST I DISASSEMBLY OF RADIATOR 1 REMOVE TANK PLATE a Raise the claws of the tank plates with SST in tt numerical order shown in the figure SST 09230 00010 NOTE Be careful not to damage the core plate ...

Page 255: ...ipes face b Remove the nuts plate washers and oil cooler c Remove the O rings from the oil cooler ASSEMBLY OF RADIATOR See page CO lo 1 MA with A T INSTALL OIL COOLER TO LOWER TANK a Clean the O ring contact surface of the lower tank and oil cooler _ b Install new O rings 1 to the oil cooler 2 c Install the oil cooler 2 with O rings 1 to the lower tank 3 d Install the plate washers 4 and nuts 5 To...

Page 256: ...0 kg cm 16 ft lb 22 N m e Install the pipes 7 Torque 150 kg cm 11 ft lb 15 N mI NOTE Face the pipes in the same direction they were before disassembly INSPECT CORE PLATE Inspect the core plate for damage NOTE l If the sides of the core plate groove are deformed reassembly of the tank will be impossible Therefore first correct any deformation with pliers 0 Water leakage will result if the bottom of...

Page 257: ... Set the punch on SST to LOW SST 09230 00010 b Stake the claws of the tank plates with SST in the numerical order shown in the figure SST 09230 00010 CAUTION If the bottom of the core plate is staked with the SST on the guide block stopper it may result in water leakage SST 09230 00010 NOTE l Stake with just enough pressure to leave a mark on the claw the staked plate height B should be as follows...

Page 258: ...ator with SST SST 09230 00010 d Using a radiator cap tester apply pressure to the radiator Test pressure 1 5 kg cm2 21 psi 147 kPa e Inspect for water leaks NOTE On radiator with resin tanks there is a clearance between the core plate and tank plate where a minute amount of air will remain giving the apperance of an air leak when the radiator is submerged in water Therefore before performing the w...

Page 259: ... DESCRIPTION LU 2 TROUBLESHOOTING I b 4 OIL PRESSURE CHECK l LU 5 REPLACEMENT OF ENGINE OIL AND OIL FILTER I LU 6 OIL PUMP I LU 6 OIL COOLER AND OIL PRESSURE REGULATOR 7M GE LU 15 OIL COOLER AND OIL PRESSURE REGULATOR 7M GTE a LU 16 ...

Page 260: ...ly filtered lubrication system has been adopted for this engine 7M GE MS 7M GE MA Oil Co x 7M GTE A T Oil Choler VALVE GUIDES PISTONS t CONNECTING RODS t CRANKSHAFT 1 I OIL FILTER BRACKET RELIEF VALVE 1 1 RELIEF VALVE I I I OIL PUMP tI OIL STRAINER t OIL PAN l 7M GTE only ...

Page 261: ...when the gear teeth engage oil is discharged OIL PRESSURE REGULATOR At high engine speeds the engine oil supplied bYthr oil pump exceeds the capacity of the engine 10utiiize it For that reason the oil pressure regula tor i rks to prevent an oversupply of oil During norm tl oil supply a coil spring and valve keep the bYPcls sclosed but when too much oil is being fed the becomes extremely high overp...

Page 262: ... Gasket faulty Oil leakage Relief valve faulty Oil pump faulty Engine oil poor quality Crankshaft bearing faulty Connecting rod bearing faulty Oil filter clogged Relief valve faulty Remedy Repair as necessary Replace oil seal I Replace gasket Repair as necessary Repair relief valve Repair oil pump Replace engine oil Replace bearing Replace bearing Replace oil filter Repair relief valve Page EM 84 ...

Page 263: ...sity oil Europe 7M GTE Use API grade SF or better and recommended viscosity oil Others Use API grade SC SD SE SF or better and recom mended viscosity oil CHECK ENGINE OIL LEVEL The oil level should be between the L and F marks on the dipstick If low check for leakage and add oil up to the F mark REMOVE OIL PRESSURE SENDER GAUGE INSTALL OIL PRESSURE GAUGE START ENGINE Start engine and warm it up to...

Page 264: ...ries 5 0 liters 5 3 US qts 4 4 Imp qts M GE MA Others 4 9 liters 5 2 US qts 4 3 Imp qts 7M GE MS 5 3 liters 5 6 US qts 4 7 Imp qts 7M GTE A T 5 0 liters 5 3 US qts 4 4 Imp qts 7M GTE M T 5 1 liters 5 4 US qts 4 5 Imp qts Drain and refil w o oil filter change MA 3 9 liters 4 1 US qts 3 4 Imp qts MS 4 1 liters 4 3 US qts 3 6 Imp qts w oil filter change MA 4 2 liters 4 4 US qts 3 7 Imp qts MS 4 4 lit...

Page 265: ...the oil into a con tainer 2 REPLACE OIL FILTER a Using SST remove the oil filter located on right side of the engine block SST 09228 07500 NOTE 7M GTE Remove the oil filter taking it over the engine mounting bracket and down between the bracket and No 1 suspension crossmember b Clean and check the oil filter installation surface c Apply clean engine oil to the gasket of the new oil filter o ...

Page 266: ...tries 5 0 liters 5 3 US qts 4 4 Imp qts 7M GE MA Others 4 9 liters 5 2 US qts 4 3 Imp qts 7M GE MS 5 3 liters 5 6 US qts 4 7 Imp qts 7M GTE A T 5 0 liters 5 3 US qts 4 4 Imp qts 7M GTE M T 5 1 liters 5 4 US qts 4 5 Imp qts Drain and refil w o oil filter change MA 3 9 liters 4 1 US qts 3 4 Imp qts MS 4 1 liters 4 3 US qts 3 6 Imp qts w oil filter change MA 4 2 liters 4 4 US qts 3 7 Imp qts MS 4 4 l...

Page 267: ...M Oil Pump OIL PUhiP COMPONENTS Snap Ring Oil Pump Shaft Drive Gear Union Bolt MS Relief Valve Q Iriven Gear Snap Ring cs Spacer Key Oil Pump Cover 9 Oil Pump Outlet Pipe Oil Pump Drive Shaft Oil Pump Cover Non reusable part ...

Page 268: ...MOVE OIL PAN a Remove the dipstick b Remove the bolts and nuts c Insert the blade of SST between the cylinder block and oil pan cut off applied sealer and then remove the oil pan SST 09032 00100 CAUTION Be careful not to damage the oil pan flange 3 REMOVE OIL PUMP a Loosen the union nut of the oil pump outlet pipe b MA Remove the mount bolt of the oil pump strainer stay c Remove the bolt and oil p...

Page 269: ...et 2 MA REMOVE OIL PUMP STRAINER Remove the two bolts oil pump strainer and O ring 3 REMOVE RELIEF VALVE Unscrew the relief valve plug and remove the spring and relief valve 4 REMOVE OIL PUMP COVER Remove the five bolts and oil pump cover 5 REMOVE OIL PUMP DRIVEN GEAR 6 REMOVE OIL PUMP DRIVE SHAFT Using snap ring pliers remove the snap ring spacer shaft drive gear key and oil pump drive shaft ...

Page 270: ...f the clearance is greater than maximum replace the gear or oil pump assembly INSPECT GEAR BACKLASH Using a thickness gauge measure the backlash as shown in several places Standard backlash 0 5 0 6 mm 0 020 0 024 in Maximum backlash 0 9 mm 0 035 in If the backlash is greater than maximum replace the oil pump drive shaft and driven gear INSPECT SIDE CLEARANCE Using a thickness gauge and precision s...

Page 271: ...all the oil pump cover with the five bolts Torque the bolts Torque 75 kg cm 65 in lb 7 4 N m INSTALL RELIEF VALVE Install the relief valve and spring with the relief valve plug Torque the plug Torque 375 kg cm 27 ft lb 37 N m CHECK PUMP OPERATION a Immerse the suction end of the pump into clean engine oil and turn the shaft counterclockwise Oil should come out of the discharge hole b Close the dis...

Page 272: ...t pipe with a new lock washer gasket and the union bolt Finger tighten the union bolt INSTALLATION OF OIL PUMP See page LU 8 1 INSTALL OIL PUMP a install the oil pump with the bolt Torque the bolt Torque 220 kg cm 16 ft lb 22 Nam b Install the mount bolt holding the oil pump strainer stay to block Torque 60 kg cm 52 in lb 5 9 Nsm c Connect the outlet pipe with the union bolt Torque the union bolt ...

Page 273: ...ve all the loose material l Clean both sealing surfaces with a non residue solvent CAUTION Do not use a solvent which will affect the painted surfaces ib Apply seal packing to the oil pan as shown in the figure Seal packing Part No 08826 00080 or equivalent 0 Install a nozzle that has been cut to a 5 mm 0 20 in opening c Install the oil pan with the bolts and nuts Torque 130 kg cm 9 ft lb I3 N m 3...

Page 274: ... Oil Pipe I Pressure Regulator I Oil Cooler Hose I Oil Cooler G r Union I Gasket CC Countricis a Oil Cooler kg cm ft lb N rnl Specified torque Non reusable part 1 l GCC Countries udi Arabia Sultanate Of Oman Bahrain United r3b Ernirates Qatar Kuwait iuosr ir ...

Page 275: ... COMPONEljTS 1 Oil qipe I Oil Cooler Hose lsket Spr ing Gasket Relief Valve Pres Ire Regulator Gasket kg cm ft lb N rnl Specified torque Non reusable part ...

Page 276: ...INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight If it does not replace the relief valve If necessary replace the oil pressure regulator assembly ASSEMBLY AND INSTALLATION OF OIL PRESSURE REGULATOR See pages LU 15 16 1 INSTALL RELIEF VALVE Install the relief valve and spring with the plug and a new gasket Torque the plug Tor...

Page 277: ... 1 Oil Cyler Bracket Oil Filter Non reusable part LU0572 LUO5 MIT Gasket Oil Cooler Hose REMOVAL AND DISASSEMBLY OF OIL FILTER BRACKET 1 REMOVE OIL FILTER BRACKET Remove the union bolt gasket oil filter bracket and O ring 2 REMOVE OIL FILTER See page LU 6 3 REMOVE RELIEF VALVE Unscrew the plug and remove the spring relief valve and gasket ...

Page 278: ...ATION OF OIL ASSEMBLY AND FILTER BRACKET See page LU 18 1 INSTALL RELIEF VALVE a Install the relief valve and spring b Install and torque the plug with a new gasket Torque 375 kg cm 27 ft lb 37 Nsm 2 INSTALL OIL FILTER See page LU 8 3 INSTALL OIL FILTER BRACKET a Install a new O ring to bracket b Install a new gasket to union bolt c Put the oil filter bracket hole over the cylinder block stud bolt...

Page 279: ...__ _ _ I It _ SYSTEM PRECAUTIONS Page 16 2 TROUBLESHOOTING IG 3 IGNITION SYSTEM CIRCUIT ON VEHICLE INSPkTlON 7M GE IO 4 IO 5 ON VEHICLE INSPECTION 7M GTE IO 1 2 DISTRIBUTOR 7M GE IO 19 CAM POSITION SENSOR 7M GTE 16 23 ...

Page 280: ...nector terminal IG 0 CHECK CONNECTOR LOCATION See pages FI 110 111 As some tachometers are not compatible with this ignition system we recommended that you confirm the compatibility of your unit before using NEVER allow the tachometer terminals to touch ground as it could result in damage to the igniter and or ignition coil Do not disconnect the battery while the engine is run ning Make sure that ...

Page 281: ...E Distributor 7M GTE Cam position sensor 0 High tension cords Spark plugs faulty Ignition wiring faulty Incorrect ignition timing Incorrect ignition timing Incorrect ignition timing Spark plugs faulty Incorrect ignition timing Incorrect ignition timing Remedy Reset timing lrkpect coil Inspect igniter Inspect distributor Inspect cam position sensor Inspect high tension cords Inspect wiring Inspect ...

Page 282: ...IN 2 OL Battery IG2 To Tachometer 1 f Cam Position Sensor r 1 G2 IGT NE IGdA NO IGdB f To Tachome n Spark Plug Igniter I B I Ignition Coil It08 ELECTRONIC SPARK ADVANCE ESA The ECU is programmed with data for optimum ignitio timing under any and all operating conditions Using dat provided by sensors which monitor various engine func tions rpm intake air volume eng temperature etc th microcomputer ...

Page 283: ...R CONNECTORS c OK CHECK RESISTANCE OF HIGH TENSION CORDS See page IG 6 BAD Replace the cord s OK CHECK POWER SUPPLY TO IGNITION COIL 1 Ignition switch turn to ON 2 Check that there is battery voltage at ignition coil positive I terminal Check wiring between ignition switch to BAD switch to ignition coil OK CHECK RESISTANCE OF IGNITION COIL See page IG 10 9 BAD Replace the ignition coil OK 1 1 CHEC...

Page 284: ... the spark plugs CAUTION Pulling on or bending the cords ma damage the conductor inside 2 INSPECT HIGH TENSION CORD RESISTANCE Using an ohmmeter measure the resistance without dis connecting the cap Maximum resistance 25 kS2 per cord If resistance exceeds maximum check the terminals If necessary replace the high tension cord and or dis tributor cap 3 INSTALL HIGH TENSION CORDS a Install high tensi...

Page 285: ... Using a spark plug cleaner or wire brush clean the spark plug VISUALLY INSPECT SPARK PLUGS Check the spark plug for electrode wear threads damage and insulator damage If abnormal replace the plugs Recommended spark plugs ND Q20R U NGK BCPRGEY ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the correct electrode gap Correct electrode gap 0 8 mm 0 031 in INSTALL SPARK PLUGS a Usin...

Page 286: ... a If using a megger insulation resistance meter 0 Remove the high tension cords See page G 6 0 Measure the insulation resistance Correct insulation resistance 10 MQ or more If less than 10 MAI proceed to step 2 I IG01481 IG059 0 Visually inspect the spark plugs If the electrode is dry Okay If the electrode is wet Proceed to step 3 2 REMOVE SPARK PLUGS a Remove the high tension cords See page IS 6...

Page 287: ...ug Correct electrode gap of new plug 7M GE 1 1 mm 0 043 in 7M GTE 0 8 mm 0 031 in If adjusting the gap of a new plug bend only the base of 5 CLEAN SPARK PLUGS 6 the ground electrode do not touch the tip 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 NOTE If there are traces of...

Page 288: ...rimary coil resistance cold MA 0 24 0 30 n MS 0 41 0 50 rzZ If the resistance is not as specified replace the ignition coil 3 INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter measure the resistance between the positive I terminal and high tension terminal Secondary coil resistance cold MA 9 2 12 4kfi MS 10 2 13 8 ka If the resistance is not as specified replace the ignition coil 4 RECONNECT HIG...

Page 289: ...coil projection Air gap 0 2 0 4 mm 0 008 0 016 in If the gap is not as specified distributor NE Pickup Gl Pickup G2 Pickup INSPECT PICKUP COILS Using an ohmmeter check resistance of the pickup coil Gl pickup coil resistance 61 00 G2 pickup coil resistance 62 G 140 18Os1 NE pickup coil resistance NE GO 140 180 0 If the resistance is not as specified replace the distributor ...

Page 290: ...able REMOVE ISC PIPE a Disconnect the six hoses from ISC pipe b Remove the two bolts and ISC pipe REMOVE PCV PIPE WITH HOSES a Remove the oxygen sensor wire from two clamps b Disconnect the No 4 PCV hose from the PCV pipe c Remove the two bolts d Disconnect the PCV pipe with hoses from the cylinder head covers and throttle body 5 REMOVE INTAKE AIR CONNECTOR a Disconnect the air valve hose from the...

Page 291: ...Using SST remove the spark plug SST 09155 16100 PERFORM SPARK TEST Ia Install the oil filler cap b Install the spark plugs to each high tension cord 4 Ground the spark plug d Disconnect the solenoid resistor and cold start injec tor connectors e See if spark occurs while engine is being cranked INSPECTION OF HIGH TENSION CORDS INSPECT HIGH TENSION CORD RESISTANCE Using an ohmmeter measure the resi...

Page 292: ...ween ter minal 1 and body ground Voltage Approx 12 V 2 INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter measure the resistance between the positive I and negative 1 terminals Primary coil resistance cold 0 3 0 5 R NOTE Because is inside the coil it is impossible to measure secondary coil resistance 3 INSPECT IGNITION COIL GROUND Using an ohmmeter check that there is no continuity be tween the ign...

Page 293: ...4 and No 1 and No 2 c Install and torque the nut Torque 55 kg cm 48 in lb 5 4 Nmrn CAUTION Do not over tighten the nut IGOB 12 6 INSTALL IGNITION COIL COVER a Remove the oil filler cap b Install the ignition coil cover with the five nuts c install the oil filler cap 7 INSTALL INTAKE AIR CONNECTOR a Install the intake air connector b Install and tighten the two bolts c Tighten the clamp Id Connect ...

Page 294: ...b Install and tighten the two bolts c Connect the No 4 PCV hose d Install the oxygen sensor wire to the two PCV pipe clamps 9 INSTALL ISC PIPE a Install the ISC pipe with the two bolts b Connect the six hoses to ISC pipe 10 CONNECT FOLLOWING CABLES AND ROD a A T Throttle cable b Accelerator rod cl Accelerator link w cable 11 CONNECT NO 1 AIR CLEANER HOSE I ...

Page 295: ...ter connect terminal 2 of the igni tion coil C and body ground Using a 3 V dry cell battery apply voltage to terminal 2 of the connector 4 P As voltage is applied check that there is momentary continuity Using an ohmmeter connect terminal 2 of the igni tion coil A and body ground Using a 3 V dry cell battery apply voltage to terminal 4 of the connector 4 P With terminal 4 connected apply voltage t...

Page 296: ...ickup coil projection Air gap 0 2 0 4 mm 0 008 0 016 in If the gap is not within specification replace the cam posi tion sensor 2 INSPECT PICKUP COILS Using an ohmmeter check resistance of the pickup coil Gl pickup coil resistance Gl GQ 140 180n 62 pickup coil resistance G2 GO 140 180n NE pickup coil resistance NE GO 140 180n If the resistance is not as specified replace the cam posi tion sensor ...

Page 297: ...g w Rotor Non reusable part I REMOVAL OF DISTRIBUTOR 1 DISCONNECT HIGH TENSION CORDS FROM DISTRIBUTOR CAP 2 DISCONNECT DISTRIBUTOR CONNECTOR 3 REMOVE DISTRIBUTOR CAP AND PACKING ffiO60 4 SET NO 1 CYLINDER TO TOWCOMPRESSION a Remove the oil filler cap b Look through oil filler hole and turn the crankshaft clockwise until the cam nose can be seen ...

Page 298: ...approximate 1 12o Id Turn the crankshaft again approximately 10 to 4 clockwise so that the timing belt cover TDC mark ar the crankshaft pull y TDC mark are aligned IG06C 5 REMOVE DISTRIBUTOR a Remove he hold down bolt b Pull out the distributor from the cylinder head 6 REMOVE O RING ...

Page 299: ...he groove of the housing 4 Using a grinding wheel grind the gear and pin CAUTION Be careful not to damage the shaft 2 REMOVE PIN AND DRiVEN GEAR a Using a punch and hammer drive out the pin b Remove the driven gear and discard it 3 INSTALL NEW DRIVEN GEAR AND PIN a Align the matchmark with the groove of the housing b Align the drilled mark on the new driven gear with the groove of the housing c Us...

Page 300: ...new O ring when installing the dis tributor b Align the drilled mark on the driven gear with the groove of the housing c Insert the distributor aligning the center of the flange with that of the bolt hole on the cylinder head d Lightly tighten the hold down bolt 3 INSTALL DISTRIBUTOR CAP 4 CONNECT DISTRIBUTOR CONNECTOR 5 CONNECT HIGH TENSION CORDS TO DISTRIBUTOR CAP 6 ADJUST IGNITION TIMING See pa...

Page 301: ...using Gear REMOVAL OF CAM POSITION SENSOR 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL Oi BATTERY 2 DISCONNECT CAM POSITION SENSOR CONNECTOR 3 SET NO 1 CYLINDER TO TDWCOMPRESSION a Remove the oil filler cap b Look through oil filler hole and turn the crankshaft clockwise until the cam nose can be seen I it ...

Page 302: ...OVE NO 4 AIR CLEANER PIPE WITH NO 1 PND NO 2 AIR CLEANER HOSES 5 REMOVE NO 7 AIR CLEANER HOSE WITH AIR FLOW METER AND AIR CLEANER CAP a Disconnect the three air hoses and PCV hose b Disconnect the air flow meter connector c Disconnect the PS idle up air hose d Loosen the clamps and remove the bolt e Remove the No 2 air cleaner hose with air flow meter and air cleaner cap 6 REMOVE PS RESERVOIR TANK...

Page 303: ...d mark on the driven gear with the groove of the housing lb Place a matchmark on the cam position shaft that aligns with the groove of the housing cl Using a grinding wheel grind the gear and pin CAUTION Be careful not to damage the shaft 2 REMOVE PIN AND DRIVEN GEAR a Using a punch and hammer drive out the pin b Remove the driven gear and discard it 3 INSTALL NEW DRIVEN GEAR AND PIN a Align the m...

Page 304: ...am position sensor b Align the drilled mark on the driven gear with the groove of the housing c Insert the cam position sensor aligning the center of the flange with that of the bolt hole on the cylinder head d Lightly tighten the hold down bolt 3 INSTALL PS RESERVOIR TANK Install the PS reservoir tank with bracket with the two bolts and nut 4 INSTALL NO 7 AIR CLEANER HOSE WITH AIR FLOW METER AND ...

Page 305: ... the air flow meter connector e Connect the PCV hose and three air hoses 5 INSTALL NO 4 AIR CLEANER PIPE WITH NO 1 AND NO 2 AIR CLEANER HOSES 6 CONNECT CAM POSITION SENSOR CONNECTOR 7 WARM UP ENGINE Allow the engine to reach normal operating temperature 8 ADJUST IGNITION TIMING See page EM 171 ...

Page 306: ...i ...

Page 307: ...aulty starter Flywheel teeth broken Replace switch Replace fusible link Replace starter relay Repair starter Replace ignition switch Check battery specific gravity Charge or replace battery Repair or replace cables Repair starter Repair starter Replace ignition switch Repair wiring Repair starter Replace flywheel STARTING SYSTEM CIRCUIT ST 3 CH 3 ST 3 ST 3 ST 3 Ignition Switch Clutch MS with M T o...

Page 308: ...Retainer 1 4 kW Type Bearing 4 O Fling Bearing End Starter Housing Non reusable part 6 I 62 Return Spring ...

Page 309: ...pe only 2 REM E STARTER HOUSING FROM MAGNETIC SWITCH ASSEMBLY 1 O kW type1 a Remove the two screws L b Remove the starter housing with the idler gear bear ing and clutch assembly 1 4 kW type a Remove the two screws b Remove the starter housing with the pinion gear idler gear bearing and clutch assembly ...

Page 310: ...S NOT GROUNDED Using an ohmmeter check that there is no continuity be tween the field coil end and field frame If there is continuity repair or replace the field frame Brushes INSPECT BRUSH LENGTH Using vernier calipers measure the brush length Standard length 1 O kW type 13 5 mm 0 531 in 1 4 kW type 15 5 mm 0 610 in Minimum length 1 0 kW type 8 5 mm 0 335 in 1 4 kW type 10 0 mm 0 394 in If the le...

Page 311: ...Clutch and Gears 1 INSPECT GEAR TEETH Check the gear teeth on the pinion gear idler gear and clutch assembly for wear or damage If damaged replace the gear or clutch assembly If damaged also check the flywheel ring gear for wear or damage 2 INSPECT CLUTCH Rotate the clutch pinion gear clockwise and check that it turns freely Try to rotate the clutch pinion gear coun terclockwise and check that it ...

Page 312: ...20 c Using a press press in a new rear bearing Magnetic Switch 1 PERFORM PULL IN COIL OPEN CIRCUIT TEST Using an ohmmeter check that there is continuity be tween terminal 50 and C If there is no continuity replace the magnetic switch assembly 2 PERFORM HOLD IN COIL OPEN CIRCUIT TEST Using an ohmmeter check that there is continuity be tween terminal 50 and the switch body If there is no continuity ...

Page 313: ...nstall the end cover to the field frame INSERT STEEL BALL INTO CLUTCH SHAFT HOLE a Apply grease to the steel ball b Insert the steel ball into the clutch shaft hole INSTALL GEARS AND CLUTCH ASSEMBLY 1 0 kW type a Apply grease to the gear and clutch assembly b Place the clutch assembly idler gear and bearing in the starter housing 1 4 kW type a Apply grease to the gears and clutch assembly b Place ...

Page 314: ...T000 ST028 1 4 kw Type STOX ST021 6 INSTALL FIELD FRAME WITH ARMATURE TO MAGNETIC SWITCH ASSEMBLY a Ha a new O ring on the field frame 1 4 kW type b Align the protrusion of the field frame with the cutout of the magnetic switch ...

Page 315: ...t the negative 1 lead from terminal C Check that the pinion gear remains out If the clutch pinion gear returns inward replace the mag netic switch assembly INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative I 1 lead from the switch body Check that the clutch pinion gear returns inward If the clutch pinion gear does not return replace the mag netic switch assembly PERFORM NO LOAD PERFORMANCE...

Page 316: ...erminals 1 and 3 zt cqk that there is no continuity between terminals 2 lf 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 ...

Page 317: ... CHARG NG SYSTEM Page PRECAUTIONS CH 2 TROUBLESHOOTING CH 2 CH ARGlNG SYSTEM CIRCUIT n m C H 3 ON VEHICLE INSPECTION w 3 ALTERNATOR CH 7 ...

Page 318: ...ine not running Problem Discharge warning light does not go out with engine running battery requires fre quent recharging Possible cause Fuse blown Light burned out Wiring connection loose IC regulator faulty TROUBLESHOOTING Remedy Check CHG and IGN fuses Replace light Tighten loose connections Replace IC regulator Drive belt loose or worn Battery cables loose corroded or worn Fuse blown Fusible l...

Page 319: ...CIFIC GRAVITY a Check the specific gravity of each cell Standard specific gravity When fully charged at 1 25 1 27 If not within specifications charge the battery b Check the electro yte quantity of each cell If insufficient refill with distilled or purified water 2 CHECK BATTERY TERMINALS FUSIBLE LINKS AND FUSES a Check that the battery terminals are not loose or cor roded b Check the fusible link...

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Page 331: ... LUSRlCATlOIjl SY T M J4 1 IGAITION SYSTEM 1 A 12 STIJRiiNG S EM A 13 1 CilARGING SY EM A 434 I Y 1 I ...

Page 332: ... 70 80 kg I5 17 mm 0 59 0 87 in 30 45 kg I 8mm 0 28 0 31 in 55 65 kg 3 llmm 0 35 0 43 in 25 40 kg 7 1 9 5 mm 0 28 0 374 in 53 77 kg 7 5 9 5 mm 0 295 0 374 in 53 77 kg 10 5 12 mm 0 413 0 47 in 30 40 kg IO 13 mm 0 39 0 51 in 30 40 kg 8 1 liters 8 0 liters 7 5 liters 7 4 liters 8 5 liters 7 8 liters 7 8 liters 7 1 liters 8 5 US qts 8 5 US qts 7 9 us qts 7 8 US qts 9 0 us qts 8 2 US qts 8 2 US qts 7 5...

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Page 347: ...NEW CAR FEATURES Introduction _ New Model Highlights Technical Description Appendix ...

Page 348: ...the clutch piates are splined to the side gears A barrel shaped compression spring is fitted be tween the left and right side gears to keep the thrust washers pressed up against the clutch plates via the retainers and side gears This means in effect that the side gears are kept pressed against the differential case via the thrust washers and clutch plates by the spring Differential CaseRH I Thrust...

Page 349: ...sult in slippage between the thrust washers plates Since these are pushed together by the spring friction torque is created between washers and clutch Plates cthat isy between their surfaces which are in direct contact with her This torque attemPtS to make the differential caseand side gearsrotate asaunit This is jihe limited slip effect Ring Gear DrivePinion Differential Pinion SideGearShaft 1 LH...

Page 350: ...he driving conditions and which dehvers superb riding Comfort and fie shock damping force changes in 3 stages better driving stability Also the driver can select 2 modes A diagnosis System and fail safe function are also included LOCATION OF SYSTEM COMPONENTS Stop Light Switch TEMS Indicator Vehicle Speed Sensor Steering Sensor I Actuators A I Throttle Position Selectol Switch Neutral Start Switch...

Page 351: ... sends avehicle speed signal to the computer This indicates the damping force conditions of the shock absorbers Shock Absorber Actuator These shock absorbers have abuilt in rotary valve which changes the damping force in 3 stages By asignal from the computer the actuator drives the shock absorber control rod rotary valve and changes the damping force Absorber Control Computer This computer usessig...

Page 352: ...TD 106 SUSPENSION TEMS a WIRING DIAGRAM _ F L Selector Switch Absorber Control Computer Vehicle Speed Sensor L I I I Actuators M T Open A T Short ...

Page 353: ...USTMENT 1 Construction rHinge pin when seenfrom the front The same axis asthe Inner Gear and The same axis asthe Upper Arm and To Inner Adjuster Back 8 n Upper Arm Q Upper Arm Fastened to the Seat Back Side Inner Gear Fastened to the Seat Cushion Hinge Pin Eccentric Axis ...

Page 354: ...ating center 0 of the upper arm crown gear fastened to the seat back turns with center O1 of the inner gear asits axis 0 Therefore the upper arm crown gear turns around the inner gear by the turning of the hinge pin Furthermore when the hinge pin has made N turns the reclining angle of the seat back can be expressed by the flowing formula 2 1 x 360 I Reclining Angle N No of Turns of Hinge Pin a Nx...

Page 355: ...e seat back can be steplessly reclined Inner Gear Tension Spring Foward Reclining Position j 1 7 he figure below shows the seat back reclining forward The quick lever is operated in direction A vith the seat back in the normal position At this time the spacer releases from the paGl and the force of the paw1 pressing on the latch is removed Therefore with the hinge pin as the axis the upper arm and...

Page 356: ... latch I 0 of the inner gear Further in the backward reclining lock position steplessreclining of the seat back can be done Also even if the seat back is returned to the normal position it will return to the originally set reclining position POWER SIDE SUPPORT AND POWER LUMBAR SUPPORT 1 Description The previous manual side support and lumbar support systemshave been changed to electrical systems t...

Page 357: ... thesupport link and adjusting the side support MConnecting Rod I Side B Lumbar and Side Support Switch POWER LUMBAR SUPPORT ADJUSTMENT Previously lumbar support adjustment was accomplished by moving a lever on the side of the seat which moved the support pad linked to the torsion bar forward or backward Now however with power lumbar support adjustment the screw nut on the lumbar support motor is ...

Page 358: ...TD 142 BODY FRONT SEAT 3 System Circuit Side Spread 0 O Q o OFF Close 0 0 I I I 0 b I I Lumbar Push Spread Close Release Lumbar and Side Support Switch Connecter for Lumbar and Side Support Switch ...

Page 359: ...om each sensorand controls total CCSfunctioning This is controlled by the CCS computer to increase or decreasethe throttle valve opening angle Control Switch This is used to control the CCS when setting the vehicle at a desired cruising speed or resetting it at another cruising speed and to cancel the CCS Main Switch with Power Indicator This is used to connect the CCS to the power source Lights u...

Page 360: ...EM WIRING DIAGRAM _ Stop Light Fuse I Stop Light 1 Aa T I Speed Sensor MAJOR CONNECTORS Sjop Light Switch 1 Z Main Switch I I w Actuator Clutch Switch l Models with RHD Cruise Control Computer Actuator Control Switch Stop Light Switch Clutch Switch ...

Page 361: ...rough the On Switch Off Switch and Relay Coil The Relay Switch goes on and current flows to Terminal 8 Also since current is flowing through the Relay Coil through D even if the Relay Switch is separated from the On switch it remains ON Self hold Circtiit The Power Indicator Lamp Lights up 2 Main Switch OFF 0 0 When the Main Switch is ON if the Off Switch is pressed the current flowing from D1 is ...

Page 362: ...e manifold is not sufficient 0 as when the vehicle is climbing a hill or during full acceleration To Actuator I To Engine Check Valve A B Cross Section A C Cross Section OPERATION Check valve is normally kept open due to vacuum in the manifold and supplies vacuum to the actuator When manifold vacuum is low the computer sendsa signal to turn the vacuum pump on As i esult vacuum is supplied to the a...

Page 363: ...tch This switch detects vacuum in the intake manifold _ It turns on when thii vacuum is 170 mmHg or lower and sendsan ON signal to the computer To Vacuum Pump and Intake Manifold To Cruise Control Computer hragm i ...

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